I 3

2002 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX

GENERAL INFOMATION
SECTION

This service manual has been prepared

to provide SUBARU service personnel
with the necessary information and data
for the correct maintenance and repair
of SUBARU vehicles.
This manual includes the procedures
c- . for maintenance, disassembling, reas-
sembling, inspection and adjustment of
components and diagnostics for guid-
ance of experienced mechanics.
Please peruse and utilize this manual
fully to ensure complete repair work for
satisfying our customers by keeping
their vehicle in optimum condition.
When replacement of parts during
repair work is needed, be sure to use
SUBARU genuine parts.

All information, illustration and specifi-

cations contained in this manual are
based on the latest product information
available at the time of publication
approval.

FUJI HEAVY INDUSTRIES LTD. G1830BE1

FOREWORD

~~~~
FWa
Page
1. Foreword.....................................................................................................2
 FOREWORD
FOREWORD
~

1. Foreword
A: FOREWORD
These manuals are used when performing mainte-
nance, repair or diagnosis of the Subaru IMPREZA.

Applied model: GG***** and GD***** from 2001MY.

The additional manuals below are also available:

AUTOMATIC TRANSMISSION SERVICE MANU-
AL (Pub. No. G0853ZE)

The manuals contain the latest information at the

time of publication. Changes in the specifications,
methods, etc. may be made without notice.

FW-2
HOW TO USE THIS MANUALS
HU
- -
Paae
1. How to Use This Manuals ........................................................................... 2
I HOW TO USE THIS MANUALS
HOW TO USE THIS MANUALS

1. How to Use This Manuals

A: HOW TO USE THIS MANUALS
1. STRUCTURE
Each section consists of SCT that are broken down
into SC that are divided into sections for each com-
ponent. The specification, maintenance and other
information for the components are included, and
the diagnosis information has also been added
where necessary.
2. INDEX
The first page has an index with tabs. And at the
end of each section is an alphabetical index.
3. COMPONENTS
For each component, a composition drawing is in-
cluded.
4. SPECIFICATIONS
f f necessary, specifications are also included
5. INSPECTION
Inspections are included to be carried out before
and after maintenance.
6. MAINTENANCE
Maintenance instructions are provided for each
component. When multiple components comprise
one process, refer to the instructions for that pro-
cess for each component.
7. DIAGNOSIS
Tables showing a step-by-step process make it
easy to conduct diagnosis.
8. SI UNITS
Measurements in these manuals are according to
the SI units. Metric and yard/pound measurements
are also included.

HU-2
SPECIFICATIONS
SPC
1. lmpreza ...................,................,.......,................,.......,.................................2
Page a
 IMPREZA
SPECIFICATIONS

1. lmpreza
A: DIMENSIONS
Model Sedan Waaon OUTBACK
Overall lennth mm (in) I 4,405 (173.4)
Overall width mm (in) 1,730 (68.1) 1,695 (66.7) 1,710 (67.3)
Overall height (at CW) mm (in) 1,465 (57.7), 1,475 (58.1),
1,440 (56.7)
1,485 (58.5)*2 1,495 (58.9)*2
Compartment Length mm (in) 1,890 (74.4) 1,845 (72.6)
Width mm (in) 1,380 (54.3)

I Height
mm (in)
I 1, I 80 (46.5)
I 1,200 (47.2),
1,150 (45.3)*3 I 1,200 (47.2),
1,150 (45.3)*3

Tread I Front mm (in) I

\ I
1.485 (58.5)
, \ ,
1.465 (57.7)
. \ ,
1.460 (57.5)
I \ ,

Rear mm (in) 1,475 (58.1),

1,455 (57.3) 1,455 (57.3)
1,480 (58.3)*1
Minimum road clearance mm (in) 150 (5.9), 150 (5.9),
160 (6.3)
155 (6.1)*1 155 (6.1)*1

B: ENGINE
Model Turbo 2.0 L 2.5 L

I valve arranqement I Overhead camshaft tvDe 1

Bore x Stroke mm (in) 92 x 75 99.5 x 79.0
(3.62 x 2.95) (3.917 x 3.1 IO)
Displacement cm3 (cu in) 1,994 (121.67) 2,457 (149.9)
ComDression ratio 8.0 10.0
I Firinq order I 1-3-2-4 -1
I Idle speed at Park/Neutral
position (NC OFF)
Maximum output kW (HP)/rpm
rpm I 750
169 (227)/6,000
650 (MT)
700 (AT)
123 (165)/5,600
Maximum torque N.m (kgf-m, ft-lb)/rpm 294 (30.0, 217)/4,000 226 (23.0, 166)/4,000

SPC-2
 IMPREZA I
SPECIFICATIONS

C: ELECTRICAL
Model I
Turbo 2.0 L I
2.5 L
Ignition timing at idling speed BTDC/rpm MT: 1O"k10°/650
12"+10"/750
AT: 1O"k10"/700
Spark plug CHAMPION: RCI OYC4(Standard)
NGK: PFR6G NGK: BKR5E-11
NGK: BKR6E-11
Generator 12V - 75A 12V - 90A
Battery Type MT: 12V - 48AH (55D23L) MT: 12V - 48AH (55D23L)
AT: 12V - 52AH (65D23L) AT: 12V - 52AH (75D23L)
Reserve capacity min MT: 99 MT: 99
AT: 111 AT: 118
Cold cranking amp MT: 356 MT: 356
amperes AT: 420 AT: 520

r M m ~ I Turbo 2.0 L I
Transmission type 5MTSrl 4ATlr2
Clutch type DSPD TCC
-'
Gear ratio I 1st 3.454 2.785
I L I I 4
II 1L 3rd I
I
1.366 I 1.ooo I
I
14th I 0.972 I 0.694 I
5th 0.738 -

,
' Reductiongear
(Front drive)
1st reduction

Final reduction
Reverse
Type of gear
Gear ratio
Type of gear
3.333
-
-
Hypoid
2.272
Helical
1.000
Hypoid
I I I Gear ratio I 3.900 I 4.1 11 I
Reductiongear Transfer reduction Type of gear Helical -
(Rear drive) Gear ratio 1.100 -
Final reduction Type of gear Hypoid Hypoid
Gear ratio 3.545 4.111

SPC-3
 IMPREZA I
SPECIFICATIONS

Model 2.5 L
RS Others
Transmission type 5MT*1 4ATlr2 5MTlrl 4AT*2
Clutch type DSPD TCC DSPD TCC
I 1st I 3.454 I 3.027 I 3.454 I 2.785 I
2nd 2.062 1.619 2.062 1.545
3rd 1.448 1.ooo 1.448 1.ooo
~~~

4th 1.088 0.694 1.088 1.694

5th 0.780 - 0.780 -
I Reverse I 3.333 I 2.272 I 3.333 I 2.272 1

r
Dual range - - - -
Reductiongear 1st reduction Type of gear - Helical - Helical
(Front drive) Gear ratio - 1.ooo - 1.ooo
...

Final reduction Type of gear Hypoid Hypoid Hypoid Hypoid

r
Gear ratio 4.1 11 4.444 3.900 4.1 11
Reductiongear Transfer reduction Type of gear HeIical - HeIical -
(Rear drive) Gear ratio 1.ooo - 1.000 -
Final reduction Type of gear Hypoid Hypoid Hypoid Hypoid
Gear ratio 4.1 11 4.444 3.900 4.1 11
I
5 M T M : 5 forward speeds with synchromesh and I -reverse
4AT+2: Electronically controlled fully-automatic, 4-forward speeds and 1-reverse
DSPD: Dry Single Plate Diaphragm
TCC: Torque Converter Clutch

E: STEERING
I

Type Rack and Pinion

Turns, lock to lock 3.2 3
Minimum turning circle m (ft) Curb to curb 10.2 (33.5) 10.8 (35.4)
Wall to wall 11.I (36.3) 11.7 (38.3)

Front Macpherson strut type, Independent, Coil spring

Rear Dual-link strut type, Independent, Coil spring

Model SEDAN WAGON

Service brake system Dual circuit hydraulic with vacuum suspended power unit
Front Ventilated disc brake
Rear Disc brake Drum brake, Disc brakelrl
Parking brake Mechanical on rear brakes

H: TIRE

Rim size 15 x 6JJ 16 x 6’/2JJ

Tire size P I 95/60R15 87H P205/55R16 89V
Type Steel belted radial, Tubeless

SPC-4
 IMPREZA
SPECIFICATIONS

I: CAPACITY

I 5MT I
I
4AT I 5MT I 4AT I
Fuel tank Q (US gal, Imp gal) 60 (15.9, 13.2) 60 (15.9, 13.2)
Engine oil Upper level Q (US qt, Imp qt) 4.5 (4.8, 4.0) 4.0 (4.2, 3.5)
Lower level Q (US qt, Imp qt) 3.5 (3.7, 3.1) 3.0 (3.2, 2.6)
Transmission gear oil Q (US qt, Imp qt) 3.5 - 3.5 -
(3.7, 3.1) (3.7, 3.1)
Automatic transmission fluid Q (US qt, Imp qt) - 9.3 (9.8, 8.2) - 9.5 (10.0, 8.4)
AT differential gear oil Q (US qt, Imp qt) - 1.2 (1.3, 1. I ) - 1.2 (1.3, 1.1)
AWD rear differential gear oil Q (US qt, Imp qt) 0.8 (0.8, 0.6)
Power steering fluid Q (US qt, Imp qt) 0.7 (0.7, 0.6)
Engine coolant Q (US qt, Imp qt) 7.7 (8.1, 6.8) I 7.6 (8.0, 6.7) I 7.0 (7.4, 6.2) 1 6.9 (7.3, 6.1)

t-
Model I AWD I
Turbo 2.0 L 2.5 L
WRX RS
5MTlrl 4ATJrl 5MT 4AT
Curb weight (C.W.) Front kg (Ib) 826 (1,820) 851 (1,875) 778 (1,715) 803 (1,770)
Rear ka (IblI 1
w . 569 (1.255)
. . 569 (1.255) 567 (1.250). 567 (1,250)
I I I
I
I I . I
I I .
I

Total ka (Ib) I 1,395 (3,075) I 1,420 (3,130) 1 1,345 (2,965) I 1,370 (3,020)
Gross vehicle weight Front kg (Ib) 998 (2,200) 998 (2,200) 939 (2,070) 939 (2,070)
(G.V.W.) Rear kg (Ib) 857 (1,890) 857 (1,890) 857 (1,890) 857 (1,890)
Total kg (Ib) 1,837 (4,050) 1,795 (4,050) 1,778 (3,920) 1,837 (4,050)

SPC-5
 IMPREZA I
SPECIFICATIONS

Model AWD
Xirbo 2.0 L
WRX
5MTt2 4ATt2
Curb weight (C.W.) Front kg (Ib) 825 (1,820) 851 (1,875)
Rear ka (Ib) 606 (1.335) 605 (1,335)
ka ob) 1 I
~~

htai 1,431 (3,155) 1,458 (3,210)

~

Gross vehicle weight Front kg (Ib) 998 (2,200) 998 (2,200)

(G.V. W.) Rear kg (Ib) 925 (2,040) 925 (2,040)
Total kg (Ib) 1,901 (4,190) 1,901 (4,190)

2.5 L
-
TS OUTBACK
5MTtl 4ATt 1 5MT 4AT
Curb weight (C.W.) Front kg (Ib) 773 (1,705) 796 (1,755) 783 (1,725) 805 (1,775)
Rear kg (Ib) 603 (1,330) 606 (1,335) 601 (1,325) 603 (1,330)
Total kg (Ib) 1,376 (3,035) 1,402 (3,090) 1,384 (3,050) 1,408 (3,l 05)
Gross vehicle weight Front kg (Ib) 939 (2,070) 939 (2,070) 939 (2,070) 939 (2,070)
-(G.v.w.) Rear kg
- (Ib) 925 (2,040) 925 (2,040) 925 (2,040) 925 (2,040)
Total kg (Ib) [ 1,833 (4,040) I 1,833 (4,040) I 1,833 (4,040) I 1,833 (4,040)
tl:Excludes weight of ABS, cruise control.
t 2 : Excludes weight of side air bag.

SPC-6
 IMPREZA
SPECIFICATIONS
I
2. CANADA SPEC. VEHICLE
Sedan
Model
Turbo 2.0 L 2.5 L
WRX RS
5MT 4AT 5MT 4AT
Curb weight (C.W.) Front kg (Ib) 826 (1,820) 851 (1,875) 778 (1,715) 803 (1,770)
Rear kg (Ib) 573 (1,265) 573 (1,265) 567 (1,250) 567 (1,250)
Total kg (Ib) 1,399 (3,085) 1,424 (3,140) 1,345 (2,965) 1,370 (3,020)
Gross vehicle weight Front kg (Ib) 998 (2,200) 998 (2,200) 939 (2,070) 939 (2,070)
(G.V.W.) Rear kg (Ib) 857 (1,890) 857 (1,890) 857 (1,890) 857 (1,890)
Total kg Ob) 1,837 (4,050) 1,837 (4,050) 1,778 (3,920) 1,778 (3,920)
Wagon

.-

*1: Excludes weight of air conditioner

SPC-7
 IMPREZA
SPECIFICATIONS

c- .

SPC-8
 I

PRECAUTION

PC
Page
1. Precaution................................................................................................... 2
 PRECAUTION
PRECAUTION

1. Precaution 7. AIRBAG MODULE

Adhere to the following when handing and storing
A: PRECAUTION the airbag module to prevent bodily injury from un-
Please clearly understand and adhere to the follow- expected deployment:
ing general precautions. They must be strictly fol- Do not hold the harnesses or connectors to carry
lowed to avoid minor or serious injury to the person the module.
doing the work or people in the area. Do not face the bag in the direction that it opens
1. ABS towards yourself or other people.
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
when needed or cause it to operate incorrectly and To prevent unexpected deployment, only use spe-
result in injury. cial tools.
2. BRAKE FLUID 9. WINDOW
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-
Wash out your eyes and seek immediate medical ing your eyes.
attention.
Wash your skin with soap and then rinse thor- 1O.WINDOW ADHESIVE
oughly with water. Atways use the specified urethane adhesive when
3. ELECTRIC FAN attaching glass to prevent it from coming loose and
falling, resulting in accidents and injury.
The electric fan may rotate without warning, even
when the engine is not on. Do not place your hand,
cloth, tools or other items near the fan at any time.
4. ROADTESTS
Always conduct road tests in accordance with traf-
fic rules and regulations to avoid bodily injury and
interrupting traffic.
5. AIRBAG
To prevent bodily injury from unexpected deploy-
ment of airbags and unnecessary maintenance, fol-
low the instructions in this manual when performing
maintenance on the airbag components or nearby,
and the airbag wiring harnesses or nearby.
To prevent unexpected deployment, perform one of
the steps below and then wait at least 20 seconds
to discharge electricity before beginning work.
Step 1: Turn the ignition switch OFF.
Step 2: Remove the negative battery terminal.
6. AIRBAG DISPOSAL
To prevent bodily injury from unexpected airbag
deployment, do not dispose the airbag modules in
the same way as other refuse. Follow instructions
of SOA (distributor) service for disposal of airbag
module. Follow all government regulations con-
cerning the disposal of refuse.

PC-2
 I

NOTE

NT
Page
1. Note ............................................................................................................. 2
 NOTE
NOTE

1. Note
A: NOTE
This is the information that can improve the effi-
ciency of maintenance and assure the sound work.
1. FASTENER NOTICE
Fasteners are used to prevent the parts from dam-
age 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 cor-
rect torque and result in looseness and other prob-
lems.
2. STATIC ELECTRICITY DAMAGE
Do not touch the ECM, connectors, logic boards
and other such parts when there is a risk of static
electricity. Always use a static electricity prevention
cord or touch grounded metal before conducting
work.
3. IGNITION OFF BATTERY
When removing the battery cables, always be sure
to turn the ignition off to prevent electrical damage
to the ECM from rush current.
4. SERVICE PARTS
Use authentic service parts for maximum perfor-
mance and maintenance, when conducting repairs.
Subaru/FHI will not be responsible for poor perfor-
mance resulting from the use of parts not specified
by a genuine dealer.

NT-2
 NOTE I
NOTE

5. LIFTS AND JACKS

When using a lift or jack-ridged rack to raise a vehicle, always follow the 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

Pantograph jack
I Without side sill cover

With-ver

fi.w

Lift

Safety stand

GI0166

NT-3
 NOTE I
NOTE

Front
nt cross member

Rear Rear differential

GI0121

NT-4
 NOTE 3
NOTE

6. TIE DOWNS
Tie downs are used when transporting vehicles and when using the chassis dynamo. Attach tie downs only
to the specified points on the vehicle.

Hook for tie-down

Hook for towing

-1

Hook for tie-down Hook for towing

and tie-down

GI0122

NT-5
I NOTE I
NOTE

20 20’
20 20”

20 20”
20 20”

7. TOWING
Avoid towing vehicles except when the vehicle can-
not be driven. For vehicles with AWD, AT or VTD,
use a loader instead of towing. When towing other
vehicles, to prevent excessive weight from damag-
ing the hook or vehicle:
Do not tow other vehicles with a front towing
hook.
Make sure the vehicle towing is heavier than the
vehicle being towed.
8. TRAINING
For an information about training, contact a dealer
or agent.
9. GENERAL SCAN TOOL
Using general scan tools will greatly improve the ef-
ficiency of repairing engine electronic controls. The
Subaru Select Monitor can be used to diagnose the
engine and also the ABS, the air conditioner and
other parts.

NT-6
IDENTIFICATION

ID
Page
1. Identification................................................................................................2
 IDENTIFICATION I
IDENTIFICAT10 N

1. Identification
A: IDENTIFICATION
1. IDENTIFICATION NUMBER AND LABEL LOCATIONS
The VIN (Vehicle Identification Numbers) is used to classify the vehicle.
Positioning of the plate label for identification

Vacuum hose piping label

/
number plate

pressure label

..
Vehicle

' Model number plate

GI0161

Transmission serial number

Engine sdrial number G l0007A I o. G10008A I

ID-2
 IDENTIFlCATlON I
IDENTIFICATION

Model number plate /

b 'I L3 F r'z"'!it
trim code engine type E J 2 0 ENMABA~
9+#L2-F 230 s v 5 3 > w

GlOOllA

ID-3
 IDENTIFICATION
IDENTIFICATION

2. MEANING OF V.I.N.
The meaning of the VIN is as follows:
North America
]JF1GD255X2G500001[
The starting and ending brackets ( I[ ) are stop marks.

Digits Code Meaning Details

1to3 JFI Manufacturer body area JFI: Passenger car, FHI made
4 G Car line G: IMPREZA
5
ID
2 Displacement
D: 4 Door Sedan
G: Waaon
2: 2.0 L AWD Turbo
6
6: 2.5 LAWD
7 5 Grade 5: TS
7: RS
8: OUTBACK
9: WRX
8 5 Restraint 5: Manual belts, dual airbag.
6: Manual belts, dual airbag, side airbag.
9 X Check digit 0-9 & x
10 2 Model year 2: 2002MY
3: 2003MY
11 G Transmission type G: Full-time AWD 5-speed MT
H: Full-time AWD 4-speed AT
12 to 17 500001 Manufacture number From 500001: 4 Door Sedan
From 800001: Waaon

ID-4
 IDENTIFICATION
IDENTIFICATION

3. MODEL NUMBER PLATE

The model number plate indicates: the applied model, the option code, the trim code, the engine type, the
transmission type, and the exterior color code. This information is helpful when placing orders for parts.
GDEAY4R

Digits Code Meaning Details

Series G: IMPREZA
2
ID Body style D: 4 Door Sedan
G: Wagon
Engine displacement A: 2.0 L AWD Turbo
Drive system E: 2.5 L AWD
Sumension svstem
Minor chanae A: Initial
5 IY Destination Y: Left-hand drive for United States and Canada
Grade 4: TS
6: RS
7: OUTBACK
8: WRX
7 IR Transmission, fuel feed R: SOHC MPI 4-speed AT
system P: DOHC B MPI 4-speed AT
J: SOHC MPI 5-speed MT AWD
D: DOHC B MPI 5 - s ~ e e dMT AWD

Digits Code Meaning Details

3 and 4 25 Displacement 20: 2.0 L

25: 2.5 L
5 1 Fuel feed system 1: D-MPI SOHC-A
5: MPI Turbo
6 A Exhaust reuulations US Federal & California
7

8
Iw
3
Transmission

Minor change
I 3: 3 is applied for this vehicle.
9to10 AB Detailed specifications Used when ordering parts. See the parts catalog for details.

ID-5
I IDENTIFlCATlON
IDENTIFICATION

Transmission
TV1 A421AA
Digits Code Meaning Details
Transmission T: Transmission

I3 and 4

5
14
Transmission type

Classification

Series
Y: Full-time AWD MT center differential
V: Full-time AWD AT center differential
Z: Full-time AWD AT MPT
75: MT
1A: AT
I M T 14:5MT
AT 14: New AT
I
6 Z Transmission specifica- V: Full-time AWD 5-speed MT with viscous coupling center dif-
tions ferential single range
Z: Full-time AWD 4-speed AT with MPT
Y: Full-time AWD 4-speed AT with VTD
7 I1 Minor change I I : Initial I
8 to 10 I AA Detailed specifications I Used when ordering parts. See the parts catalog for details. I
Rear differential
EH
Code Reduction LSD
aear ratio
I EG 13.900 I No I
4.1 11

4.1 11 Viscous

ID-6
 I

RECOMMENDED MATERIALS

RIM
Page
1. Recommended Materials ,..........................,................................................2
I RECOMMENDED MATERIALS
RECOMMENDED MATERIALS
~

1. Recommended Materials
A: RECOMMENDED MATERIALS
1. GENERAL
To insure the best performance, always use the
specified oil, gasoline, adhesive, sealant, etc. or
that of equivalent quality.
2. FUEL
Always use a gasoline of the same or higher octane
value than specified in the owner's manual. Ignor-
ing the specifications below will result in damage or
poor operation of the engine and fuel injection sys-
tem. Use the specified gasoline to correct perfor-
mance.
Unleaded gasoline
Use unleaded gasoline and not leaded gasoline on
vehicles with a catalytic converter installed to re-
duce air pollution. Using leaded gasoline will dam-
age ihe catalytic converter.

RM-2
 RECOMMENDED MATERIALS
RECOMMENDED MATERIALS

3. LUBRICANTS
Use either the lubricants in the table below or equivalent lubricants. See the table below to choose the correct
SAE viscosity.
Lubricant Recommended Alternative
API Spec. ACEA Spec.
Engine oil SJ Grade “Energy conserving” A1 , A2 or A3 API: SH or SG

GlOOOl

GI0002
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

< 5W-30 Recommend I

G10003A

RM-3
 RECOMMENDED MATERIALS
RECOMMENDED MATER IALS

SAE viscosity SAE viscosity No. and applicable temperature SAE J300
Manual transmission oil
("C) -30 -20 -1 0 0 10 20 30 40

(OF) -22 -4 14
I
32 50 68 86 104
I I I I
>
I I I I

l l
I I I
90
/

85W
3ear differential
I

80W
I I I I I I
7 75W-90 2
G10004A
'ront differential
('C) -30 -20 -1 0 0 10 20 30 40

(OF) -22 -4 14 32 50 68 86 104

G10005A

4. FLUID
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 I l l -
Power steerina fluid DEXRON Ill -
Brake fluid FMVSS No. 116 DOT3 FMVSS No. 116 DOT4
Clutch fluid FMVSS No. 1 16 DOT3 FMVSS No. 116 DOT4
5. COOLANT
Use the 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

Air conditioner Recommended Item number Alternative

Refrigerant HFC134a - None
Compressor oil DH-PR - None
 RECOMMENDED MATERIALS I
RECOMMENDED MATERIALS

7. GREASE
Use the grease and supplementary lubricants shown in the table below.

Grease Application point Recommended Item number Alternative

Supplementary lubricants 0 2 sensor SUBARU CRC 004301003 -
Bolts. etc.
Grease MT main shaft I FX clutch clrease I 000040901 I -
Clutch master cylinder Slicolube G-40M 004404003 -
push rod
Steering shaft bush SUNLIGHT2 003602010 -
(Toe board)
Gear shift bush
Steering gear box Valiant grease M-2 003608001 -
Disc brake Niglube RX-2 003606000 or -
725191040
I I -
~~

I
Drum brake
Brake pad
Brake shoe
1 Molvkote No. 7439
Molykote AS-880N
72519460
26298AC000
I
Front axle SFJ SSG-6003 28093TAOOO -
Front axle EBJ NTG 2218 28093AA000 -
Rear axle EBJ NTG 2218 28093AA000 -
._ (Turbo model)
Rear axle BJ Molylex No. 2 723223010 -
(Non-turbo model)
Rear axle DOJ VU-3A702 23223GA050 -
Control cable Slicolube G-30M 004404002 -
Throttle linkage
Water pump
Door latch
Door striker
8. ADHESIVES
Use the adhesives shown in the table below, or equivalent.

Adhesive Windshield and body
Soft vinyl
Momentarv sealant
9. SEAL MATERIAL
Essex Chemical Crop’s Ure- - Sunstar 580
thane E
Cemedine 540 - 3M’s EC-776 EC-847 or EC-1022
(Spray type)
Cemedine 3000 - Armstrona’s Eastman 910

I Enaine case I Three Bond 1215 I004403007 I Dow Corning’s No. 7038 I
Transmission oil pan Three Bond 12178 K0877YA020 -
Torque converter clutch Three Bond 12158 004403007 Dow Corning’s No. 7038
case
Rear differential Three Bond 1324 004403042 -
Rear differential Three Bond 1105 004403010 -
I Weatherstrip I Starcalking B-33A I000018901 I Butyl Rubber sealant I
Steering adjusting screw Three Bond 1102 004403006 -
SOHC cam cap Three Bond 12808 K0877YA018 -

RM-5
I RECOMMENDED MATERIALS 1
RECOMMENDEDMATERIALS

c-

RM-6
 I

PRElDELlVERY INSPECTION

PI
Page
1. Pre-delivery Inspection...................... ........................ .................................. 2
I PRE-DELIVERY INSPECTION
PRE-DELIVERY INSPECTION

1. Pre-delivery Inspection
A: GENERAL
The purposes of the pre-delivery inspection (PDI)
are as follows.
Remove the additional parts used for ensuring
the vehicle quality during transportation and restore
the vehicle to its normal state.
Check if the vehicle before delivery is in a normal
state.
Check for any damage or missing parts that may
have taken place during transportation or storage.
Make sure to provide a complete vehicle to the
customer.
Because of the above reasons, all dealerships
must always carry out the PDls before delivering a
vehicle.
In addition, all franchised shops and PDI centers
must check the status of every vehicle received to
identify who is responsible for any possible defects.

PI-2
 PRE-DELIVERY INSPECTION
PRE-DELIVERY INSPECTION

B: PDI PROCEDURE
Follow the procedures shown in the table below.
Static Checks Just After Vehicle Receipt

Step Check point

I . 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 (4) Check the tires for damage, abnormal conditions, and dents on the
wheels.
f5) Check the tire air Dressure.
~

3. Fuse installation (6) If the vehicle is about to be delivered to the customer, attach a room lamp
fllRF!

E h e c k the doors for locklunlock and openlclose
iperations.
5 . Power window oDeration check
ii+Check the trunk lid openlclose operations.
7. Check the rear gate for locklunlock and open1
:lose operations.
3. Operation check of trunk lid release handle
3. Operation check of fuel lid opener lock release
ever
10. Accessory check
11. Operation check of hood lock release system
~
(7) Using the key, check if the door can be locked and unlocked normally.
(8) Open and close all doors to see that there are no abnormal conditions.
(9) Operate the power door locking switch to check that all doors is locked
and unlocked normally.
(10) Check the power window for correct operations.
(11) Operate the trunk lock release lever to check that the trunk opens nor-
mally.
(12) Using the key, check if the trunk lid can be unlocked normally.
(13) Open and close the trunk lid to see that there are no abnormal condi-
tions.
(14) Using the key, check if the rear gate can be lock and unlocked normally.
(15) Open and close the rear gate to see that there are no abnormal condi-
tions.
(16) Operate the power door locking switch to check that the rear gate is
locked and unlocked normally.
(17) Operate the trunk lid release lever to check the trunk is unlocked nor-
mally.
(18) Operate the fuel lid opener to check that the fuel lid is unlocked normally.
Check the following accessories are provided:
Owner's manual
Warranty booklet
Service booklet
Spare key
Jack
Tool set
Spare tire
(1) Operate the hood lock release lever to check that the hood opens nor-
mallv.

12. Connection of air conditioner harness (2) If the vehicle is about to be delivered to the customer, connect the air con-
ditioner harness.
13. Battery (3) Check the battery for any abnormal conditions such as rust and trace of
battery fluid leaks.
14. Brake fluid (4) Check the fluid amount.
15. Engine oil (5) Check the oil amount.
16. Transmission fluid (6) Check the fluid amount.
(7) For AT, check the front differential oil.
17. AT front differential oil (8) Check the AT front differential oil amount.
18. Coolant f9) Check the coolant amount.
19. Clutch fluid (10) Check the clutch fluid amount.
20. Window washer fluid (11) Check the window washer fluid amount.
21. Hood latch check (12) Check that the hood is closed and latched securely.

PI-3
 PRE-DELIVERY INSPECTION I
PRE-DELIVERY INSPECTION

Step Check point

22. Keyless entry system (13) Check that the keyless entry system operates normally.
23. Securitv svstem (14) Check that the securitv svstem operates normallv.
(15) Check the seat surfaces for smears or dirt.
124. Seat (16) Check the seat installation conditions and functionality.
125. Seat belt I (17) Check the seat belt installation conditions and functionality. I
126. Wheel alignment I (18) Check that the wheel alignments are properly adjusted.
Checks with the Engine Running
I Step I Check point I
27. Read memory and test mode connectors (1) Read memory and test mode connectors
28. Starting condition (2) Start the engine and check that the engine starts smoothly.
29. Exhaust system (3) Check that the exhaust noise is normal and no leaks are found.
30. Indicator liaht (4) Check that all indicator liahts operate normally.
I 31. Clock I (5)Check that the clock operates normally. I
132. Radio I (6) Check that the radio system operates normally. I
33. Cigarette lighter (7) Check that the cigarette lighter operates normally.
34. Lighting system (8) Check that the lighting systems operate normally.
35. Window washer (9) Check that the window washer system operates normally.

I
36. WiDer ~. Check that the wiper
(10) . svstem
- oDerates normally. I

Pynamic Test with the Vehicle Running

Step Check point
37. Brake test (1) Check that the foot brake operates normally.
38. Parkina brake (2) Check that the parkina brake operates normally.
M A T shift control I (3) Check that the AT shift patterns are correct. I
I 40. Heater & ventilation I (4) Check that the heater & ventilation system operates normally. I
41. Air conditioner (5) Check that the air conditioner operates normally.
42. Cruise control (6) Check that the cruise control system operates normally.

I Step I Check point I

43. ATF level I (1) Check that the ATF level is normal.
44. Power steerina fluid level I 12) Check that the Dower steerina fluid level is normal.
I
, \ I

1
8. I

45. Fluid leak check I 13) Check for fluid/oil leaks.

\ ,

146. Water leak check I (4) Sprav the vehicle with water and check for water leaks.
47. Appearance check 2 (5) Remove the protective coating (if any).
(6) Check the body paints for damage and smears.
(7) Check the plated parts for damage and rust.

PI-4
 PRE-DELIVERY INSPECTION 1
PRE-DELIVERY INSPECTION

1. APPEARANCE CHECK 4. CHECK THE DOOR OPERATIONS,

If the vehicle is covered with protective coating, LOCWUNLOCK AND OPENELOSE, AS
visually check the vehicle body for damage and FOLLOWS.
dents. Using the key, lock and unlock the door several
If there is no protective coating, check the body times to check for normal operation. Open and
paints for small areas of damage or stains and re- close the door several times for smooth movement.
pair as necessary.
Check the window glass, door glass, and lights
for any cracks or damage and repair or replace the
parts as necessary.
Check the plated parts, such as the grilles and
door knobs, for damage or loss of gloss and repair
or replace the parts as necessary.
2. TIRECHECK
Check the tire outer faces for any damage.
Check the tire air pressure by referring to the fol- GI0148
lowing table.
Operate the power door locking switch on the front
Tire size Tire inflation pressure door arm rest, and check that all doors lock and un-
kPa (kg/cm2, psi) lock normally.
Front
P I 95/60R1587H 220 (2.2, 32) 200 (2.0, 25)
P205/55R1689V 220 (2.2. 32) 200 (2.0, 25)

3. FUSE INSTALLATION
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.

5. POWER WINDOW OPERATION CHECK

Manipulate the power window switches one by one
to check that each of the power windows goes up
and down with no abnormal noises.

(A) G10084A

PI-5
I PRE-DELIVERY INSPECTION
PRE-DELIVERY INSPECTION

6. CHECK THE TRUNK LID OPERATIONS,
OPEN/CLOSE, AS FOLLOWS.
Operate the trunk lock release lever and verify
that the trunk lid opens.
Using the key, open the trunk lid several times to
check for normal operation.
Open and close the trunk lid several times for
smooth movement.
8. OPERATION CHECK OF TRUNK LID RE-
LEASE HANDLE
1) Use a screwdriver with a thin blade. Slide the
screwdriver blade from the slit aperture of the lock
assembly fully to the end until you hear a click. This
places the latch in the locked position.

GI0157

7. CHECK THE REAR GATE OPERATIONS,

kOCWUNLOCK AND OPEN/CLOSE, AS
FOLLOWS.
Using the key, lock and unlock the rear gate sev-
eral times to check for normal opeartion.
Open and close the rear gate several times for
smooth movement.
I Locked
mni w

2) Move the release handle from outside the vehi-

cle, in the direction of the arrow to check if the latch
is released.

171

Operate the power door locking switch to check

that the rear gate is locked and unlocked normally.

I GI0160 I

PI-6
 PRE-DELIVERY INSPECTION I
PRE-DELIVERY INSPECTION

9. OPERATION CHECK OF FUEL LID 11.OPERATION CHECK OF HOOD LOCK

OPENER LOCK RELEASE LEVER RELEASE SYSTEM
Operate the fuel lid opener and verify that the fuel Unlatch and open the hood while checking that no
lid opens normally. Check that the filler cap is se- abnormal conditions are found. Then, support the
curely closed. hood with the hood stay.
1O.ACCESSORY CHECK
Check that the following accessories are provided
in the luggage compartment or cargo area.
Owner's manual
Warranty booklet
Service booklet
Spare key
Jack
Tool set
Spare tire

GI0151

P1-7
I PRE-DELIVERY INSPECTION I
PRE-DELIVERY INSPECTION

12.CONNECTION OF AIR CONDITIONER 16.TRANSMISSION FLUID

HARNESS
A vehicle just delivered has its air conditioner har-
ness disconnected to protect the air conditioner
compressor. Connect the harness as shown in the
figure.
Check the transmission fluid amount. If the amount
is insufficient, check that no leaks are found. Then,
add the necessary amount of the specified fluid.
Oil level gauge

Upper level
Lower level

I
_- G10088A I

17.AT FRONT DIFFERENTIAL OIL

13.BATTERY
Check the battery terminals to make sure that no
rust or corrosions due to fluid leaks are found.
check that the battery caps are securely tightened.
Check the AT front differential oil amount. If the
amount is insufficient, check that no leaks are
found. Then, add the necessary amount of the
specified AT front differential oil.

1
18.COOLANT
_I
- Upper level
-Lower level
GlOO89Al

14.BRAKE FLUID Check the coolant amount on the reservoir. If the

Check the brake fluid amount. If the amount is in-
sufficient, carry out a brake line test to identify
brake fluid leaks and check the brake operation. Af-
ter that, refill the brake fluid tank with the specified
type of fluid.
15.ENGINE OIL
Check the engine oil amount. If the amount is insuf-
ficient, check that no leaks are found. Then, add
the necessary amount of the specified engine oil.
amount is insufficient, check that no leaks are
found. Then, add the necessary amount of coolant
with the specified concentration.
19.CLUTCH FLUID
Check the clutch fluid amount. If the amount is in-
sufficient, check that no leaks are found. Then, add
the necessary amount of the specified fluid.
I

P Upper level
About 1.Oe
(1.1 us qt,
0.9 Imp qt)

Lower level

I G10087A I
PI-8
 PRE-DELIVERY INSPECTION I
PRE-DELIVERY INSPECTION

20.WlNDOW WASHER FLUID Press the “LOCWARM” button on the transmitter

momentarily once with one of the doors including
Check the window washer fluid amount. If the
the rear gate (wagon) open and check if the horn
amount is insufficient, check that no leaks are
chirps three times to warn of a door ajar.
found. Then, add the necessary amount of washer
Then, bring all the doors including the rear gate
fluid commercially available.
(wagon) in closed condition and check if all the
21.HOOD LATCH CHECK doors are locked and the horn chirps once.
Press the “LOCK side of the power door locking
Retract the hood stay and close the hood. Check
switch with any one of the doors including the rear
that the hood is securely latched.
gate (wagon) open. Then, bring all the doors in-
22.KEYLESS ENTRY SYSTEM cluding the rear gate (wagon) in the closed condi-
tion and check if all the doors are locked and the
Check the keyless entry system operations as fol-
horn chirps once.
lows:
Fully open all the door windows.
LOCK
Remove the key from the ignition switch and
close all the doors including rear gate (wagon).
Press the “LOCWARM” button on the transmitter
momentarily once and check if all the doors are
locked and the horn chirps once.
I

Check selecting audible signal operation.

GI0091
Press the “UNLOCWDISARM” button on the
transmitter momentarily once and check if the driv-
er’s door is unlocked, the horn chirps twice and the
dome light illuminates.
I I
Using the horn, the system will give you an audi-
ble signal when the doors lock and unlock.
If desired, you may turn the audible signal off.
To turn the audible signal off, carry out the unlock-
ing procedure of keyless entry system, then simul-
taneously depress LOCWARM and UNLOCW
DISARM buttons for more than two seconds.
The horn will sound two times to inform you that the
audible signal has been turned off.
To turn the audible signal on, carry out the unlock-
ing procedure of keyless entry system, then simul-
taneously depress LOCWARM and UNLOCW
DISARM buttons for more than two seconds.
The forn will sound one time to inform you that the
audible signal has been turned on.

GI0092

Press the “UNLOCWDISARM” button on the

transmitter momentarily once again within five sec-
onds and check if all the doors including the rear
gate on wagon are unlocked.
Press the “LOCWARM” button on the transmitter
a little bit of time (approx. 1.5 sec.) and check if a
panicking condition occurs; the horn sounds contin-
uously. Also, check if that condition lasts for 30 sec-
onds or until any button of the transmitter is
pressed.
I PRE-DELIVERY INSPECTION
PRE-DELIVERY INSPECTION
23.SECURITY SYSTEM
Check the security system operations as follows:
Fully open all the door windows.
Remove the key from the ignition switch and
close all the doors including rear gate (wagon).
Press the “LOCWARM” button on the transmitter
momentarily once and check if all the doors are
locked, the horn chirps once, the parking lights
flash once and the security indicator light flashes
slowly to ensure that the security system has been
brought into the arming state.
c-
GI0091
Press the “UNLOCWDISARM” button on the
transmitter momentarily once and check if the driv-
er’s door is unlocked, the horn chirps twice, the
parking light flash twice, the dome light illuminates
and the security indicator light goes off to ensure
that the system has been brougt into the disarming
state.
I I
GI0092
Press the “UNLOCWDISARM” button on the
transmitter momentarily once again within five sec-
onds and check if all the doors including the rear
gate on wagon are unlocked.
Press the “LOCWARM” button on the transmitter
a little bit of time (approx. 1.5 sec.) and check if a
panicking condition occurs; the horn sounds contin-
uously, the parking lights flash and the security in-
dicator light flashes rapidly. Also, check if that
condition lasts for 30 seconds or until any button of
the transmitter is pressed.
Press the “LOCWARM” button on the transmitter
momentarily once with one of the doors including
the rear gate (wagon) open and check if the horn
chirps three times to warn of a door ajar.
PI-I 0
Then, bring all the doors including the rear gate
(wagon) in closed condition and check if the arming
condition is brought about; all the doors are locked,
the horn chirps once and the parking lights flash
once.
Press the “LOCK’ side of the power door locking
switch with any one of the doors including the rear
gate (wagon) open. Then, bring all the doors in-
cluding the rear gate (wagon) in the closed condi-
tion and check if all the doors are locked, the horn
chirps once and the parking lights flash once to en-
sure that the security system has been brought into
the arming state.
LOCK
Unlock a door using the inner lock knob or the
key and open the door while the security system is
in the arming state. Check to ensure that the alarm-
ing condition occurs, i.e. the horn sounds continu-
ously, the parking lights flash and security indicator
light flashes rapidly, and that it lasts for 30 seconds
or until the “UNLOCWDISARM” 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 prevented from start-
ing.
Apply a shock to the vehicle body with the secu-
rity system in arming state, and check to ensure
that the alarming condition occurs.
Troubleshoot the security system if any one of
the above-mentioned checks does not meet the re-
quirements.
24.SEAT
Check that each seat provides full functionality in
sliding and reclining. Check all available functions
of the rear seat such as a trunk-through center arm
rest.
25.SEAT BELT
Pull out the seat belt and then release it. Check
that the belt webbing retracts smoothly.
Check the seatbelt warning light and chime oper-
ations.
 PRE-DELIVERY INSPECTION 1
PRE-DELIVERY INSPECTION

26.WHEEL ALIGNMENT 35. LIGHTING SYSTEM

Check the wheel alignments. <Ref. to FS-8, Wheel Check the headlight operations.
Alignment.> and <Ref. to RS-9, Wheel Alignment, Check the brake light operations.
.> Check the other lights for normal operations.
Check the daytime running light system opera-
27.READ MEMORY AND TEST MODE CON- tions.
NECTORS Check the illumination brightness control system
Turn the ignition switch to ON and check that the operations.
check-engine light starts blinking. If the light blinks,
return the ignition key to LOCK and disconnect the 36.WINDOW WASHER
test mode connector. Then, turn the ignition key to Check that the window washer system injects
ON again. If the check-engine light blinks at that washer fluid to the specified area of the windshield
time in spite of the disconnected test mode connec- shown in the figure.
tor, carry out an engine diagnosis.
Front Injection position:
A: 257” (IO.12 in)
B: 512” (20.16 in)

___

28.KEY WARNING SYSTEM

Check that the chime sounds when the driver’s
door opens and the key is in the “LOCK’ or “ACC” Rear Injection position:
position. A: 39 mm (2.36 in)
29. STA RTING CONDIT10N B: 72”
Start the engine and check that the engine starts Nozzle
smoothly. If any battery voltage problems are (/
I \
found, recharge or replace the battery. If any ab- I
I \
\
normal noises are observed, immediately stop the 1?K
engine and check and repair the necessary compo-
nents.
30.EXHAUST SYSTEM
Listen to the exhaust noise to see if no abnormal
noises are observed.
31.INDICATOR LIGHT
Check that all the indicator lights are off.
32.CLOCK
Check the clock for normal operations and enough
accuracy.
33.RADIO
Check the radio for full functionality and normal
noise level. Also check the CD unit operations.
34.CIGARETTE LIGHTER
Check the cigarette lighter operations.

PI-I 1
I PRE-DELIVERY INSPECTION
PRE-DELIVERY INSPECTION

40.AT SHIFT CONTROL 45.POWER STEERING FLUID LEVEL

Set the AT selector lever to each gear position
while checking that the demanded gear position is
correctly attained.
Selector lever gate pattern
Check that the power steering fluid level is normal.
If insufficient, check that no leaks are found. Then
add the necessary amount of the specified power
steering fluid.

Selector Gear Position

Position 46.FLUID LEAK CHECK
Yes Yes Yes Check the entire areas of the vehicle for any trace
Yes Yes Yes of coolant/oil/fluid leaks.
I I I
I 2
1 I
Yes
Yes I
Yes 47.WATER LEAK TEST
Spray the vehicle with water and check that no wa-
Check the shift lock system operations. ter enters the passenger compartment.
Check the key interlock system operations. Before performing the water leakage test, re-
move anything that may obstruct the operation or
41 .HEATER & VENTILATION which must be kept dry.
Operate the heater and ventilation system to check Close all of the windows completely, and then
for normal airflow and heating capacity. close all of the doors tightly. Close the hood and
trunk lid before starting the test.
42.AIR CONDITIONER Connect a hose to a tap, and spray water on the
Operate the air conditioner. Check that the A/C vehicle. The rate of water discharge must be ap-
compressor operates normally and enough cooling prox. 20 to 25 liters (5.3 to 6.6 US gal, 4.4 to 5.5
is provided. Imp gal) per minute.
When spraying water on areas adjacent to the floor
43.CRUISE CONTROL and wheel house, increase the pressure. When di-
Operate the cruise control system. Check that the recting water on areas other than the floor portion
system is activated and deactivated correctly. and wheel house, decrease the pressure. But the
force of water must be made strong occasionally by
44.ATF LEVEL pressing the end of the hose.
Check that the ATF level is normal. If insufficient, NOTE:
check that no leaks are found. Then add the neces- Be sure to keep the hose at least 10 cm (3.9 in)
sary amount of the specified ATF. 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

1-
Rear window and body framework mating
Lower level <-upper level portion
Lower level Around roof drips
G10098A

PI-I 2
I PRE-DELIVERY INSPECTION I
PRE-DELIVERY INSPECTION

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
Check the vehicle body paints, plated faces, glass,
and lenses for any dirt or damage.

PI-I 3
 PRE-DELIVERY INSPECTION I
PRE-DELIVERY INSPECTION

PI-I 4
 PERIODIC MAINTENANCE SERVICES
PM
Page
1. General Description .................................................................................... 2
2. Schedule ..................................................................................................... 3
3. Engine Oil .................................................................................................... 5
4. Engine Oil Filter........................................................................................... 7
5. Spark Plugs ................................................................................................. 8
6. Drive Belt(s) ................................................................................................ 9
7. Camshaft Drive Belt .................................................................................. 11
8. Fuel Line ................................................................................................... 14
9. Fuel Filter .................................................................................................. 15
10. Air Cleaner Element .................................................................................. 16
.
11. Cooling System ......................................................................................... 17
12. Coolant ...................................................................................................... 18
13. Idle Mixture................................................................................................ 20
14. Clutch System ........................................................................................... 21
15. Transmission Oil ....................................................................................... 22
16. ATF ........................................................................................................... 23
17. Front & Rear Differential Oil ...................................................................... 24
18. Brake Line ................................................................................................. 25
19. Brake Fluid ................................................................................................ 27
20 . Disc Brake Pads and Discs ....................................................................... 28
21 . Brake Linings and Drums .......................................................................... 29
22 . Suspension ............................................................................................... 31
23 . Wheel Bearing........................................................................................... 33
24 . Axle Boots & Joints ................................................................................... 34
25 . Steering System (Power Steering) ............................................................ 35
26 . Supplemental Restraint System ................................................................ 38
 GENERAL DESCRIPTION I
PERIODIC MAINTENANCE SERVICES

1. General Description
A: GENERAL
Be sure to perform periodic maintenance in order to
maintain vehicle performance and find problems
before they become serious.

PM-2
 SCHEDULE I
PERIODIC MAINTENANCE SERVICES

--I1--Clutchsystem I I I I I I I I
12 Transmission oil I I I I
13 ATF I I I I Note (3)
14 Front 8, rear I I I I
differential oil
15 Brake line I I I I I I I I
16 Brake fluid R R R R
17 Disc brake pads & I I I I
discs
18 Brake linings and I I I I
drums
19 Parking brake I I I I I I I I
20 Suspension I I I I I I I I
21 Wheel bearing I I (1)
22 Axle boots &joints I I I I I I I I
23 Tire rotation I I I I I I I I I I I I I I I INote(4)
24 Steering system I I I I I I I I
(Power steering)
25 Supplement
Inspect every 10 years
restraint system
Symbols used:
R: Replace
I: Inspection
(R) or (I): Recommended service for safe vehicle operation.
NOTE:
(1)This inspection is not required to maintain emission warranty eligibility and it dose not affect the manufacturer’sobligations under
EPA’s in-use compliance program.
(2)When the vehicle is used in extremely dusty conditions, the air cleaner element should be replaced more often.
(3)ATF filter is maintenance free part. ATF filter needs replacement, when it has physically damaged or ATF leaked.
(4) 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 (0.063in) or less.

PM-3
I SCHEDULE
PERIODIC MAINTENANCE SERVICES

B: MAINTENANCE SCHEDULE 2
Item High humid- Repeat tow-
ity or moun- ing trailer
road drive used or tain area
coastal area
Engine oil R

Engine oil filter 3.75 months R

6,000 km
3,750 miles
Fuel filter 15 months
24,000 km
15,000 miles
Fuel line 15 months
24,000 km
15,000 miles
Transmission oil 15 months

-. 15,000 miles
AT F

Front & rear

differential oil

Brake line
15 months
24,000 km
15,000 miles
15 months
24,000 km
I I
R
15,000 miles
Brake fluid 15 months

15,000 miles
Disc brake pads
& discs
I
1 I

Brake linings 15 months I I I I

and drums 24,000 km
15,000 miles
Parking brake 15 months I I
ziGlK-7 I
I
I
15,000 miles I I
Suspension 7.5 months

Axle boots &

joints

Steering system
(Power steering)
7,500 miles

-izzzGl
7,500 miles
7.5 months
12,000 km
7,500 miles
I
I
I

II
I
I
I
I
I
I

II
I
I
I
T
-
PM-4
 ENGINE OIL I
PERIODIC MAINTENANCE SERVICES

3. Engine Oil 5) Fill the engine oil through filler pipe up to the up-
per point on level gauge. Make sure that the vehicle
A: REPLACEMENT is placed level when checking oil level. Use engine
1) Drain the engine oil by loosening engine oil drain oil of proper quality and viscosity, selected in accor-
Plug. dance with the table in figure.
Engine oil capacity (Non-TURBO model):
Upper level
4.0 0 (4.2 US qt, 3.5 Imp qt)
Lower level
3.0 0 (3.2 US qt, 2.6 Imp qt)
Engine oil capacity (TURBO model):
Upper level
4.5 0 (4.8 US qt, 4.0 Imp qt)
Lower level
3.5 0 (3.7 US qt, 3.1 Imp qt)
2) Open the engine oil filler cap for quick draining of
the engine oil.
SAE Viscosity No. and Applicable Temperature
("C) -30 -20-15 0 15 30 40
( O F ) -22 4 5 32 59 86 104
I I I I I I I
Upper level
About 1.0 L
(1.1 us qt,
0.9 Imp qt)
Lower level
G10015A

U
Thc proper viscosity helps vehicle get good cold
G10013A and hot starting by reducing viscous friction and
thus increasing cranking speed.
3) Replace the drain plug gasket.
4) Tighten the engine oil drain plug after draining NOTE:
engine oil. When replenishing oil, it does not matter if the oil
to be added is a different brand from that in the en-
Tightening torque: gine; however, use oil having the API classification
44 N-m (4.5 kgf-m, 33 fi-lb) and SAE viscosity No. designated by SUBARU.
If vehicle is used in desert areas with very high
temperatures or for other heavy duty applications,
the following viscosity oils may be used:
API classification: SJ or SH
SAE Viscosity No.: 30, 40, 1OW-50, 2OW-40, 20W-
50
6) Close the engine oil filler cap.
7) Start the engine and warm it up for a time.

PM-5
I ENGINE OIL
PERIODIC MAINTENANCE SERVICES

8) After the engine stops, recheck the oil level. B: INSPECTION

If necessary, add the engine oil up to the upper lev-
el on level gauge.
Oil level gauge
1) Park vehicle on a level surface.
2) Remove the oil level gauge and wipe it clean.
3) Reinsert the level gauge all the way. Be sure that
I-& Notch mark the level gauge is correctly inserted and in the
proper orientation.
Upper level 4) Remove it again and note the reading. If the en-
About 1 . O L gine oil level is below the “L” line, add oil to bring
(1.1 us qt, the level up to the “ F line.
0.9 Imp qt)
Lower level
5 ) After turning off the engine, wait a few minutes
for the oil to drain back into the oil pan before
checking the level.
6) Just after driving or while the engine is warm, the
G10016A engine oil level may show in the range between the
‘IF” line and the notch mark. This is caused by ther-
mal expansion of the engine oil.
7) To prevent overfilling the engine oil, do not add
the oil above the ‘IF’ line when the engine is cold.

PM-6
I ENGINE OIL FILTER
1
PERIODIC MAINTENANCE SERVICES

4. Engine Oil Filter

A: REPLACEMENT
1) Remove the oil filter with ST.
ST 498547000 OIL FILTER WRENCH

2) Get a new oil filter and apply a thin coat of engine

oil to the seal rubber.
3) Install the oil filter by turning it by hand, being
careful not to damage seal rubber.
4)-Tighten more (approximately 2/3 to 3/4 turn) af-
ter the seal rubber contacts the oil pump case. Do
not tighten excessively, or oil may leak.
5 ) After installing oil filter, run the engine and make
sure that no oil is leaking around seal rubber.
NOTE:
The filter element and filter case are permanently
joined; therefore, interior cleaning is not necessary.
6) Check the engine oil level. <Ref. to PI-3, PDI
PROCEDURE, Pre-delivery Inspection.>

PM-7
I SPARK PLUGS
PERIODIC MAINTENANCE SERVICES

5. Spark Plugs
A: REPLACEMENT
1) Remove the intake duct and intake chamber.
2) Remove the washer tank and put it aside.
3) Disconnect the spark plug cord.
4) Remove the spark plug with a plug-wrench.

5) Set the new spark plug.

Recommended
c-- spark plug :
Non-Turbo model
CHAMPION RClOYC4 (Standard)
NGK BKRSE-11
NGK BKRGE-11
Spark plug gap
1.0 - 1.1 mm (0.039 - 0.043 in)
Turbo model
NGK PFRGG
Spark plug gap
0.7- 0.8 mm (0.028 - 0.031 in)
6) Tighten the spark plug lightly with hand, and then
secure with a plug-wrench to the specified torque.
Tightening torque:
20.6 N.m (2.10 kgf-m, 15.19 ft-lb)
NOTE:
Be sure to place the gasket between the cylinder
head and spark plug.
If the 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) 1
PERIODIC MAINTENANCE SERVICES

6. Drive Belt(s) B: REPLACEMENT

A: INSPECTION 1. V-BELT COVER
1) Replace the belts, if cracks, fraying or wear is 1) Remove the V-belt cover.
found.
2) Check the drive belt tension and adjust it if nec-
essary by changing generator installing position
and/or idler pulley installing position.
Belt tension
(4
replaced: 7 - 9 mm (0.276 - 0.354 in)
reused: 9.0 - 10.0 mm (0.354 - 0.394 in)
( 9 )*
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 con- 2. FRONT SIDE BELT (DRIVING POWER
ditioner. STEERING OIL PUMP AND GENERATOR)
98 N (10 ka. 22 Ib) NOTE:
Wipe off any oil or water on the belt and pulley.
1) Loosen the lock bolt (A).
2) Loosen the slider bolt (B).
3) Remove the front side belt (C).
4) Install a new belt, and tighten the slider bolt so as
to obtain the specified belt tension.
5) Tighten the slider bolt (B).
6) Tighten the lock bolt (A).
Tightening torque:
C/P Crankshaft pulley
Lock bolt, through bolt:
25 N-m (2.5 kgf-m, 18 ft-lb)
GEN Generator
Slider bolt:
P/S Power steering oil pump pulley
8 N.m (0.8 kgf-m, 5.8 ft-lb)
A/C Air conditioning compressor pulley
I/P Idler pulley

G10021A

PM-9
I DRIVE BELT(S)
PERIODIC MAINTENANCE SERVICES

3. REAR SIDE BELT (DRIVING AIR CONDI-

TIONER)
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 (9).
3) Remove the rear side belt.
4) Install a new belt, and tighten the slider bolt so as
to obtain the specified belt tension.
5) Tighten the slider bolt (9).
6) Tighten the lock nut (A).
Tightening torque:
22.6 N*m (2.3 kgf-m, 16.6 ff-lb)

PM-10
 CAMSHAFT DRIVE BELT
1
PERIODIC MAINTENANCE SERVICES

7. Camshaft Drive Belt 10) Turn the crankshaft and align alignment marks
on crankshaft, and left and right camshaft sprock-
A: REPLACEMENT ets with notches of belt cover and cylinder block:
ST 499987500 CRANKSHAFT SOCKET
1. SOHC MODEL
Notch
1) Remove the radiator fan <Ref. to CO-9, Radia-
tor Main Fan System.> and air conditioner fan.
<Ref. to CO-17, Radiator Sub Fan System.>
2) Remove the V-belt cover.

ent mark

Notch

3)Remove the V-belts. <Ref. to ME(S0HC)-43, V-

belt.>
4) Remove the air conditioning compressor drive
belt tensioner.
5 ) Remove the pulley bolt. To lock crankshaft use
ST. G10025A
ST 499977t00 CRANKSHAFT PULLEY 11) Remove the belt idler.
WRENCH 12) Remove the belt idler (No. 2).

GI0026
6) Remove the crankshaft pulley. 13) Remove the timing belt.
7) Remove the left side belt cover. 14) Remove the automatic belt tension adjuster as-
8) Remove the front belt cover. sembly.
9) Remove the timing belt guide. (MT vehicle only)

PM-11
I CAMSHAFT DRIVE BELT 3
PERIODIC MAINTENANCE SERVICES

2. DOHCMODEL 10) Turn the crankshaft and align alignment marks

on crankshaft, and left and right camshaft sprock-
1) Remove the radiator fan and air conditioner fan. ets with notches of belt cover and cylinder block. To
turn crankshaft, use ST:
ST 499987500CRANKSHAFT SOCKET

Notch Notch

Alignment
mark

Alignment
mark
Notch -
2) Remove the V-belts. <Ref. to ME(D0HC TUR- Alignment
BO)-44, V-belt.> mark
3) Remove the air conditioning compressor drive
belt tensioner.
4) Remove the pulley bolt. To lock crankshaft use ,Alignment

ST.
ST. 499977300
c-
CRANKSHAFT PULLEY
WRENCH

BOO139

11) Remove the belt idler.

5) Remove the crankshaft pulley.

6) Remove the air conditioning compressor drive
belt tensioner.
7) Remove the left side belt cover.
8) Remove the right side belt cover.
9) Remove the front belt cover.
12) Remove the timing belt.
13) Remove the automatic belt tension adjuster as-
sembly.

PM-12
 CAMSHAFT DRIVE BELT
B: INSTALLATION
1. SOHC MODEL
To install, reverse order of removal procedures.
<Ref. to ME(S0HC)-47, Timing Belt Assembly.>
2. DOHCMODEL
To install, reverse order of removal procedures.
<Ref. to ME(D0HC TURBO)-48, Timing Belt As-
sem bly.>
CAUTION:
When installing the timing belt, be sure to align
all alignment marks on the belt with corre-
sponding marks on the sprockets. If incorrectly
installed, interference between pistons and
valves may occur.
--
PM-13
I
PERIODIC MAINTENANCE SERVICES
C: INSPECTION
1. SOHC MODEL
1) Remove the left and right timing belt covers.
2) While cranking engine at least four rotations,
check the timing belt back surface for cracks or
damage. Replace the faulty timing belt as needed.
3) Measure the timing belt width W. If it is less than
27 mm (1.06 in), check the idlers, tensioner, water
pump pulley and cam sprocket to determine idler
alignment (squareness). Replace the worn timing
belt.
I
4) Install the left and right timing belt covers.
2. DOHCMODEL
1) Remove the left and right timing belt covers.
2) While cranking engine at least four rotations,
check the timing belt back surface for cracks or
damage. Replace the faulty timing belt as needed.
3) Measure the timing belt width W. If it is less than
30 mm (1.18 in), check the idlers, tensioner, water
pump pulley and cam sprocket to determine idler
alignment (squareness). Replace the worn timing
belt.
4) Install the left and right timing belt covers.
GI0143
I FUEL LINE
PERIODIC MAINTENANCE SERVICES

8. Fuel Line
A: INSPECTION
The fuel line is located mostly internally, so check
the pipes, areas near pipes, and engine compart-
ment piping for rust, hose damage, loose bands,
etc. If the faulty parts are found, repair or replace
them. <Ref. to FU(S0HC)-68, Fuel Delivery, Re-
turn and Evaporation Lines.> or <Ref. to FU(D0HC
TURBO)-68, Fuel Delivery, Return and Evapora-
tion Lines.>

c- .

PM-14
 FUEL FILTER
PERIODIC MAINTENANCE SERVICES

9. Fuel Filter
A: REPLACEMENT
For fuel filter replacement procedures, refer to “FU”
section.
<Ref. to FU(S0HC)-65, Fuel Filter.> or <Ref. to
FU(D0HC TURBO)-65, Fuel Filter.>

PM-15
I AIR CLEANER ELEMENT
PERIODIC MAINTENANCE SERVICES

1O.Air Cleaner Element 2. TURBO MODEL

A: REPLACEMENT
NOTE:
Do not attempt to clean the air cleaner element.
The filter paper of the element is wetted with a spe-
cial non-inflammable slow-evaporating viscous liq-
uid. 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 012E
cleaned, the filtration layer thus formed will be lost 1) Remove the clip (B) above the air cleaner case.
along with the viscous liquid.
1. NON-TURBO MODEL

2) Remove the air cleaner.

1) Remove the bolt (A) which install air cleaner
case to stays.
2) Remove the clip (B) above the air cleaner case.
3) Install in the reverse order of removal.
CAUTION:
Before installing air cleaner upper cover, align
holes with protruding portion of air cleaner low-
er case, then secure upper cover to lower case.

3) Remove the air cleaner.

4) Install in the reverse order of removal.
CAUTION:
Fasten with a clip after inserting the lower tab
of the case.

PM-16
 COOLING SYSTEM
3
PERIODIC MAINTENANCE SERVICES

11.Cooling System Radiator cap valve open pressure

Standard value:
A: INSPECTION 93 - 123 kPa (0.95 - 1.25 k g / c d , 14 - 18
1) Check the radiator for leakage, filling it with cool- Psi)
ant and attach radiator cap tester to the filler neck. Service limit:
Then apply a pressure of 157 kPa (1.6 kg/cm2 , 23 83 kPa (0.85 k g / c d , 12 psi)
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 ra-
diator filler neck.

TURBO model tion,

/
Crack, deformation
damage, rust
G10035P

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
76.0 to 80.0"C (169 to 176"F), replace it with a new
one.
4) If electric fan does not operate when coolant
temperature exceeds 90 to 94°C (194 to 201"F),
check thermoswitch or fan motor.
When performing this check, be sure to keep the
engine stationary and fill radiator with coolant.
Wipe off check points before applying pressure.
Use care not to spill coolant when detaching
tester from radiator.
2) Check the radiator cap valve open pressure us-
ing 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.

PM-17
I COOLANT
PERIODIC MAINTENANCE SERVICES

12.Coolant 11) Stop the engine and wait until coolant temper-
ature lowers. Then open the radiator cap to check
A: REPLACEMENT coolant level and add coolant up to radiator filler
neck. Next, add coolant into reservoir tank up to
1. REPLACEMENT OF COOLANT “FULL” level.
WARNING: 12) After adding coolant, securely the install radia-
The radiator is of the pressurized type. Do not tor and reservoir tank caps.
attempt to open the radiator cap immediately
after the engine has been stopped.
1) Lift up the vehicle.
2) Remove the under cover.
3) Place a container under drain pipe.
4) Loosen and remove the drain plug to drain en-
gine coolant into the container.

5) For quick draining, open the radiator cap.

CAUTION:
Be careful not to spill coolant on the floor.
6) Drain the coolant from reservoir tank.
7) Tighten the radiator drain screw securely after
draining coolant.
8) Slowly pour the prepared coolant from radiator
filler port to neck of filler, then pour into the reser-
voir tank up to “FULL” level.
Coolant capacity (fill up to “FULL” level)
Non-turbo AT model:
Approx. 6.9 Q (7.3 US qt, 6.1 Imp qt)
Non-turbo MT model:
Approx. 7.0 Q (7.4 US qf, 6.2 Imp qt)
Turbo AT model:
Approx. 7.6 Q (8.0 US qt, 6.7 Imp qt)
Turbo MT model:
Approx. 7.7 Q (8.1 US qt, 6.8 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 the 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 cooling system.)

PM-18
 COOLANT I
PERIODIC MAINTENANCE SERVICES

2. RELATIONSHIP OF SUBARU COOLANT 3. PROCEDURE TO ADJUST THE CON-

CONCENTRATION AND FREEZING TEM-
PERATURE
The concentration and safe operating temperature
of the SUBARU coolant is shown in the diagram.
Measuring the temperature and specific gravity of
the coolant will provide this information.
[Example]
If the coolant temperature is 25°C (77°F) and its
specific gravity is 1.054, the concentration is 35%
(point A), the safe operating temperature is -1 4°C
(7°F) (point B), and the freezing temperature is -
20°C (-4°F) (point C).
Safe operating temperature
CENTRATION OF THE COOLANT
To adjust the concentration of the coolant accord-
ing to temperature, find the proper fluid concentra-
tion in the above diagram and replace the
necessary amount of coolant with an undiluted so-
lution 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 in-
creased from 25% to 40%. Find point A, where the
25% line of coolant concentration intersects with
the 40% curve of the necessary coolant concentra-
tion, and read the scale on the vertical axis of the

/ ,Concentration
of coolant
graph at height A. The quantity of coolant to be
drained is 2.1 liters (2.2 US qt, 1.8 Imp qt). Drain
2.1 liters (2.2 US qt, 1.8 Imp qt) of coolant from the
cooling system and add 2.1 liters (2.2 US qt, 1.8
Imp qt) of the undiluted solution of SUBARU cool-
ant.
If a coolant concentration of 50% is needed, drain
all the coolant and refill with the undiluted solution
only.

-
I

-2
I
U Necessary concentration
r of coolant

Coolant temperature "C ("F)

G10037A

I
c 10 20 30 40 5C
0

-
c
%

c
(t(
Concentration of coolant in the vehicle
cooling system

3 Concentration of coolant in vehicle

and quantity to be drained

G10038A

PM-19
 IDLE MIXTURE
PERIODIC MAINTENANCE SERVICES

13.Idle Mixture
A: INSPECTION AND ADJUSTMENT
1. IDLE MIXTURE
Before measuring the idle mixture, make sure that
the ignition timing and the engine idle speed are
within specifications.
1) Set the gear position at “Neutral” for MT, or “N” or
“P” for AT.
2) Warm up the engine sufficiently until cooling fan
starts to operate.
3) Measure the idle mixture with the CO meter.
Engine idle speed co
700+100 rpm 1.0+0.5% I

I GI01 14A 1
NOTE:
If driving the vehicle on out of specified data, the
“trouble code 49” is indicated in many case.

PM-20
 CLUTCH SYSTEM
1
PERIODIC MAINTENANCE SERVICES

14.Clutch System
A: INSPECTION AND ADJUSTMENT
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.
5) Check the fluid level using the scale on the out-
side of the clutch master cylinder tank (A). If the lev-
el 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.

TURBO model, \

2) If the fluid level rises, pedal free play is correct.

3) If the fluid level does not rise, or the push rod
cannot be retracted, adjust the clutch pedal. <Ref.
to CL-26, Clutch Pedal.>
4) Inspect the underside of master cylinder, clutch
damper and operating cylinder for clutch system,
hoses, piping and their couplings for fluid leaks.
If the fluid leaks are found, correct them by retight-
ening their fitting bolt and/or replacing their parts.

PM-21
I TRANSMISSION OIL
PERIODIC MAINTENANCE SERVJCES
~ ~~

15.Transmission Oil
A: REPLACEMENT
1. MANUAL TRANSMISSION
1) Drain the gear oil by removing drain plug after al-
lowing the engine to cool for 3 to 4 hours.
NOTE:
Before starting work, cool off the engine well.

2) Reinstall the 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-lb)
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 the transmission gear oil through the oil level
gauge hole up to the upper point of level gauge.
Gear oil capacity:
3.5 8 (3.7 US qt, 3.1 Imp qt)

\-upper
--Lower level

I
G10042P

PM-22
 ATF 1
PERIODIC MAINTENANCE SERVICES

16.ATF 2. ATF FILTER

A: REPLACEMENT
1. AUTOMATIC TRANSMISSION FLUID
1) Drain ATF (Automatic Transmission Fluid) by re-
moving drain plug after allowing the engine to cool
for 3 to 4 hours.
NOTE:
Before starting work, cool off the engine well.
NOTE:
ATF filter is maintenance free part. ATF filter needs
replacement, when it has physically damaged or
ATF leaked.
For the replacement procedures Of the ATF filter:
<Ref. to AT-44, ATF Filter.>

2) Reinstall the drain plug after draining ATF, and

tighten it to the specified torque.
Tighfening torque:
24.5 N.m (2.5 kgf-m, 78.7 ff-16)
3 ) Fill ATF up to the middle of the “COLD” side on
level gauge by using the gauge hole.
Recommended fluid:
Dexron 111 type automatic transmission fluid
Fluid capacity:
Fill the same amount drained from ATF drain
plug hole.
4) Run the vehicle until the ATF temperature rises
to 60 to 80°C (140 to 176°F) and check the ATF
level.
I “Hot”

Lower
level

G10044P

PM-23
I FRONT & REAR DIFFERENTIAL OIL I
PERIODIC MAINTENANCE SERVICES

17.Front & Rear Differential Oil 3. REAR DIFFERENTIAL

A: REPLACEMENT
1. FRONT DIFFERENTIAL (MANUAL
TRANSMISSION)
For M/T vehicle, manual transmission oil works as
differential oil to lubricate differential. Refer to
“Transmission Oil”. <Ref. to PM-22, Transmission
Oil.>
2. FRONT DIFFERENTIAL (AUTOMATIC
TRANSMISSION)
1) Drain the differential gear oil by removing drain
plug after allowing the engine to cool for 3 to 4
hours.
NOTE:
Before starting work, cool off the engine well.
1) Drain the oil by removing drain plug.
2) Remove the filler plug for quick draining oil.
3) Reinstall the drain plug after draining oil.
NOTE:
Apply the fluid packing to drain plug threads be-
fore installation in Except Non-TURBO AT model.
Fluid packing:
Three Bond 1105
Tightening torque:
49.0 N-m (5.0 kgf-m, 36.2 ff-lb)
4) After installing drain plug onto rear differential
gear case firmly, fill oil up fully to the mouth of filler
Plug.

L Drain plug
GI0165

Oil capacity:
0.8 8 (0.8 US 9t, 0.7 Imp 9t)
2) Reinstall drain plug after draining differential NOTE:
gear oil and tighten it to the specified torque. Each oil manufacturer has its base oil and addi-
tives. Thus, do not mix two or more brands.
Tightening torque:
5) Install the filler plug onto rear differential gear
44 N-m (4.5 kgf-m, 32.5 ff-lb)
case firmly.
NOTE:
NOTE:
Be sure to place a gasket between the transmis-
Apply the fluid packing to filler plug before installa-
sion case and drain plug.
Replace the gasket with a new one. tion.
Each oil manufacturer has its base oil and addi- Fluid packing:
tives. Thus, do not mix two or more brands. Three Bond 1105
3) Fill differential gear oil through the oil level gauge Tightening torque:
hole up to the upper point of level gauge. 49.0 Nom(5.0 kgf-m, 36.2 ff-lb)
Differential gear oil capacity:
1.1-1.3 8 (1.2-11.4US9t, l.0-11.11mp9t)

-Upper level
-Lower level
G10046A

PM-24
 BRAKE LINE I
PERIODIC MAINTENANCE SERVICES

18.Brake Line B: CHECKING

A: INSPECTION 1. SERVICE BRAKE
1) Check the free play of brake pedal with a force of
1. BRAKE LINE less than 10 N (1 kgf, 2 Ib).
1) Check the scratches, swelling, corrosion and/or
Brake pedal free play:
traces of fluid leakage on brake hoses or pipe
joints. 1 - 3 mm (0.04 - 0.12 in)
2) Check the possibility of adjacent parts interfering
with brake pipedhoses during driving, and loose
connections/clamps.
3) Check any trace of fluid leakage, scratches, etc.
Brake booster
on master cylinder, wheel cylinder and pressure operating rod
control valve. Pedal play
1-3"
NOTE: (0.04 - 0.12 in)
When the brake fluid level in the reservoir tank is
lower than the specified limit, the brake fluid warn-
ing light on the combination meter will come on. G10050A
Visually check brake hose (using a mirror where
it is difficult to see) for any damage. he free play is out of specifications above, ad-
- just the brake pedal as follows:
C. - (1) Be sure the engine is off. (No vacuum is ap-
plied to brake booster.)
(2) There should be play between brake boost-
er clevis and pin at brake pedal installing por-
tion.
[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.
48A (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).

Brake switch

/
Lock nut
56 \ 0.3 mm (0.012 in)

Brake booster
operating rod

Play at pin

(0.04.- 0.12 in)

G10051A

PM-25
I BRAKE LINE I
PERIODIC MAINTENANCE SERVICES

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
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 less than 95 mm (3.74 in). If the dis-
tance is more than specified, there is a possibility
air is in the inside of the hydraulic unit.
Brake pedal reserve distance: A
more than 95 mm (3.74 in)/490 N (50 kgf, 1 10
lb)
ti - 1 2 = A
4) Check the valve is built into vacuum hose. Dis-
connect the 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 the both check valve and vacuum hose if
the check valve is faulty. Engine side of vacuum
hose is indicated by marking “ENGINE as shown.
Engine side Brake booster side

I steer i ng 4\

G10053A
.
c-
5) Check the vacuum hose for cracks or other dam-
age.
NOTE:
4) Check to see if air is in the hydraulic brake line by When installing the vacuum hose on the engine
the feel of pedal operation. If air appears to exist in and brake booster, do not use soapy water or lubri-
the line, bleed it from the system. cating oil on their connections.
5) Check for even operation of all brakes, using a 6) Check the vacuum hose to make sure it is tight
brake tester or by driving the vehicle for a short dis- and secure.
tance on a straight road.
2. BRAKE SERVO SYSTEM
1) With the engine off, depress the brake pedal
several times applying the same pedal force: Make
sure the travel distance should not change.
2) With the brake pedal depressed, start the en-
gine: Make sure the pedal should move slightly to-
ward the floor.
3) With the brake pedal depressed, stop the engine
and keep the pedal depressed for 30 seconds:
Make sure the pedal height should not change.

PM-26
 BRAKE FLUID I
PERIODIC MAINTENANCE SERVICES

19.Brake Fluid NOTE:

A: REPLACEMENT
1) Either jack up the vehicle and place a safety
stand under it, or lift up the vehicle.
2) Remove the both front and rear wheels.
3) Draw out the brake fluid from master cylinder
with syringe.
4) Refill the reservoir tank with recommended
brake fluid.
Recommended brake fluid:
FMVSS No. 116, fresh DOT3 or 4 brake fluid
NOTE:
Avoid mixing different brands of brake fluid to
prevent degrading the quality of the fluid.
Be careful not to allow dirt or dust to get into the
reservoir tank.
Bleeding sequence (1) -+ (2) -+ (3) -+ (4)
I I
(1) Front right
(2) Rear left
(3) Front left
(4) Rear right
(5) Secondary
(6) Primary
5) Install one end of a vinyl tube onto the air bleeder
and insert the other end of the tube into a container
to collect the brake fluid.
Cover the bleeder with waste cloth, when loosen-
ing it, to prevent brake fluid from being splashed
over surrounding parts.
During bleeding operation, keep the brake re-
serve tank filled with brake fluid to eliminate entry of
air.
Brake pedal operation must be very slow.
For convenience and safety, it is advisable to
have two men working.
The amount of brake fluid required is approxi-
mately 500 m 0 (16.9 US fl oz, 17.6 Imp fl 02) for to-
tal brake system.
6) Instruct your co-worker to depress the brake
pedal slowly two or three times and then hold it de-
pressed.
7) Loosen the bleeder screw approximately 1/4 turn
until a small amount of brake fluid drains into con-
tainer, and then quickly tighten screw.
8) Repeat steps 6) and 7) above until there are no
air bubbles in drained brake fluid and new fluid
flows through vinyl tube.
NOTE:
Add the brake fluid as necessary while performing
the air bleed operation, in order to prevent the tank
from running short of brake fluid.
9) After completing the bleeding operation, hold
brake pedal depressed and tighten the screw and
install the bleeder cap.
Tightening torque:
8 Nom(0.8 kgf-m, 5.8 ft-lb)
10) Bleed the air from each wheel cylinder by fol-
lowing the previous 5 steps.
11) Depress the brake pedal with a force of approx-
imately 294 N (30 kgf, 66 Ib) and hold it there for ap-
proximately 20 seconds. At this time check pedal to
see if it makes any unusual movement. Visually in-
spect bleeder screws and brake pipe joints to make
sure that there is no fluid leakage.
12) Install the wheels, and drive the vehicle for a
short distance between 2 to 3 km (1 to 2 miles) to
make sure that brakes are operating properly.

I GI0055

PM-27
 DISC BRAKE PADS AND DISCS
PERIODIC MAINTENANCE SERVICES

20.Disc Brake Pads and Discs 4) Measure the disc rotor runout at a point less than
5 mm (0.20 in) from the outer periphery of the rotor.
A: INSPECTION Disc rotor runout limit:
1. DISC BRAKE PAD AND DISC Front: 0.075 mm (0.0030 in)
Rear: 0.070 mm (0.0028 in)
1) Jack up the vehicle and support with rigid racks.
Then remove wheels. NOTE:
2) Visually check pad thickness through inspection When replacing a pad, always replace the pads for
hole of disc brake assembly. Replace the pad if both the left and right wheels at the same time. Also
necessary. replace pad clips if they are twisted or worn.

G10056A
GI0147

Pad thickness including back metal mm (in)

Front Rear
Standard 17 (0.67) 14 (0.55)
. .
I I

I
~I
1

Service limit I 7.5 (0.295) I 6.5 (0.256)

Thickness
of pad

3) Check the disc rotor, and correct or replace if it is

damaged or worn.
Brake disc thickness mm (in) 1
Front Rear
Standard 24 (0.94) 10 (0.39)
Wear limit 22 (0.87) 8.5 (0.335)

PM-28
 BRAKE LININGS AND DRUMS 1
PERIODIC MAINTENANCE SERVICES

21.Brake Linings and Drums 3) Check the brake drum for wear, dents or other
damage.
A: INSPECTION If the inside surface of brake drum is streaked, cor-
rect the surface with emery cloth (#200 or more). If
1. REAR DRUM BRAKE it is unevenly worn, tapered, or the outside surface
1) Remove the brake drum, and check that there is of brake drum is damaged, correct or replace it.
no fluid leakage from wheel cylinder. Brake drum inner diameter
If there is fluid leakage from wheel cylinder, replace Standard value: 228.6 mm (9.000 in)
it. Service limit: 230.6 mm (9.079 in)
2) Inspect the brake shoes for damage or deformi-
If deformation or wear of back plate, shoe, etc. is
ties and check the brake linings for wear.
noticeable, replace the affected parts.
NOTE:
Always replace both leading and trailing brake
shoes for the left and right wheels at the same time.
When either the left or the right brake assembly
is replaced, always replace the leading shoe and
trailing shoe of the other.
The cotter pin, once removed, cannot be reused.
Thickness of lining (except back metal)
Standard value: 4.1 mm (0.161 in)
--
- Service limit: 1.5 mm (0.059 in)
I Y
I Measuring inside diameter
G10060A

2. PARKING BRAKE (REAR DISC BRAKE)

Inspect brake linings and drums of both sides of the
rear brake at the same time by removing brake
drums.
1) Inspect the brake shoes for damage or deforma-
tion and check the brake linings for wear.
NOTE:
Always replace both primary and secondary brake
shoes for the left and right wheels at the same time.
Brake lining thickness excluding back metal
(1) Rotational direction of drum (Forward) Standard value: 3.2 mm (0.126 in)
(2) Wheel cylinder
Wear limit: 1.5 mm (0.059 in)
(3) Upper shoe return spring
(4) Adjusting lever
(5) Trailing shoe
(6) Lower shoe return spring
(7) Leading shoe

To replace the trailing shoe, remove the cotter pin.

Clevis pin should also be replaced if worn.
Brake -shoe’ Brake shoe
(Primary) (Secondary)
G10061A

PM-29
I BRAKE LININGS AND DRUMS 1
PERIODIC MAINTENANCE SERVICES

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

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

-Uinside diameter
Measuring
G10062A

3).If the deformation or wear of back plate, shoe,

etc. is noticeable, replace them.
4) When the shoe return spring tension is exces-
sively weakened, replace it, taking care to identify G10063A
upper and lower springs.
3)Turn back (downward) the adjuster 3 to 4 notch-
es.
4) Install the cover (rubber) at original position cor-
rectly.

PM-30
 SUSPENSION I
PERIODIC MAINTENANCE SERVICES

22.Suspension 5 ) Damage of dust seal

A: INSPECTION
1. SUSPENSION BALL JOINT
1) Jack up the vehicle until front wheels are off
ground.
2) Next, grasp the bottom of tire and move it in and
out. If relative movement is observed between
brake disc cover and end of transverse link, ball
joint may be excessively worn.
3) Next, grasp the end of transverse link and move
it up and down. Relative movement between hous-
ing and transverse link boss indicates ball joint may
be excessively worn.
4) If the relative movement is observed in the im-
mediately preceding two steps, remove and inspect
the ball joint. If the free play exceeds standard, re-
place the ball joint. <Ref. to FS-19, Front Ball
Joint.>
Visually inspect ball joint dust seal. If it is damaged,
remove the transverse link. <Ref. to FS-17, Front
Transverse Link.> And measure free play of ball
joint. <Ref. to FS-19, 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-8, Wheel Alignment.>

G10066b

2. TRANSVERSE LINK'S REAR BUSHING

-Disc cover Check oil leaks at around liquid-filled bushing. If oil
Transv leaks, replace bushing.
Ball join{ w i v e movement
G10064A

Relative movement

Transverse link
Ball join;
G10065A

PM-31
I SUSPENSION I
PERIODIC MAINTENANCE SERVICES

3. WHEEL ARCH HEIGHT 3) When the toe-in and thrust angle are out of stan-
dard value, adjust them so that they conform to re-
1) Unload the cargoes and set the vehicle in curb
spective service standard.
weight (empty) condition.
2) Then, check the wheel arch height of front and 6. OIL LEAKAGE OF STRUT AND SHOCK
rear suspensions to ensure that they are within ABSORBER
specified values.
Visually inspect front strut and rear strut for oil leak-
3) When the wheel arch height is out of standard,
age as instructed. Replace front strut and rear strut
visually inspect following components and replace
if oil leaks excessively.
deformed parts.
Suspension components [Front strut assembly 7. TIGHTNESS OF BOLTS AND NUTS
and rear strut assembly]
Check the bolts and nuts shown in the figure for
Body parts to which suspensions are installed.
looseness. Retighten the bolts and nuts to speci-
4) When no components are deformed, adjust fied torque. If self-lock nuts and bolts are removed,
wheel arch height by replacing coil spring in the replace them with new ones.
suspension whose wheel arch height is out of stan-
Front suspension: <Ref. to FS-2, General Descrip-
dard. <Ref. to FS-8, Wheel Alignment.> <Ref. to
tion.>
RS-9, Wheel Alignment.>
Rear suspension: <Ref. to RS-2, General Descrip-
4. WHEEL ALIGNMENT OF FRONT SUS- tion.>
PENSI0N 8. DAMAGE TO SUSPENSION PARTS
1) Check the alignment of front suspension to en- 1) Check the following parts and the fastening por-
Sure that following items conform to standard val- tion of the vehicle body for deformation or exces-
ues. sive rusting which impairs the suspension. If
Toe-in necessary, replace damaged parts with new ones.
Camber angle If minor rust formation, pitting, etc. are noted, re-
Caster angle move rust and apply remedial anti-corrosion mea-
Steering angle sures.
<Ref. to FS-8, Wheel Alignment.> Front suspension
2) When the caster angle does not conform to stan- Transverse link
dard value, visually inspect following components Crossmember
and replace deformed parts. Strut
Suspension components [Strut assembly, cross- Rear suspension
member, transverse link, etc.] Crossmember
Body parts to which suspensions are installed. Lateral links
3) When the toe-in and camber are out of standard
Trailing link
value, adjust them so that they conform to respec-
Strut
tive service standard.
In the district where salt is sprayed to melt snow
4) When the right-and-left turning angles of tire are
out of standard, adjust to standard value. on a road in winter, check suspension parts for
damage caused by rust every 12 months after
5. WHEEL ALIGNMENT OF REAR SUS- lapse of 60 months. Take rust prevention measure
PENSI0N as required.
1) Check the alignment of rear suspension to en-
sure that following items are within standard val-
ues.
Toe-in
Camber angle
Thrust angle
<Ref. to RS-9, Wheel Alignment.>
2) When the camber angle does not conform to
standard value, visually inspect parts listed below.
If the deformation is observed, replace damaged
parts.
Suspension components [Strut assembly, cross-
member, trailing link, lateral links, etc.]
Body parts to which suspensions are installed.

PM-32
 WHEEL BEARING 1
PERIODIC MAINTENANCE SERVICES

23.Wheel Bearing 6) While supporting rear drive shaft horizontally

with one hand, turn the hub COMPL with the other
A: INSPECTION to check for noise or binding.
If the hub COMPL is noisy or binds, disassemble
1. FRONT WHEEL BEARING the rear axle and check condition of oil seals, bear-
NOTE: ings, etc.
Inspect the condition of front wheel bearing grease.
1) Jack up the front of vehicle.
2) While holding front wheel by hand, swing it in
and out to check bearing free play.
3) Loosen the wheel nuts and remove the front
wheel.
4) If the bearing free play exists in step 2) above, at-
tach a dial gauge to hub and measure axial dis-
placement in axial direction.
Service limit:
Straight-ahead position within 0.05 mm
(0.0020 in)
5) Remove the bolts and self-locking nuts, and ex-
tract transverse link from the front crossmember.
--
6) While lightly hammering spring pin which se-
cures S.F.J. to transmission spindle, remove it.
7) Extract S.F.J. from the transmission spindle.
<Ref. to DS-17, Front Axle.>
8) While supporting front drive shaft horizontally
with one hand, turn the hub with the other to check
for noise or binding.
If the hub is noisy or binds, disassemble the front
axle and check condition of oil seals, bearing, etc.

Outer oil seal

I Hub’
GI0133

2. REAR WHEEL BEARING

1) Jack up the rear of vehicle.
2) While holding rear wheel by hand, swing it in and
out to check bearing free play.
3) Loosen the wheel nuts and remove the rear
wheel.
4) If the bearing free play exists in step 2) above, at-
tach a dial gauge to hub COMPL and measure ax-
ial 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 dif-
ferential. <Ref. to DS-39, Rear Drive Shaft.>

PM-33
I AXLE BOOTS & JOINTS I
PERIODIC MAINTENANCE SERVICES

24.Axle Boots & Joints

A: INSPECTION
1. FRONT AND REAR AXLE BOOTS
Inspect the front axle boots (A) and rear axle boots
(B) for deformation, damage or failure. If faulty, re-
place them with new ones. <Ref. to DS-32, Front
Drive Shaft.> <Ref. to DS-39, Rear Drive Shaft.>

c- .

2. PROPELLER SHAFT
Inspect the propeller shaft for damage or failure. If
faulty, replace with new one. <Ref. to DS-14, Pro-
peller Shaft.>

PM-34
 STEERING SYSTEM (POWER STEERING) I
PERIODIC MAINTENANCE SERVICES

25.Steering System (Power 2. STEERING SHAFT JOINT

Steering)
A: INSPECTION
1. STEERING WHEEL
1) Set the steering wheel in a straight-ahead posi-
tion, and check the wheel spokes to make sure
they are correctly set in their specified positions.
2) Lightly turn the steering wheel to the left and right
to determine the point where front wheels start to
move.
Measure the distance of the movement of steering
wheel at the outer periphery of wheel.
Steering wheel free play:
0 - 17 mm (0 - 0.67 in)
1) When the steering wheel free play is excessive,
disconnect the universal joint of steering shaft and
check it for any play and yawing torque (at the point
of the crossing direction). Also inspect for any dam-
age to sealing or worn serrations. If the joint is
loose, retighten the mounting bolts to the specified
torque.
Tightening torque:
24 N.m (2.4 kgf-m, 17.4 ff-lb)

I -Free play

3. GEARBOX
1) With wheels placed on a level surface, turn the
steering wheel 90" in both the left and right direc-
tions.
G10074A While the wheel is being rotated, reach under vehi-
cle and check for looseness in gearbox.
Move the steering wheel vertically toward the shaft
to ascertain if there is play in the direction. Tightening torque:
59 N-m (6.0 kgf-m, 43.4 ff-lb)
Maximum permissible play:
0.5 mm (0.020 in)
3 ) Drive the vehicle and check the following items
during operation.
(1) Steering force:
The effort required for steering should be
smooth and even at all points, and should not
vary.
(2) Pull to one side:
Steering wheel should not be pulled to either
side while driving on a level surface.
(3) Wheel runout:
Steering wheel should not show any sign of 2) Check the boot for damage, cracks or deteriora-
runout. tion.
(4) Return factor: 3) With vehicle on a level surface, quickly turn
steering wheel to the left and right.
Steering wheel should return to its original posi-
tion after it has been turned and then released. While steering wheel is being rotated, check the
gear backlash. If any unusual noise is noticed, ad-
Maximum permissible play: just the gear backlash in the following manner.
0.5 mm (0.020 in) (1) Tighten adjusting screw to 7.4 N.m (0.75
kgf-m, 5.4 ft-lb) and then loosen. Repeat this op-
eration twice.
(2) Retighten adjusting screw to 7.4 N.m (0.75
kgf-m, 5.4 ft-lb) and back off 25".

PM-35
I STEERING SYSTEM (POWER STEERING)
PERIODIC MAINTENANCE SERVICES

(3) Apply the liquid packing to at least 113 of en-
tire perimeter of adjusting screw thread.
Apply liquid packing
to at least 1/3 of entire
perimeter
5. POWER STEERING FLUID LEVEL
NOTE:
The fluid level must be checked when the temper-
ature of the reservoir tank surface is approximately
20°C (68°F).
1) Place the vehicle with engine “off” on the flat and
level surface.
2) Check the fluid level using the scale on the out-
side of the reservoir tank (A). If the level is below
“MIN” (B), add fluid to bring it up to “MAX’ (C).

w G10077A

(4) Install the lock nut. While holding adjusting

screw with a wrench, tighten lock nut using ST.
ST 926230000 SPANNER
Tightening torque (Lock nut):
39 N.m (4.0 kgf-m, 29 ft-lb)
Hold the adjusting screw with a wrench to pre-
vent it from turning while tightening the lock nut.
c-

4. TIE-ROD
1) Check the tie-rod and tie-rod ends for bends,
scratches or other damage.
\ Dexron IIE or Ill
G10105A
2) Check the connections of knuckle ball joints for
play, inspect for damage on dust seals, and check
free play of ball studs. If castle nut is loose, retight-
en it to the specified torque, then tighten further up
to 60” until cotter pin hole is aligned.
Tightening torque:
27 N.m (2.75 kgf-m, 79.9 ft-lb)
3) Check the lock nut on the tie-rod end for tight-
ness. If it is loose, retighten it to the specified
torque.
Tightening torque:
83 N-m (8.5 kgf-m, 67.5 ft-lb)
NOTE:
If fluid level is at MAX level or above, drain fluid to
keep the level in the specified range of indicator by
using a syringe or the like.
Recommended fluid:
Fluid capacity:
0.7 Q (0.7 US qt, 0.6 Imp qt)
6. POWER STEERING FLUID FOR LEAKS
Inspect the underside of oil pump and gearbox for
power steering system, hoses, piping and their
couplings for fluid leaks.
If the fluid leaks are found, correct them by retight-
ening their fitting bolts (or nuts) and/or replacing
their parts.
NOTE:
Wipe the leakage fluid off after correcting fluid
leaks, or a wrong diagnosis is taken later.
Also pay attention to clearances between hoses
(or pipings) and other parts when inspecting fluid
leaks.

PM-36
 STEERING SYSTEM (POWER STEERING)
PERIODIC MAINTENANCE SERVICES
~

7. HOSES OF OIL PUMP FOR DAMAGES

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

8. POWER STEERING PIPES FOR DAM-

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

Apply clrease

G10023A

10.FITTING BOLTS AND NUTS

Inspect the fitting bolts and nuts of oil pump and
bracket for looseness, and retighten them if neces-
sary.
Inspect and/or retighten them when engine is cold.

PM-37
I SUPPLEMENTAL RESTRAINT SYSTEM
PERIODIC MAINTENANCE SERVICES

26.Supplemental Restraint System

A: INSPECTION
Check the airbag system in accordance with the result of the self-diagnosis. <Ref. to AB-2, Basic Diagnostic
Procedure.>
1) Ensure that airbag connectors are connected. If not, properly connect. When the ignition switch is turned
ON with the connector(s) disconnected, the airbag warning light blinks to identify the fault.

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 trouble-
shooting procedure. <Ref. to AB-2, Basic Diagnostic Procedure.>

PM-38
2002 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX

ENGINE1 SECTION

This service manual has been prepared

to provide SUBARU service personnel
with the necessary information and data
for the correct maintenance and repair
of SUBARU vehicles.
This manual includes the procedures
for maintenance, disassembling, reas-
sembling, inspection and adjustment of
components and diagnostics for guid-
ance of experienced mechanics.
Please peruse and utilize this manual
fully to ensure complete repair work for
satisfying our customers by keeping
their vehicle in optimum condition.
When replacement of parts during
repair work is needed, be sure to use
SUBARU genuine parts.

All information, illustration and specifi-

cations contained in this manual are
based on the latest product information
available at the time of publication
approval.
FUJI HEAVY INDUSTRIES LTD. G1830BE2
FUEL INJECTION (FUEL SYSTEMS)

FU(S0HC)r
Page
1. General Description .................................................................................... 2
2. Throttle Body ............................................................................................. 14
3. Intake Manifold.......................................................................................... 15
4. Engine Coolant Temperature Sensor ........................................................ 27
5. Crankshaft Position Sensor ....................................................................... 28
6. Camshaft Position Sensor ......................................................................... 29
7. Knock Sensor ............................................................................................ 30
8. Throttle Position Sensor ............................................................................ 31
9. Intake Air Temperature and Pressure Sensor ........................................... 34
10. Atmospheric Pressure Sensor .................................................................. 35
11. Idle Air Control Solenoid Valve ................................................................. 36
12. Air Assist Injector Solenoid Valve ............................................................. 37
13. Fuel Injector .............................................................................................. 38
14. Front Oxygen (NF) Sensor ....................................................................... 43
15. Rear Oxygen Sensor ................................................................................. 45
16. Engine Control Module.............................................................................. 47
17. Main Relay ................................................................................................ 48
18. Fuel Pump Relay....................................................................................... 49
19. Fuel ........................................................................................................... 50
20 . Fuel Tank .................................................................................................. 51
21 . Fuel Filler Pipe .......................................................................................... 54
22 . Fuel Pump ................................................................................................. 59
23 . Fuel Level Sensor ..................................................................................... 62
24. Fuel Sub Level Sensor .............................................................................. 63
25 . Fuel Filter .................................................................................................. 65
26 . Fuel Cut Valve ........................................................................................... 66
27. Fuel Damper Valve ................................................................................... 67
28 . Fuel Delivery, Return and Evaporation Lines ............................................ 68
29 . Fuel System Trouble in General ............................................................... 71
 GENERAL DESCRIPTION
FUEL INJECTION (FUEL SYSTEMS)

Fuel tank
I Capacity I 60 8 (15.9 US aal, 13.2 Imp aal) I
I Location I Under rear seat I
Type Impeller
Shutoff discharge pressure 370 - 677 kPa (3.77 - 6.9 kg/cm2, 53.6 - 98 psi)
Fuel pump
More than 65 9 (17.2 US gal, 14.3 Imp gal)/h
Discharge flow
I12 V at 300 kPa (3.06 kn/cm2,43.5 usi)l
Fuel filter I Cartridge type I

FU(S0HC)-2
GENERAL DESCRIPTION
FUEL INJECTION (FUEL SYSTEMS)

FU(SOHC)9
 GENERAL DESCRIPTION
FUEL INJECTION (FUEL SYSTEMS)

B: COMPONENT
1. INTAKE MANIFOLD

EN1172

FU(S0HC)-4
 GENERAL DESCRIPTION
FUEL INJECTION (FUEL SYSTEMS)

Intake manifold gasket O-ring (28) Accelerator cable bracket

Fuel injector pipe RH Plug cord holder LH
Fuel injector Fuel pipe protector RH Tightening torque: N.m (kgf-m, ft-lb)
O-ring Fuel pipe ASSY T1: 3.4 (0.35,2.5)
O-ring Fuel hose T2: 4.9 (0.5, 3.6)
O-ring Clip T3: 6.4 (0.65, 4.7)
Plug Clip T4: lg(1.9, 13.7)
PCV valve Air assist injector solenoid valve T5: 16 (1.6, 11.8)
Purge control solenoid valve Air assist injector solenoid valve T6: 25 (2.5, 18.1)
Nipple bracket T7: 7.35 (0.75, 5.42)
Intake manifold Guide pin T8: 17f1.7, 12.5)
Fuel injector pipe LH Atmospheric pressure sensor T9: l.S(O.15, 1.1)
Fuel pipe protector LH bracket
Intake air temperature and pres- Atmospheric pressure sensor
sure sensor Plug cord holder RH

FU(S0HC)-5
 GENERAL DESCRIPTION
FUEL INJECTION(FUEL SYSTEMS)

2. AIR INTAKE SYSTEM

1;;1

B2M3455C

(1) Gasket (4) Throttle body Tightening torque: N.m (kgf-m, ft-lb)
(2) Throttle position sensor T l : l.S(O.16, 1.2)
(3) Idle air control solenoid valve T2: 22 (2.2, 15.9)

FU(S0HC)-6
 GENERAL DESCRIPTION
FUEL INJECTION (FUEL SYSTEMS)

3. CRANKSHAFT POSITION, CAMSHAFT

POSITION AND KNOCK SENSORS
I

(1) Crankshaft position sensor (4) Camshaft position sensor support Tightening torque: N-m (kgf-m, ft-lb)
(2) Knock sensor T1: 6.4 (0.65, 4.7)
(3) Camshaft position sensor T2: 24 (2.4, 17.4)

FU(S0HC)-7
 GENERAL DESCRIPTION
FUEL INJECTION (FUEL SYSTEMS)

4. FUELTANK

EN1119

FU(S0HC)-8
 GENERAL DESCRIPTION
FUEL INJECTION [FUEL SYSTEMS)

Heat shield cover Evaporation hose C (29) Fuel sub level sensor gasket
Fuel tank band Evaporation hose €3 (30) Jet pump filter
Protector LH Evaporation hose D (31) Fuel sub level sensor
Protector RH Evaporation hose E (32) Protector cover
Fuel tank Evaporation pipe ASSY (33) Vent valve hose
Canister hose A Retainer (34) Vent valve
Clamp Quick connector (35) Fuel tank pressure sensor
Fuel pump gasket Jet pump hose A (36) Fuel tank pressure sensor hose
Fuel pump ASSY Fuel return hose A (37) Vent valve gasket
Fuel cut valve gasket Fuel pipe ASSY
Fuel cut valve Jet pump hose €3 Tightening torque: N-m (kgf-m, ft-lb)
Evaporation hose A Fuel return hose B T I : 4.4 (0.45, 3.3)
Clip Evaporation hose F T2: 7.4 (0.75, 5.4)
Joint pipe Evaporation hose G T3: 33 (3.4,25)

FU(S0HC)-9
 GENERAL DESCRIPTION
FUEL INJECTION(FUEL SYSTEMS)

5. FUELLINE

EN1120

FU(S0HC)-10
 GENERAL DESCRIPTION
FUEL INJECTION (FUEL SYSTEMS)

Clip Evaporation hose J (25) Canister holder

Fuel delivery hose A Evaporation hose K (26) Evaporation hose L
Fuel filter bracket Joint pipe (27) Pressure control solenoid valve
Fuel filter holder Canister hose A (28) Canister hose B
Fuel filter cup Air filter hose A (29) Canister
Fuel filter Drain valve hose (30) Fuel pipe ASSY
Evaporation hose Air filter hose B
Clip Drain filter
Fuel delivery hose B Drain valve Tightening torque: N-m (kgf-m, ft-lb)
Fuel return hose A Canister upper bracket T1: 25(2.5, 18.1)
Fuel return hose 6 Cushion rubber T2: 23 (2.3, 16.6)
Fuel damper Canister lower bracket T3: 1.25 (0.13, 0.94)

FU(S0HC)-11
 GENERAL DESCRIPTION
FUEL INJECTION (FUEL SYSTEMS)

6. FUEL FILLER PIPE

EN1121

Fuel filter pipe ASSY (9) Filler ring Tightening forque: N.m (kgf-m, ft-lb)
Evaporation hose holder (10) Filler cap T1: 4.4 (0.45, 3.3)
Clamp (1 1) Shut valve T2: 7.5 (0.76, 5.53)
Clamp (12) Evaporation hose B
Evaporation hose A (1 3) Evaporation hose C
Evaporation pipe (14) Joint pipe
Evaporation pipe holder (15) Fuel filler pipe protector
Filler pipe packing

FU(S0HC)-12
 GENERAL DESCRIPTION
FUEL INJECTION (FUEL SYSTEMS)

C: CAUTION Be careful not to burn your hands, because each

0 Wear working clothing, including a cap, protec-
tive goggles, and protective shoes during opera-
tion.
0 Remove contamination including dirt and corro-
sion before removal, installation or disassembly.
0 Keep the disassembled parts in order and pro-
tect them from dust or dirt.
Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary re-
moval, installation, disassembly, and replacement.
part On the vehicle is hot after running.
Be sure to tighten fasteners including bolts and
nuts to the specified torque.
Place shop jacks or safety stands at the specified
points.
Before disconnecting electrical connectors of
sensors or units, be sure to disconnect negative
terminalfrom
0 Place “NO F I R E signs near the working area.
o Be careful not to Spill fuel on the floor-

D: PREPARATION TOOL
ILLUSTRATION TOOL NUMBER DESCRlPTlON REMARKS
24082AA150 ZARTRIDGE
Newly adopted
001)

82M3076 Troubleshootingfor electrical system.

22771AA030 SELECT MONI- Troubleshooting for electrical systems.
TOR KIT English: 22771AA030 (Without printer)
German: 22771AA070 (Without printer)
French: 22771AA080 (Without printer)
Spanish: 22771AA090 (Without printer)

FU(S0HC)-13
 THROTTLE BODY
FUEL INJECTION (FUEL SYSTEMS)

2. Throttle Body 7) Disconnect the engine coolant hoses from the

throttle body.
A: REMOVAL
1) Disconnect the battery ground cable.

8) Remove the bolts which install throttle body to

the intake manifold.
2) Remove the air cleaner case.<Ref. to IN(S0-
HC)-6, REMOVAL, Air Cleaner Case.>
B: INSTALLATION
3) Disconnect the accelerator cable (A). Install in the reverse order of removal.
4) Disconnect the cruise control cable (B). (With NOTE:
cruise control model) Always use a new gasket.
Tightening torque:
Throttle body;
22 N-m (2.2 kgf-m, 15.9 ft-lb)

5) Disconnect the connectors from the idle air con-

trol solenoid valve and throttle position sensor.
6) Disconnect the air by-pass hose from the throttle
body.
I

B2M3457A

(A) Throttle position sensor

(B) Idle air control solenoid valve
(C) Air by-pass hose from air assist injector sole-
noid valve

FU(S0HC)-14
 INTAKE MANIFOLD
FUEL INJECTION (FUEL SYSTEMS)

(3) Remove the bolts which hold power steering

3. Intake Manifold pipes onto the intake manifold protector.
A: REMOVAL NOTE:
1) Release the fuel pressure. <Ref. to FU(S0HC)- Do not disconnect the power steering hose.
50, RELEASING OF FUEL PRESSURE, OPERA-
TION, Fuel.>
2) Open the fuel flap lid, and remove the fuel filler
cap.
3) Disconnect the battery ground cable.

(4) Remove the bolts which install power steer-

ing pump bracket

4) Remove the air intake duct and air cleaner as-

sembly. <Ref. to IN(S0HC)-7, REMOVAL, Air In-
take Duct.> and <Ref. to IN(S0HC)-6, REMOVAL,
Air Cleaner Case.>
5 ) Disconnect the accelerator cable (A).
6) Disconnect the cruise control cable (B). (With
cruise control model)

(5) Disconnect the connector from the power

steering pump switch.

7) Remove the power steering pump.

(1) Remove the resonator chamber. <Ref. to
IN(S0HC)-8, REMOVAL, Resonator Cham-
ber.> (6) Remove the power steering tank from the
(2) Remove the front side V-belt. <Ref. to bracket by pulling it upwards.
ME(S0HC)-43, REMOVAL, V-belt.>

/t/
EN0361

FU(S0HC)-15
 INTAKE MANIFOLD
FUEL INJECTION (FUEL SYSTEMS)
(7) Place the power steering pump on the right 12) Remove the air cleaner case stay RH and en-
side wheel apron. gine harness bracket, and disconnect the engine
harness connectors from the bulkhead harness
connectors.

8) Disconnect the spark plug cords from the spark

plugs.
r . I I 7- - 9 B2M4260

9) Disconnect the PCV hose from the intake mani- 13) Disconnect the connectors from the engine
fold. coolant temperature sensor.

10) Disconnect the engine coolant hose from the 14) Disconnect the knock sensor connector.
throttle body.

15) Disconnect the connector from the crankshaft

11) Disconnect the brake booster hose. position sensor.

FU(S0HC)-16
 INTAKE MANIFOLD
FUEL INJECTION (FUEL SYSTEMS)

16) Disconnect the connector from the oil pressure 19) Remove the bolts which hold intake manifold
switch. onto the cylinder heads.

17) Disconnect the connector from the camshaft 20) Remove the intake manifold.
position sensor.

B: INSTALLATION
18) Disconnect the fuel hoses from the fuel pipes. 1) Install the intake manifold onto the cylinder
WARNING: heads.
Do not spill fuel. NOTE:
Catch fuel from hoses in a container or cloth. Always use new gaskets.
Tightening torque:
25 N-m (2.5 kgf-m, 18.1 fi-lb)

(A) Fuel delivery hose

(B) Return hose
(C) Evaporation hose

FU(S0HC)-17
 INTAKE MANIFOLD
FUEL INJECTION (FUEL SYSTEMS)
2) Connect the fuel hoses. 6) Connect the knock sensor connector

7) Connect the connectors to the engine coolant

(A) Fuel delivery hose
temperature sensor.
(B) Return hose
(C) Evaporation hose

3) Connect the connector to the camshaft position

sensor.

8) Install the air cleaner case stay RH and engine

harness bracket, and connect the engine harness
connectors to the bulkhead connectors.

4) Connect the connector to the oil pressure switch.

9) Connect the brake booster hose.

5) Connect the connector to the crankshaft position

sensor.
-.--

FU(S0HC)-18
I INTAKE MANIFOLD
FUEL INJECTION (FUEL SYSTEMS)

10) Connect the engine coolant hose to the throttle (3) Tighten the bolts which install power steer-
body. ing pump bracket.
Tightening torque:
22 N.m (2.2 kgf-m, 15.9 ft-16)

11) Connect the PCV hose to the intake manifold.

(4) Install the power steering pipes onto the

right side intake manifold protector.

12) Connect the spark plug cords to the spark

plugs.
13) Install the power steering pump.
(1) Install the power steering tank on the brack- (5) Install the front side V-belt. <Ref. to ME(S0-
et. HC)-43, INSTALLATION, V-belt.>

1
(6) Install the resonator chamber.
Tightening torque:
33 N.m (3.4 kgf-m, 24.6 ft-16)
I

EN0361

(2) Connect the connector to the power steering

pump switch.

14) Connect the accelerator cable (A).

FU(S0HC)-19
 INTAKE MANIFOLD
FUEL INJECTION (FUEL SYSTEMS)

15) Connect the cruise control cable (B). (With C: DISASSEMBLY

cruise control models) 1) Disconnect the engine ground terminal from the
intake manifold.

16) Install the air intake duct and air cleaner as-
sembly. <Ref. to IN(S0HC)-7, INSTALLATION, Air 2) Disconnect the connector from the ignition coil
Intake Duct.> and <Ref. to IN(S0HC)-6, INSTAL- and ignitor assembly.
LATION, Air Cleaner Case.>
17) Connect the connector to the fuel pump relay.

--.

R7M3477

EN0344 3) Remove the ignition coil and ignitor assembly.

18) Connect the battery ground cable.

82M3473

4) Remove the intake air temperature and pressure

sensor from the intake manifold.<Ref. to FU(S0-
HC)-34, REMOVAL, Intake Air Temperature and
Pressure Sensor.>
5 ) Remove the throttle body.<Ref. to FU(S0HC)-
14, REMOVAL, Throttle Body.>
6) Remove the air assist injector solenoid valve
from the intake manifold.<Ref. to FU(S0HC)-37,
REMOVAL, Air Assist Injector Solenoid Valve.>

FU(S0HC)-PO
 INTAKE MANIFOLD
FUEL INJECTION (FUEL SYSTEMS)

7) Disconnect the pressure regulator vacuum hose 11) Disconnect the connector from the purge con-
from the intake manifold. trol solenoid valve.

I/ H2M2961 02M3485

8) Remove the fuel pipe protector LH.
12) Disconnect the air by-pass hose from the purge
control solenoid valve.
13) Remove the harness bands (A) and harness
bracket (B) which hold engine harness onto the in-
take manifold.

9) Remove the fuel pipe protector RH.

02M4271P

14) Remove the engine harness from the intake

manifold.
15) Remove the purge control solenoid valve.

02M4130

IO) Disconnect the connectors from the fuel injec-

tors.

02M3487

02M4270

FU(S0HC)-21
 INTAKE MANIFOLD
FUEL INJECTION (FUEL SYSTEMS)

16) Remove the bolt which installs injector pipe on (2) Remove the fuel injector while lifting up the
the intake manifold as shown in figure. fuel injector pipe.

H2M2970

17) Remove the bolt which installs injector pipe on 20) Disconnect the air by-pass hoses from the in-
the intake manifold. take manifold.

LH side
I RH side

B2M4149A

18) Remove the two bolts which hold fuel pipes on 21) Loosen the clamp which holds the front left side
the left side of intake manifold. fuel hose to the injector pipe and remove the pipe.

19) Remove the fuel injectors. 22) Loosen the clamp which holds the front right
(1) Remove the fuel injector securing clip. side fuel hose to the injector pipe and remove the
pipe.

82M4274

FU(S0HC)-22
 INTAKE MANIFOLD
FUEL INJECTION (FUEL SYSTEMS)

23) Remove the fuel injector pipe. 3) Connect the right side fuel hose to the injector
pipe, and tighten the clamp screw.

H2M2975
~

B2M4274
24) Remove the bolt which installs the fuel pipes on
the intake manifold. 4) Install the fuel injector pipe.

B2M349 1 H2M297E

25) Remove the fuel pipe assembly and pressure 5 ) Connect the left side fuel hose to the injector
regulator, from the intake manifold. pipe, and tighten the clamp screw.
D: ASSEMBLY
1) Install the fuel pipe assembly and pressure reg-
ulator, etc. to the intake manifold.
2) Tighten the bolt which installs the fuel pipes on
the intake manifold.
Tightening torque:
4.9 N-m (0.5 kgf-m, 3.6 ff-lb)

6) Connect the air assist hoses.

LH side
I RH side

B2M3491

B2M4149A

FU(SO HC)-23
 INTAKE MANIFOLD
FUEL INJECTION (FUEL SYSTEMS)
7 ) Install the fuel injectors. Tightening torque:
NOTE: 19 N.m (1.9 kgf-m, 13.7 ft-lb)
Always use new O-rings.

9) Tighten the two bolts which install the fuel pipes

on the left side of intake manifold.
(A) O-ring
(B) Fuel injector
Tightening torque:
4.9 N-m (0.5 kgf-m, 3.6 ft-lb)
NOTE:
Do not forget to install the fuel injector securing clip.

I 10) Tighten the bolt which install the injector pipe

B2M3488 on the intake manifold.
8) Tighten the bolt which installs the injector pipe Tightening torque:
on the intake manifold. 4.9 N-m (0.5 kgf-m, 3.6 ft-lb)
Tightening torque:
4.9 N-m (0.5 kgf-m, 3.6 ft-lb)

FU(S0HC)-24
 INTAKE MANIFOLD
FUEL INJECTION (FUEL SYSTEMS)

11) Install the purge control solenoid valve. 16) Install the fuel pipe protector RH.
Tightening torque: Tightening torque:
16 N-m (1.6 kgf-m, 11.8 ff-lb) 19 N.m (1.9 kgf-m, 13.7 ff-lb)

\\ n

02M3487 B2M4130

12) Connect the hoses to the purge control sole- 17) Install the fuel pipe protector LH.
noid valve. Tightening torque:
CAUTION: 19 N-m (1.9 kgf-m, 13.7 ff-lb)
Carefully connect the evaporation hoses.

To fuel +
+To intakc
Pipe
manifold

B2M1893P
18) Connect the pressure regulator vacuum hose
13) install the engine harness onto the intake man- to the intake manifold.
ifold.
14) Connect the connectors to the fuel injectors
and purge control solenoid valve.
15) Hold the engine harness by harness band (A)
and harness bracket (9).
Tightening torque:
16 N-m (1.6 kgf-m, 11.8 ff-lb)

// H2M2961

19) install the air assist injector solenoid valve to

I EN11731
NOTE:
Do not use harness band on harnesses where they
are supposed to be protected by the fuel pipe pro-
tector.
the bracket.<Ref. to FU(S0HC)-37, INSTALLA-
TION, Air Assist Injector Solenoid Valve.>
20) Install the throttle body to the intake mani-
fold.<Ref. to FU(S0HC)-14, INSTALLATION,
Throttle Body.>
21) Install the intake air temperature and pressure
sensor. <Ref. to FU(S0HC)-34, INSTALLATION,
Intake Air Temperature and Pressure Sensor.>
22) Connect the connector to the intake air temper-
ature and pressure sensor.

FU(S0HC)-25
 INTAKE MANIFOLD
FUEL INJECTION (FUEL SYSTEMS)
23) Install the ignition coil and ignitor assembly.

I 82M3473

24) Connect the connector to the ignition coil and

ignitor assembly.
25) Install the engine ground terminal to the intake
manifold.
Tightening torque:
79 " I(7.9 kgf-m, 73.7 ft-lb)

E: INSPECTION
Make sure the fuel pipe and fuel hoses are not
cracked and that connections are tight.

FU(S0HC)-26
 ENGINE COOLANT TEMPERATURE SENSOR
FUEL INJECTION (FUEL SYSTEMS)

4. Engine Coolant Temperature B: INSTALLATION

Install in the reverse order of removal.
Sensor
Tightening torque:
A: REMOVAL 18 N-m (1.8 kgf-m, 13.3 ft-lb)
1) Disconnect the battery ground cable.

2) Remove the air intake duct and air cleaner as-

sembly. <Ref. to IN(S0HC)-7, REMOVAL, Air In-
take Duct.> and <Ref. to IN(S0HC)-6, REMOVAL,
Air Cleaner Case.>
3) Disconnect the connector from the engine cool-
ant temperature sensor.

4) Remove the engine coolant temperature sensor.

FU(SOHC)-27
 a
CRANKSHAFT POSITION SENSOR
FUEL INJECTION (FUEL SYSTEMS)

5. Crankshaft Position Sensor B: INSTALLATION

Install in the reverse order of removal.
A: REMOVAL
1) Disconnect the battery ground cable. Tightening torque:
T: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb)

2) Remove the bolt which install crankshaft position

sensor to the cylinder block.

3) Remove the crankshaft position sensor, and dis-

connect the connector from it.

FU(S0HC)-28
 CAMSHAFT POSITION SENSOR
FUEL INJECTION (FUEL SYSTEMS)

6. Camshaft Position Sensor 5) Remove the camshaft position sensor and cam-
shaft position sensor support as a unit.
A: REMOVAL 6) Remove the camshaft position sensor itself.
1) Disconnect the battery ground cable.

2) Disconnect the connector from the camshaft po-

sition sensor.
8
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
Camshaft position sensor support;
6.4 N.m (0.65 kgf-m, 4.7 ff-lb)
B2M2322

Camshaft position sensor;

6.4 N-m (0.65 kgf-m, 4.7 ft-lb)

3) Remove the bolt which installs camshaft position

sensor to the camshaft position sensor support.

4) Remove the bolt which installs camshaft position

sensor support to the camshaft cap LH.

\' 02M2321 I

FU(S0HC)-29
I
KNOCK SENSOR
FUEL INJECTION (FUEL SYSTEMS)

7. Knock Sensor B: INSTALLATION

1) Install the knock sensor to the cylinder block.
A: REMOVAL
1) Disconnect the battery ground cable from the Tightening torques
battery ground terminal. 24 N-m (2.4 kgf-m, 17.4 fi-lb)
NOTE:
The extraction area of the knock sensor cord must
be positioned at a 60" angle relative to the engine
rear.

2) Remove the air cleaner case.<Ref. to IN(S0-

HC)-6, REMOVAL, Air Cleaner Case.>
3) Disconnect the knock sensor connector.

(A) Front side

2) Connect the knock sensor connector.

4) Remove the knock sensor from the cylinder

block.

3) Install the air cleaner case.

<Ref. to IN(S0HC)-6, REMOVAL, Air Cleaner
Case.>
4) Connect the battery ground cable.

FU(S0HC)-30
 THROTTLE POSITION SENSOR
FUEL INJECTION (FUEL SYSTEMS)

8. Throttle Position Sensor B: INSTALLATION

Install in the reverse order of removal.
A: REMOVAL
1) Disconnect the battery ground cable.
Tightening torque:
1.6 N.m (0.16 kgf-m, 1.2 W b )
CAUTION:
When installing throttle position sensor, adjust
to the specified data.

2) Disconnect the connector from the throttle posi-

tion sensor.

02M3493

3) Remove the throttle position sensor holding

screws, and remove it.

FU(S0HC)Sl
 THROTTLE POSITION SENSOR
FUEL INJECTION(FUEL SYSTEMS)

C: ADJUSTMENT 4) When using Subaru Select Monitor;

1) Turn the ignition switch to OFF. (1) Turn the ignition switch to OFF.
2) Loosen the throttle position sensor holding (2) Loosen the throttle position sensor holding
screws. screws.

02M3765 02M3765

3) When using voltage meter; NOTE:

(1) Take out the ECM. For detailed operation procedures, refer to the Sub-
(2) Turn the ignition switch to ON. aru Select Monitor Operation Manual.
(3) Adjust the throttle position sensor to the (3) Insert the cartridge to the Subaru Select
proper position to allow the voltage signal to the Monitor.
ECM to be in specification.
Connector & terminal / Specified voltage
(8136) NO. 15 - (B136) NO. 17/0.45 - 0.55 V
[Fully closed.]

-
76" n3 2 1

(4) Connect the Subaru Select Monitor to the

data link connector.

02M4131A

(4) Tighten the throttle position sensor holding

screws.
Tightening torque:
1.6 Nom(0.16 kgf-m, 1.2 ff-lb)

5 ) Turn the ignition switch to ON, and the Subaru

Select Monitor switch to ON.
6) Select the {2. Each System Check} in Main
Menu.
7) Select the {Engine Control System} in Selection
Menu.
02M376E
8) Select the 11. Current Data Display & Save} in
Engine Control System Diagnosis.
9) Select the (1.12 Data Display} in Data Display
Menu.

FU(S0HC)-32
 THROTTLE POSITION SENSOR
FUEL INJECTION (FUEL SYSTEMS)
10) Adjust the throttle position sensor to the proper
position to match with the following specifications.
Condition: Throttle fully closed
Throttle opening angle 0.00%
Throttlesensor voltage 0.50 V
11) Tighten the throttle position sensor holding
screws.
Tightening torque:
1.6 N.m (0.16 kgf-m, 1.2 ft-16)

FU(S0HC)-33
 INTAKE AIR TEMPERATURE AND PRESSURE SENSOR
FUEL INJECTION (FUEL SYSTEMS)

9. Intake Air Temperature and B: INSTALLATION

Pressure Sensor Install in the reverse order of removal.
Tightening torque:
A: REMOVAL 3.4 N.m (0.35kgf-m, 2.5 ff-lb)
1) Disconnect the battery ground cable.

I B2M3497

NOTE:
2) Disconnect the spark plug cord from the ignition
Replace O-ring with new one.
coil and ignitor assembly.

B2M3495
0 H2M2999

3) Disconnect the connector from the intake air

temperature and pressure sensor.

4) Remove the intake air temperature and pressure

sensor.

FU(S0HC)-34
 ATMOSPHERIC PRESSURE SENSOR
FUEL INJECTION (FUEL SYSTEMS)

1O.Atmospheric Pressure Sen- B: INSTALLATION

Install in the reverse order of removal.
sor
Tightening torque:
A: REMOVAL 6.4 N.m (0.65 kgf-m, 4.7 ff-lb)
1) Disconnect the battery ground cable.

EN1001

2) Disconnect the connector from the atmospheric

pressure sensor.
3) Remove the atmospheric pressure sensor from
the bracket.

I EN1001

FU(S0HC)-35
 IDLE AIR CONTROL SOLENOID VALVE
FUEL INJECTION (FUEL SYSTEMS)

11.Idle Air Control Solenoid B: INSTALLATION

Valve Install in the reverse order of removal.
NOTE:
A: REMOVAL Always use new gasket.
1) Disconnect the battery ground cable.
Tightening torque:
7.6 N*m (0.76 kgf-m, 7.2 fWb)

2) Disconnect the connector from the idle air con-

trol solenoid valve.
I

3) Remove the idle air control solenoid valve from

the throttle body.

FU(S0HC)-36
 AIR ASSIST INJECTOR SOLENOID VALVE
FUEL INJECTION (FUEL SYSTEMS)

12.Air Assist Injector Solenoid 9: INSTALLATION

Install in the reverse order of removal.
Valve
Tightening torque:
A: REMOVAL 6.4 N-m (0.65 kgf-m, 4.7 ff-lb)
1) Disconnect the battery ground cable.

B2M350:

2) Disconnect the connector from the air assist in-

jector solenoid valve and disconnect the air by-
pass hoses.

3) Remove the air assist injector solenoid valve

from the intake manifold.

B2M3.50:

FU(S0HC)-37
 FUEL INJECTOR
FUEL INJECTION (FUEL SYSTEMS)

13.Fuel Injector 6) Remove the power steering pump and tank from
the brackets.
A: REMOVAL (1) Remove the front side V-belt. <Ref. to
ME(S0HC)-43, REMOVAL, V-belt.>
1. RH SIDE (2) Remove the bolts which hold the power
1) Release the fuel pressure. steering pipes onto the intake manifold protec-
<Ref. to FU(S0HC)-50, RELEASING OF FUEL tor.
PRESSURE, OPERATION, Fuel.>
2) Open the fuel flap lid, and remove the fuel filler
cap.
3) Disconnect the battery ground cable.

(3) Remove the bolts which install the power

steering pump to the bracket.

4) Remove the resonator chamber. <Ref. to IN(S0-

HC)-8, REMOVAL, Resonator Chamber.>
5 ) Remove the spark plug cords from the spark
plugs (#1 and #3 cylinders).

(4) Disconnect the connector from the power

steering pump switch.

FU(S0HC)-38
I FUEL INJECTOR
FUEL INJECTION (FUEL SYSTEMS)

(5) Remove the power steering tank from the 9) Remove the bolt which holds the injector pipe to
bracket by pulling it upwards. the intake manifold.

(6) Place the power steering pump and tank on

the right side wheel apron.

' I 02M4282

10) Remove the fuel injector from the intake mani-

fold.
7) Remove the fuel pipe protector RH. (1) Remove the fuel injector securing clip.

B2M4130

8) Disconnect the connector from fuel injector. (2) Remove the fuel injector while lifting up the
fuel injector pipe.
I

FU(SOHC)S9
 FUEL INJECTOR
FUEL INJECTION (FUEL SYSTEMS)

2. LH SIDE 8 ) Move the washer tank, and secure it away from

the working area.
1) Release the fuel pressure. <Ref. to FU(S0HC)-
50, RELEASING OF FUEL PRESSURE, OPERA-
TION, Fuel.>
2) Open the fuel flap lid, and remove the fuel filler
cap.
3) Disconnect the battery ground cable.

9) Remove the spark plug cords from the spark

plugs (#2 and #4 cylinders).

4) Remove the two bolts which install the washer

tank on the body.

10) Remove the fuel pipe protector LH.

5) Disconnect the connector from the front window

washer motor.
6) Disconnect the connector from the rear gate
glass washer motor.

11) Disconnect the connector from the fuel injector.

7) Disconnect the rear window glass washer hose

from the washer motor, then plug the connection
with a suitable cap.

FU(S0HC)-40
 FUEL INJECTOR
FUEL INJECTION (FUEL SYSTEMS)

12) Remove the bolt which holds the injector pipe (2) Remove the fuel injector while lifting up the
to the intake manifold. fuel injector pipe.

B: INSTALLATION
1. RH SIDE
Install in the reverse order of removal.
CAUTION:
Replace O-rings with new ones.

13) Remove the bolt which holds the fuel pipe on

the left side intake manifold.

(A) O-ring
(B) Fuel injector

Tightening torque:
4.9 N.m (0.5 kgf-m, 3.6 ff-lb)

14) Remove the fuel injector from the intake mani-

fold.
(1) Remove the fuel injector securing clip.

FU(SOHC)-41
 FUEL INJECTOR
FUEL INJECTION (FUEL SYSTEMS)

Tightening torque: Tightening torque:

19 N.m (1.9 kgf-m, 13.7 ft-lb) 4.9 Nom(0.5 kgf-m, 3.6 ft-lb)

Tightening torque: Tightening torque:

19 N-m (1.9 kgf-m, 73.7 ft-lb) 4.9 N-m (0.5 kgf-m, 3.6 ft-lb)

I B2M4130

2. LH SIDE Tightening torque:

Install in the reverse order of removal. 19 Nom(1.9 kgf-m, 13.7 ft-lb)
CAUTION:
Replace O-rings with new ones.

Tightening torque:
19 N.m (7.9 kgf-m, 13.7 ft-lb)

(A) O-ring
(B) Fuel injector

FU(S0HC)-42
 FRONT OXYGEN (NF) SENSOR
FUEL INJECTION (FUEL SYSTEMS)

14.Front Oxygen (NF) Sensor B: INSTALLATION

1) Before installing front oxygen (NF)sensor, apply
A: REMOVAL the anti-seize compound only to the threaded por-
1) Disconnect the battery ground cable. tion of front oxygen (NF)sensor to make the next
removal easier.
An ti-seize compound:
SS-30 by JET LUBE
CAUTION:
Never apply anti-seize compound to protector
of front oxygen (NF)sensor.

2) Disconnect the connector from the front oxygen

(NF)sensor.
I

2) Install the front oxygen (NF)sensor.

Tightening torque:
21 N.m (2.7 kgf-m, 15.2 ff-lb)

I I

3) Lift-up the vehicle.

4) Apply SUBARU CRC or its equivalent to the
threaded portion of front oxygen (NF)sensor, and
leave it for one minute or more.
SUBARU CRC (Part No. 004301003)
5) Remove the front oxygen (NF)sensor.
CAUTION:
When removing the oxygen (NF)sensor, wait iwer the vehicle.
until exhaust pipe cools, otherwise it will dam-
4) Connect the connector of front oxygen (NF)sen-
age exhaust pipe.
sor.

FU(S0HC)-43
 FRONT OXYGEN (NF) SENSOR
a
FUEL INJECTION (FUEL SYSTEMS)

5 ) Connect the battery ground cable.

FU(S0HC)-44
 REAR OXYGEN SENSOR
81
FUEL INJECTION (FUEL SYSTEMS)

15.Rear Oxygen Sensor B: INSTALLATION

1) Before installing rear oxygen sensor, apply the
A: REMOVAL anti-seize compound only to the threaded portion of
1) Disconnect the battery ground cable. rear oxygen sensor to make the next removal eas-
ier.
CAUTION:
Never apply anti-seize compound to protector
of rear oxygen sensor.
Anti-seize compound:
SS-30 by JET LUBE

2) Lift-up the vehicle.

3) Disconnect the connector from the rear oxygen
sensor.

R7M0742A

2) Install the rear oxygen sensor.

Tightening torque:
27 N.m (2.7 kgf-m, 75.2 ft-lb)

4) Apply SUBARU CRC or its equivalent to the

threaded portion of rear oxygen sensor, and leave
it for one minute or more.
SUBARU CRC (Part No. 004307003)
5 ) Remove the rear oxygen sensor.
CAUTION:
When removing the oxygen sensor, wait until 3) Connect the connector to the rear oxygen sen-
exhaust pipe cools, otherwise it will damage ex- sor.
haust pipe.

__ .

4) Lower the vehicle.

FU(S0HC)-45
 REAR OXYGEN SENSOR
FUEL INJECTION (FUEL SYSTEMS)

5) Connect the battery ground cable.

FU(S0HC)-46
 ENGINE CONTROL MODULE
FUEL INJECTION (FUEL SYSTEMS)

16.Engine Control Module B: INSTALLATION

Install in the reverse order of removal.
A: REMOVAL CAUTION:
1) Disconnect the battery ground cable. When replacing ECM, be careful not to use the
wrong spec. ECM to avoid any damage to the
fuel injection system.
Tightening torque:
50 Nom(0.51 kgf-m, 3.7 ff-lb)

2) Remove the lower inner trim of passenger side.

<Ref. to El-46, REMOVAL, Lower Inner Trim.>
3) Detach the floor mat of front passenger seat.
4) Remove the protect cover.

I EN118t

5) Remove the nuts (A) which hold ECM to the

bracket.
6) Remove the clip (B) from the bracket.

186

7) Disconnect the ECM connectors and take out

the ECM.

FU(S0HC)-47
 MAIN RELAY
FUEL INJECTION (FUEL SYSTEMS)

17.Main Relay B: INSTALLATION

Install in the reverse order of removal.
A: REMOVAL
1 ) Disconnect the battery ground cable.

2) Remove the passenger's side front side sill cov-

er.
3) Remove the bolt which holds main bracket on
the body.
4) Disconnect the connectors from the main relay.

FU(S0HC)-48
 FUEL PUMP RELAY
FUEL INJECTION (FUEL SYSTEMS)

18.Fuel Pump Relay B: INSTALLATION ~

Install in the reverse order of removal.

A: REMOVAL
1) Disconnect the battery ground cable.

2) Remove the passenger’s side front side sill cov-

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

5) Remove the fuel pump relay from the mounting

bracket.

FU(S0HC)-49
 FUEL
FUEL INJECTION (FUEL SYSTEMS)

19.Fuel 4) Drain the fuel from the fuel tank.

Set a container under the vehicle and remove the
A: OPERATION drain plug from the fuel tank.
1. RELEASING OF FUEL PRESSURE
WARNING:
Place “NO FIRE” signs near the working area.
Be careful not to spill fuel on the floor.
1) Disconnect the connector from the fuel pump re-
lay.

---. 5) Tighten the fuel drain plug.

Tightening torque:
26 N.m (2.65 kgf-m, 19.2 ft-lb)

EN0344

2) Start the engine and run it until it stalls.

3) After the engine stalls, crank it for five more sec-
onds.
4) Turn the ignition switch to OFF.
2. DRAINING FUEL
WARNING:
Place “NO FIRE” signs near the working area.
Be careful not to spill fuel on the floor.
1) Set the vehicle on the lift.
2) Disconnect the battery ground cable.

3) Lift-up the vehicle.

FU(S0HC)-50
 im
FUEL TANK
FUEL INJECTION (FUEL SYSTEMS)

20.Fuel Tank 10) Disconnect the connector from the drain valve.

A: REMOVAL
WARNING:
Place “NO FIRE” signs near the working area.
Be careful not to spill fuel on the floor.
1) Set the vehicle on the lift.
2) Release the fuel pressure. <Ref. to FU(S0HC)-
50, RELEASING OF FUEL PRESSURE, Fuel.>
3) Drain the fuel from the fuel tank. <Ref. to FU(S0-
HC)-50, DRAINING FUEL, OPERATION, Fuel.> B2M 1743
4) Remove the rear seat.
5) Disconnect the connector (A) of fuel tank cord to 11) Loosen the clamp and disconnect the fuel filler
the rear harness. hose (A) and air vent hose (B) from the fuel filler
6) Push the grommet (B) which holds the fuel tank pipe.
cond on the floor panel into under the body.

S2M0193A

EN0537 12) Move the clips, and disconnect the quick con-
7) Remove the rear crossmember. <Ref. to RS-19, nector. <Ref. to FU(S0HC)-68, REMOVAL, Fuel
REMOVAL, Rear Crossmember.> Delivery, Return and Evaporation Lines.>
8) Move the clamp, and disconnect the evaporation 13) Disconnect the fuel hoses.
hose from the canister.

\ I
S2M0949A

9) Disconnect the connector from the pressure con-

trol solenoid valve.

FU(S0HC)-51
 FUEL TANK
FUEL INJECTION (FUEL SYSTEMS)
14) Support the fuel tank with transmission jack, re- 4) Connect the fuel hoses, and hold then with clips
move the bolts from bands and dismount the fuel and quick connector. <Ref. to FU(S0HC)-68, RE-
tank from the vehicle. MOVAL, Fuel Delivery, Return and Evaporation
WARNING: Lines.>
A helper is required to perform this work.

5 ) Connect the connector to the drain valve.

B: INSTALLATION
1) Support the fuel tank with transmission jack and
push the fuel tank harness into access hole with
grommet.
2) Set the fuel tank and temporarily tighten the bolts
of fuel tank bands.
WARNING:
A helper is required to perform this work.

I B2M1743

6) Connect the connector to the pressure control

solenoid valve.
7) Connect the evaporation hose to the canister,
and hold them clamp.

3) Connect the fuel filler hose (A) and air vent hose
(B).

\
S2M0949A

FU(S0HC)-52
 FUEL TANK
FUEL INJECTION (FUEL SYSTEMS)

8) Tighten the band mounting bolts. C: INSPECTION

Tightening torque: 1) Make sure there are no cracks, holes, or other
33 N.m (3.4 kgf-m, 25 ft-lb) damage on the fuel tank.
2) Make sure that the fuel hoses and fuel pipes are
not cracked and that connections are tight.

9) Install the rear crossmember. <Ref. to RS-19,

INSTALLATION, Rear Crossmember.>
10) Connect the connectors to the fuel tank cord
and plug the service hole with gromment.

EN0537

11) Set the rear seat and floor mat.

12) Connect the connector to the fuel pump relay.

EN0344

FU(S0HC)-53
 FUEL FILLER PIPE
FUEL INJECTION (FUEL SYSTEMS)

21.Fuel Filler Pipe 8) Drain the fuel from the fuel tank. Set a container
under the vehicle and remove the drain plug from
A: REMOVAL the fuel tank.
WARNING:
Place “NO FIRE” signs near the working area.
Be careful not to spill fuel on the floor.
1) Release the fuel pressure. <Ref. to FU(S0HC)-
50, RELEASING OF FUEL PRESSURE, OPERA-
TION, Fuel.>
2) Open the fuel filler flap lid and remove the filler
cap.
3) Disconnect the battery ground cable.

9) Tighten the fuel drain plug and then install the

front right side tank cover.
Tightening torque:
26 N-m (2-65 kgf-m, 7 9.2 fi-lb)

4) Remove the screws holding packing in place.

10) Remove the fuel filler pipe protector.

5) Lift-up the vehicle.

’
6) Remove the rear right side wheel nuts
7 ) Remove the rear right side wheel.
EN0542

1EN0544

11) Separate the evaporation hoses from the clip of

fuel filler pipe.

FU(S0HC)-54
 FUEL FILLER PIPE
FUEL INJECTION (FUEL SYSTEMS)

12) Disconnect the evaporation hoses from the 17) Remove the evaporation pipe together with clip
pipes. from the body.

EN112:

13) Remove the bolts which hold the fuel filler pipe
bracket on the body.

14) Loosen the clamp and separate the fuel filler

hose (A) from the fuel filler pipe.
15) Move the clip and separate the evaporation
hose (B).

16) Remove the fuel filler pipe to under side of the

ve hicle.

FU(SOHC)-55
 FUEL FILLER PIPE
FUEL INJECTION (FUEL SYSTEMS)
B: INSTALLATION
1) Hold the fuel filler flap open.
2) Set the fuel saucer (A) with rubber packing (C)
and insert the fuel filler pipe into hole from the inner
side of apron.
3) Align the holes in fuel filler pipe neck and set the
cup (B), and tighten the screws.
NOTE:
If the edges of rubber packing are folded toward the
inside, straighten it with a screwdriver.
4) Install the evaporation pipe.
FU(S0HC)-56
5 ) Connect the evaporation hose to the pipe.
EN112:
6) Insert the fuel filler hose (A) approximately 35 to
40 mm (1.38 to 1.57 in) over the lower end of fuel
filler pipe and tighten the clamp.
CAUTION:
Do not allow clips to touch evaporation hose
(B) and rear suspension crossmember.
7) Insert the evaporation hose approximately 25 to
30 mm (0.98 to 1.18 in) into the lower end of evap-
oration pipe and hold the clip.
L = 27.5f2.5 mm (1.083-_+0.098in)
k--J
B2M1195A
(1) Hose
(2) Clip
(3) Pipe
 FUEL FILLER PIPE
FUEL INJECTION (FUEL SYSTEMS)

8) Tighten the bolt which holds the fuel filler pipe 14) Connect the connector to the fuel pump relay.
bracket on the body.
Tightening torque:
7.5 N-m (0.75 kgf-m, 5.4 ft-lb)

15) Connect the battery ground terminal.

EN1124

9) Tighten the bolts which hold the evaporation

hoses onto the clip of fuel filler pipe.

C: DISASSEMBLY
1) Move the clip, and disconnect the evaporation
hose from the joint pipe.

10) Install the fuel filler pipe protector

L
11) Install the rear right wheel.
EN0544
2) Remove the bolt which installs the joint pipe on
the fuel filler pipe.

12) Lower the vehicle.

13) Tighten the wheel nuts.

FU(SOHC)-57
 FUEL FILLER PIPE
FUEL INJECTION (FUEL SYSTEMS)

3) Disconnect the evaporation hose from the fuel D: ASSEMBLY

fiiler pipe. 1) Install the shut valve on the fuel filler pipe.<Ref.
to EC(D0HC TURBO)-16, INSTALLATION, Shut
Valve.>
2) Connect the evaporation hose to the fuel filler
pipe.

4) Remove the shut valve from the fuel filler

pipe.<Ref. to EC(D0HC TURBO)-16, REMOVAL,
Shut Valve.>

3) Connect the evaporation hose to the evaporation

pipe.

I
4) Install the evaporation pipe to the fuel filler pipe.

FU(SOHC)-SS
 FUEL PUMP
FUEL INJECTION (FUEL SYSTEMS)

22.Fuel Pump 6) Tighten the fuel drain plug.

Tightening torque:
A: REMOVAL 26 N-m (2.65 kgf-m, 19.2 ff-lb)
WARNING:
Place “NO FIRE” signs near the working area.
Be careful not to spill fuel on the floor.
NOTE:
Fuel pump assembly consists of fuel pump and fuel
level sensor.
1) Release the fuel pressure. <Ref. to FU(S0HC)-
50, RELEASING OF FUEL PRESSURE, OPERA-
TION, Fuel.>
2) Open the fuel filler flap lid and remove the fuel
filler cap.
3) Disconnect the battery ground cable. 7) Raise the rear seat and turn the floor mat up.
8) Remove the access hole lid.

EN0553
4) Lift-up the vehicle.
5) Drain the fuel from the fuel tank. Set a container 9) Disconnect the connector from the fuel pump.
under the vehicle and remove the drain plug from
the fuel tank.

10) Disconnect the quick connector and then dis-

connect the fuel delivery hose (A). <Ref. to FU(S0-
HC)-68, REMOVAL, Fuel Delivery, Return and
Evaporation Lines.>

FU(SOHC)-59
 FUEL PUMP
FUEL INJECTION(FUEL SYSTEMS)

11) Move the clip and then disconnect the fuel re-
turn hose (B) and jet pump hose (C).

I~
S2MO060A I
12) Remove the nuts which install the fuel pump

'
assembly onto the fuel tank.

I ' EN0556 I
13) Take off the fuel pump assembly from the fuel
tank.

FU(S0HC)-60
 FUEL PUMP
FUEL INJECTION (FUEL SYSTEMS)

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

S2M0063A

FU(S0HC)-61
 FUEL LEVEL SENSOR
FUEL INJECTION (FUEL SYSTEMS)

23.Fuel Level Sensor 6: INSTALLATION

Install in the reverse order of removal.
A: REMOVAL
Tightening torque:
WARNING: 4.4 N-m (0.45 kgf-m, 3.3 fi-lb)
Place “NO FIRE” signs near the working area.
Be careful not to spill fuel on the floor.
NOTE:
Fuel level sensor is built in fuel pump assembly.
1) Remove the fuel pump assembly. <Ref. to
FU(S0HC)-59, REMOVAL, Fuel Pump.>
2) Disconnect the connector from the fuel pump
bracket.

3) Remove the bolt which installs the fuel level sen-

sor on the mounting bracket.

EN113(

FU(S0HC)-62
 FUEL SUB LEVEL SENSOR
FUEL INJECTION (FUEL SYSTEMS)

24.Fuel Sub Level Sensor 6) Remove the service hole cover.

A: REMOVAL
WARNING:
Place “NO FIRE” signs near the working area.
Be careful not to spill fuel on the floor.
1) Disconnect the battery ground cable.

/ G2M0863

7) Disconnect the connector from the fuel sub

meter.
8) Disconnect the fuel jet pump hose.

2) Lift-up the vehicle.

3) Drain the fuel from the fuel tank. Set a container
under the vehicle and remove the drain plug from
the fuel tank.

// / S2M0151

9) Remove the bolts which install the fuel sub meter

unit on the fuel tank.

4) Tighten the fuel drain plug.

Tightening torque:
26 N.m (2.65 kgf-m, 19.2 ft-lb)

10) Remove the fuel sub meter unit.

5 ) Remove the rear seat.

FU(S0HC)-63
 FUEL SUB LEVEL SENSOR
FUEL INJECTION (FUEL SYSTEMS)

B: INSTALLATION
install in the reverse order of removal.
Tightening torque:
4.4 N-m (0.45 kgf-m, 3.3 ft-lb)

FU(S0HC)-64
 FUEL FILTER
25.Fuel Filter
A: REMOVAL
WARNING:
Place “NO FIRE” signs near the working area.
Be careful not to spill fuel on the floor.
1) Release the fuel pressure. <Ref.‘to FU(S0HC)-
50, RELEASING OF FUEL PRESSURE, OPERA-
TION, Fuel.>
2) Disconnect the fuel delivery hoses from the fuel
filter.
3) Remove the filter from the holder.
FU(S0HC)-65
FUEL INJECTION (FUEL SYSTEMS)
B: INSTALLATION
1) Install in the reverse order of removal.
2) Tighten the hose clamp screws.
Tightening torque:
1.25 N.m (0.13 kgf-m, 0.94 ff-lb)
C: INSPECTION
1) Check the inside of fuel filter for dirt and water
sediment.
2) If it is clogged, or if the replacement interval has
been reached, replace it.
3) If the water is found in it, shake and expel the wa-
ter from the inlet port.
4) If fuel hoses are damaged at the connecting por-
tion, replace it with a new one.
5 ) If clamps are badly damaged, replace with new
ones.
 FUEL CUT VALVE
FUEL INJECTION (FUEL SYSTEMS)

26.Fuel Cut Valve B: INSTALLATION

Install in the reverse order of removal.
A: REMOVAL
Tightening torque:
WARNING: 4.4 N.m (0.45 kgf-m, 3.3 fi-lb)
Place “NO FIRE” signs near the working area.
Be careful not to spill fuel on the floor.

REMOVAL, Fuel Tank.>

2) Remove the protect cover.

EN1132 I

EN1050

3) Move the clip and disconnect the evaporation

hose from the fuel cut valve.

I EN1131

4) Remove the bolts which install the fuel cut valve.

FU(S0HC)-66
 FUEL DAMPER VALVE
FUEL INJECTION (FUEL SYSTEMS)

27.Fuel Damper Valve

A: REMOVAL
1) Release the fuel pressure. <Ref. to FU(S0HC)-
50, RELEASING OF FUEL PRESSURE, OPERA-
TION, Fuel.>
2) Remove the fuel damper valve from the fuel re-
turn line.

\
4-m \

B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
1.25 N-m (0.13 kgf-m, 0.94 ft-lb)

FU(S0HC)-67
 FUEL DELIVERY, RETURN AND EVAPORATION LINES
FUEL INJECTION (FUEL SYSTEMS)

28.Fuel Delivery, Return and
Evaporation Lines
A: REMOVAL
1) Set the vehicle on the lift.
2) Release the fuel pressure. <Ref. to FU(S0HC)-
50, RELEASING OF FUEL PRESSURE, OPERA-
TION, Fuel.>
3) Open the fuel filler flap lid and remove the fuel
filler cap.
4) Remove the floor mat. <Ref. to El-55, REMOV-
AL, Floor Mat.>
5) Remove the fuel delivery pipes and hoses, fuel
return pipes and hoses, evaporation pipes and hos-
es .

I EN1133

6) In engine compartment, detach the fuel delivery 7) Lift-up the vehicle.

hoses, return hoses and evaporation hose.

S2M0500F

(A) Fuel delivery hose

(B) Return hose
(C) Evaporation hose

FU(S0HC)-68
 FUEL DELIVERY, RETURN AND EVAPORATION LINES
FUEL INJECTION (FUEL SYSTEMS)

8) Separate the quick connector on the fuel delivery (1) Set the new retainer (B) to connector (A).
and return line. (2) Push the pipe into the connector completely.
(1) Clean the pipe and connector, if they are NOTE:
covered with dust. At this time, two clicking sounds are heard.
(2) Hold the connector (A) and push retainer (B)
down.
(3) Pull out the connector (A) from retainer (B).
CAUTION:
Replace retainer with new ones.
(C)
I

S2M0230P

(A) Connector
(B) Retainer
-
(C) Pipe
S2M0228L
CAUTION:
(A) Connector Pull the connector to ensure it is connected
(B) Retainer securely.
(C) Pipe Ensure the two retainer pawls are engaged in
their mating positions in the connector.
B: INSTALLATION Be sure to inspect hoses and their connec-
1) Connect the quick connector on fuel delivery tions for any leakage of fuel.
line. I I

CAUTION:
Always use a new retainer.
Make sure that the connected portion is not
damaged or has dust. If necessary, clean seal
surface of pipe.

(A) Connector
(B) Retainer
(C) Pipe

S2M0229A

FU(S0HC)-69
 FUEL DELIVERY, RETURN AND EVAPORATION LINES
FUEL INJECTION (FUEL SYSTEMS)

2) Connect the fuel delivery hose to the pipe with an C: INSPECTION

overlap of 20 to 25 mm (0.79 to 0.98 in).
Type A: When the fitting length is specified.
Type B: When the fitting length is not specified.
0 :2.527.5 mm (0.098-M.059 in)
L: 22.53.5 mm (0.886-M.098 in)
1) Make sure that there are no cracks on the fuel
pipes and fuel hoses.
2) Make sure that the fuel pipe and fuel hose con-
nections are tight.

I 02M11940

(1) Fitting
(2) Clamp
(3) Hose

3) Connect the return hose and evaporation hose

to pipe by approx. 15 mm (0.59 in) from the hose
end.
Fuel return hose:
L = 22.53.5 mm (0.885_+0.098in)
Fuel evaporation hose:
L = 17.53.5 mm (0.689-M.098 in)
CAUTION:
Be sure to inspect hoses and their connections
for any leakage of fuel.

I 02M1195A

(1) Hose
(2) Clip
(3) Pipe

FU(SO HC)-70
 FUEL SYSTEM TROUBLE IN GENERAL
FUEL INJECTION (FUEL SYSTEMS)

29.Fuel System Trouble in General

A: INSPECTION
Trouble and possible cause 1 Corrective action
1. Insufficient fuel supply to the injector
1I I Fuel .DumD, will not oDerate.
Inspect connections, especially ground, and tighten
0 Defective terminal contact.
securely.
I0 Trouble in electromagnetic or electronic circuit parts. 1 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 retiahten each connection part.
6) I Clogged or bent breather tube or pipe. I Clean, correct or replace air breather tube or pipe.

1) Loosened joints of the fuel pipe. Retightening.

2) Cracked fuel pipe, hose and fuel tank. Replace.
3) Defective weldina Dart on the fuel tank. Replace.
4) I Defective drain packing of the fuel tank. I Replace.

5) I
I
Clogged or bent air breather tube or air vent tube.
I
I
Clean, correct or replace air breather tube or air vent
tube.
3. Gasoline smell inside of comeartment
Loose joints at air breather tube, air vent tube and fuel
1) Retightening,
filler pipe.
2) 1 Defective packing air tightness on the fuel saucer. I Correct or replace packing.
3) Cracked fuel separator. Replace separator.
4) Inoperative fuel pump modulator or circuit. Replace.

2) I ~ Defective operation of fuel meter. 1 Replace.

5. Noise
1) I Large operation noise or vibration of fuel pump.
NOTE:
When the vehicle is left unattended for an ex-
tended period of time, water may accumulate in the
fuel tank.
To prevent water condensation.
(1) Top off the fuel tank or drain the fuel com-
pletely.
(2) Drain the water condensation from the fuel
filter.
Refilling the fuel tank.
Refill the fuel tank while there is still some fuel left in
the tank.
Protecting the fuel system against freezing and
water condensation.
(3) Cold areas
In snow-covered areas, mountainous areas, ski-
ing areas, etc. where ambient temperatures
drop below 0°C (32°F) throughout the winter
season, use an anti-freeze solution in the cool-
ing system. Refueling will also complement the
I Replace.
effect of anti-freeze solution each time the fuc
level drops to about one-half. After the winter
season, drain the water which may have accu-
mulated in the fuel filter and fuel tank in the man-
ner same as that described under Affected
areas below.
(4) Affected areas
When the water condensation is notched in the
fuel filter, drain the water from both the fuel filter
and fuel tank or use a water removing agent (or
anti-freeze solution) in the fuel tank.
Observe the instructions, notes, etc., indicated
on the label affixed to the anti-freeze solution (wa-
ter removing agent) container before use.

FU(S0HC)-71
 FUEL SYSTEM TROUBLE IN GENERAL
FUEL INJECTION (FUEL SYSTEMS)

FU(S0HC)-72
EMISSION CONTROL
(AUX . EMISSION CONTROL DEVICES)

~~
EC(S0HC)
Page
1. General Description .................................................................................... 2
2. Front Catalytic Converter ............................................................................ 3
3. Rear Catalytic Converter ............................................................................. 4
4. Canister ....................................................................................................... 5
5. Purge Control Solenoid Valve ..................................................................... 6
6. Main Fuel Level Sensor .............................................................................. 7
7. Fuel Temperature Sensor ........................................................................... 8
8. Sub Fuel Level Sensor ................................................................................ 9
9. Fuel Tank Pressure Sensor ...................................................................... 10
10. Pressure Control Solenoid Valve .............................................................. 11
11. Drain Filter................................................................................................. 13
12. Vent Valve ................................................................................................. 14
13. Shut Valve ................................................................................................. 15
14. Drain Valve ................................................................................................ 16
 GENERAL DESCRIPTION
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

1. General Description
A: CAUTION
Wear working clothing, including a cap, protec-
tive goggles, and protective shoes during opera-
tion.
Remove contamination including dirt and corro-
sion before removal, installation or disassembly.
Keep the disassembled parts in order and pro-
tect them from dust or dirt.
Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary re-
moval, installation, disassembly, and replacement.
Be careful not to burn your hands, because each
part on the vehicle is hot after running.
Be sure to tighten fasteners including bolts and
nuts to the specified torque.
Place shop jacks or safety stands at the specified
points.
Before disconnecting electrical connectors of
sensors or units, be sure to disconnect the negative
terminal from battery.

EC(S0HC)-2
 FRONT CATALYTIC CONVERTER
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

2. Front Catalytic Converter

A: REMOVAL
1) Remove the front exhaust pipe and center ex-
haust pipe. <Ref. to EX(S0HC)-8, Removal, Cen-
ter Exhaust Pipe.>
2) Separate the front catalytic converter from front
exhaust pipe.
NOTE:
The front catalytic converter is integrated with rear
catalytic converter.

B: INSTALLATION
CAUTION:
Replace gaskets with new ones.
1) Install the front catalytic converter to front ex-
haust pipe.
Tightening torque:
30 N.m (3.1 kgf-m, 22.4 ft-lb)

\\' S2M0923

2) Install the front exhaust pipe and center exhaust

pipe. <Ref. to EX(S0HC)-8, Installation, Center Ex-
haust Pipe.>
C: INSPECTION
1) Make sure there are no exhaust leaks from con-
nections and welds.
2) Make sure there are no holes or rusting.

EC(S0HC)-3
 REAR CATALYTIC CONVERTER
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)
~

3. Rear Catalytic Converter

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

Converter.>

I B2M4164A

(A) Front catalytic converter

(B) Rear catalytic converter

B: INSTALLATION
The front and rear catalytic converter and center
exhaust pipe are integrated into one unit. There-
fore, the removal and installation procedures are
the same as those for the front catalytic converter.
<Ref. to EC(S0HC)-3, INSTALLATION, Front Cat-
alytic Converter.>

I B2M4164A

(A) Front catalytic converter

(B) Rear catalytic converter

C: INSPECTION
1) Make sure there are no exhaust leaks from con-
nections and welds.
2) Make sure there are no holes or rusting.

EC(S0HC)-4
 CANISTER~

EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

4. Canister B: INSTALLATION
Install in the reverse order of removal.
A: REMOVAL Tightening torque:
1) Lift-up the vehicle. 23 N-m (2.3 kgf-m, 17 ff-lb)
2) Loosen the two clamps which hold two canister
hoses, and disconnect the evaporation hose from
canister.

C: INSPECTION
Make sure the canister and canister hoses are not
3) Remove the canister from body. cracked or loose.

EC(S0HC)-5
 PURGE CONTROL SOLENOID VALVE
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

5. Purge Control Solenoid Valve B: INSTALLATION

Install in the reverse order of removal.
A: REMOVAL
1) Disconnect the ground terminal from battery. Tightening torque:
16 N.m (1.6 kgf-m, 11.6 ft-lb)

2) Remove the bolt which installs purge control so-

lenoid valve onto intake manifold. CAUTION:
Carefully connect the evaporation hoses.

To fuel -e-
+To intake
Pipe
manifold

02 M1893A
3) Take out purge control solenoid valve through
the bottom of the intake manifold. C: INSPECTION
4) Disconnect the connector and hoses from purge Make sure the hoses are not cracked or loose
control solenoid valve.

EC(S0HC)-6
 MAIN FUEL LEVEL SENSOR
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

6. Main Fuel Level Sensor

A: REMOVAL
For work procedures, refer to “FU” section. <Ref. to
FU(S0HC)-62, REMOVAL, Fuel Level Sensor.>
6 : INSTALLATION
For work procedures, refer to “FU” section. <Ref. to
FU(S0HC)-62, INSTALLATION, Fuel Level Sen-
sor.>

EC(S0HC)-7
 FUEL TEMPERATURE SENSOR
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

7. Fuel Temperature Sensor B: INSTALLATION

Install in the reverse order of removal.
A: REMOVAL WARNING:
Remove the pump <Ref. Io Spark may occur and ignite if fuel is nearby,
FU(S0HC)-59, REMOVAL, Fuel Pump.>
2) Disconnect the connector from fuel pump brack-
et.

3) Remove the main fuel level sensor from fuel

pump assembly. <Ref. to FU(S0HC)-62, REMOV-
AL, Fuel Level Sensor.>

S2M0855

NOTE:
Fuel temperature sensor is a unit with the fuel
pump. If replacing it, replace as a fuel pump.

EC(S0HC)-8
 SUB FUEL LEVEL SENSOR
im
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

8. Sub Fuel Level Sensor

A: REMOVAL
For work procedures, refer to <Ref. to FU(S0HC)-
63, REMOVAL, Fuel Sub Level Sensor.>
B: INSTALLATION
For work procedures, refer to <Ref. to FU(S0HC)-
64, INSTALLATION, Fuel Sub Level Sensor.>

EC(S0HC)-9
 FUEL TANK PRESS JRE SENSOR
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES

9. Fuel Tank Pressure Sensor 6) Disconnect the pressure hose from fuel tank
pressure sensor.
A: REMOVAL
1) Remove the fuel tank. <Ref. to FU(S0HC)-51,
REMOVAL, Fuel Tank.>
2) Remove the protector cover.

I B2M1779

B: INSTALLATION
Install in the reverse order of removal.
ENlO5C Tightening torque:
3) Disconnect the connector from fuel tank pres- 7.4 N.m (0.75 kgf-m, 5.4 ft-lb)
sure sensor.

C: INSPECTION
4) Release the clips which hold fuel pipes onto fuel Make sure the hoses are not cracked or loose.
tank.

Clip EN1052

5) Remove the clip, and disconnect pressure hose

from fuel tank.

EC(S0HC)-10
 PRESSURE CONTROL SOLENOID VALVE
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

1O.Pressure Control Solenoid 5 ) Disconnect the connector from pressure control

solenoid valve.
Valve
A: REMOVAL
1) Disconnect the ground terminal from battery.

6) Disconnect the two evaporation hoses from

pressure control solenoid valve.
7) Remove the pressure control solenoid valve with
bracket.
2) Remove the canister. <Ref. to EC(S0HC)-5,
REMOVAL, Canister.>
3) Disconnect the evaporation hoses (A) from joint
pipes.

8) Remove the pressure control solenoid valve

from bracket.

4) Remove the bolt which installs pressure control

solenoid valve holding bracket on body. I \ I

B2M1786 I
9) Disconnect the vacuum hose from pressure con-
trol solenoid valve.
I

78!

EC(S0HC)-11
 PRESSURE CONTROL SOLENOID VALVE
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
17.6 N-m (1.8 kgf-m, 13.0 ft-lb)

C: INSPECTION
Make sure the hoses are not cracked or loose.

EC(S0HC)-12
 DRAIN FILTER
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

11.Drain Filter 6) Remove the bolt which installs the drain filter and
drain valve brackets on body, and remove them as
A: REMOVAL a unit.
1) Disconnect the ground terminal from battery.

7) Disconnect the evaporation hoses, and remove

2) Lift-up the vehicle. the drain filter.
3) Remove the canister. <Ref. to EC(S0HC)-5,
REMOVAL, Canister.>
4) Disconnect the connector from drain valve.

B2M1791C

/
B: INSTALLATION
0
Install in the reverse order of removal.
H2M3611
Tightening torque:
5) Disconnect the evaporation hoses (A) from joint
23 N-m (2.35 kgf-m, 17.0 it-lb)
pipes.

C: INSPECTION
1) Make sure all hoses are installed correctly.
2) Make sure the hoses are not cracked or loose.

EC(S0HC)-13
 VE YT VALVE
EMISSION CONTROL (AUX. EMISSION CONTROL IEVICES)

12.Vent Valve B: INSTALLATION

Install in the reverse order of removal.
A: REMOVAL CAUTION:
1) Remove the fuel tank. <Ref. to FU(S0HC)-51,
Replace the rubber seat with a new one.
REMOVAL, Fuel Tank.>
2) Remove the protector cover. Tightening torque:
T: 4.4 Nom(0.45 kgf-m, 3.3 fl-lb)

U I ,-Rubber seat

EN1050
02M1794A
3) Remove the clips, and disconnect the hoses
from vent valve. C: INSPECTION
Make sure the hoses are not cracked or loose.

4) Remove the nuts which install the vent valve on

fuel tank.

EC(S0HC)-14
 SHUT VALVE
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

13.Shut Valve B: INSTALLATION

Install in the reverse order of removal.
A: REMOVAL
1) Disconnect the ground terminal from battery. Tightening torque:
4.5 N.m (0.46 kgf-m, 3.3 ff-lb)

I
I EN105
2) Drain fuel from the fuel tank. <Ref. to FU(S0-
HC)-51, REMOVAL, Fuel Tank.> C: INSPECTION
3) Remove the fuel filler pipe. <Ref. to FU(S0HC)- bkke Sure the hoses are not cracked Or ~Oose.
54, REMOVAL, Fuel Filler Pipe.>
4) Disconnect the evaporation hoses from shut
valve.

EN105

5) Remove the shut valve from fuel filler pipe.

FN105F

EC(S0HC)-15
 DRAIN VALVE
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

14.Drain Valve 6) Remove the bolt which installs the drain filter and
drain valve brackets on body, and remove them as
A: REMOVAL a unit.
1) Disconnect the ground terminal from battery.

7) Remove the drain valve from bracket.

2) Lift-up the vehicle.
3) Remove the canister. <Ref. to EC(S0HC)-5,
REMOVAL, Canister.>
4) Disconnect the connector from drain valve.

EN105!

B: INSTALLATION
,
’ Install in the reverse order of removal.
0 0-H2M3611 Tightening torque:
23 N-m (2.35 kgf-m, 17.0 ft-lb)
5) Disconnect the evaporation hoses from drain
valve.

------ H2M3612A
L
C: INSPECTION
EN1055

1) Make sure all hoses are installed correctly.

2) Make sure the hoses are not cracked or loose.

EC(S0HC)-16
INTAKE (INDUCTION)

IN(S0HC)
1.
2.
3.
4.
General Description .................................................................................... 2
Air Cleaner ..................................................................................................Page
Air Cleaner Case ......................................................................................... 6
Air Intake Duct............................................................................................. 7
5 a
5. Resonator Chamber .................................................................................... 8
 GENERAL DESCRIPTION
INTAKE (INDUCTION)

1. General Description
A: COMPONENT

EN0057

IN(S0HC)-2
 GENERAL DESCRIPTION
INTAKE (INDUCTION)

Spacer Air cleaner case B Tightening torque: N-m (kgf-m, ft-lb)

Bush Air cleaner case stay LH (MT vehi- T1: 33 (3.4, 24.4)
Resonator chamber cles) T2: 6.4 (0.65, 4.7)
Cushion rubber Air cleaner case stay LH (AT vehi- T3: 7.5 (0.76, 5.5)
Air intake duct A cles) T4: 6 (0.6, 4.4)
Air intake duct B Air cleaner case stay RH T5: 16 (1.6, 11.6)
Bracket Engine harness bracket T6: 3 (0.3, 2.2)
Cushion Clamp
Air cleaner case A Bush
Clip Spacer
Air cleaner element

IN(S0HC)-3
 GENERAL DESCRIPTION
INTAKE (INDUCTION)

B: CAUTION
Wear working clothing, including a cap, protec-
tive goggles, and protective shoes during opera-
tion.
Remove contamination including dirt and corro-
sion before removal, installation or disassembly.
Keep the disassembled parts in order and pro-
tect them from dust or dirt.
Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary re-
moval, installation, disassembly, and replacement.
Be careful not to burn your hands, because each
part on the vehicle is hot after running.
Be sure to tighten fasteners including bolts and
nuts to the specified torque.
Place shop jacks or safety stands at the specified
points.
Before disconnecting electrical connectors of
sensor or units, be sure to disconnect negative ter-
minal from battery.

IN(SOHC)-4
 AIR CLEANER
INTAKE (INDUCTION)

2. Air Cleaner
A: REMOVAL
1) Remove the bolt (A) which installs air cleaner
case to stays.
2) Remove the clip (B) above the air cleaner case.

3) Remove the air cleaner element.

B: INSTALLATION
Install in the reverse order of removal.
CAUTION:
Fasten with a clip after inserting the lower tab
of the case.
C: INSPECTION
Replace if excessively damaged or dirty.

IN(SOHC)-5
 AIR CLEANER CASE
INTAKE (INDUCTION)

3. Air Cleaner Case

A: REMOVAL
1) Disconnect the battery ground cable.

2) Loosen the clamp which connects air cleaner

case to throttle body.

3) Disconnect the hoses and intake duct from air

cleaner case.
4) Remove the bolts which install air cleaner case
to stays.

5) Remove the air cleaner case.

B: INSTALLATION
Install in the reverse order of removal.
C: INSPECTION
Inspect for cracks and loose connections.

IN(S0HC)-6
 AIR INTAKE DUCT
INTAKE (INDUCTION)

4. Air Intake Duct

A: REMOVAL
1) Remove the bolts which install air intake duct (A)
on the front side of body.

2) Remove the bolt which installs air intake duct (B)

on body.

3) Remove the air intake ducts as a unit.

B: INSTALLATION
Install in the reverse order of removal.
C: INSPECTION
1) Inspect for cracks and loose connections.
2) Inspect that no foreign objects are mixed in the
air intake duct.

IN(SOHC)-7
 RESONATOR CHAMBER
INTAKE (INDUCTION)

5. Resonator Chamber B: INSTALLATION

A: REMOVAL
1) Remove the air intake duct. <Ref. to IN(S0HC)-
7, REMOVAL, Air Intake Duct.>
2) Remove the resonator chamber.
Install in the reverse order of removal.
Tightening torque:
33 N.m (3.4 kgf-m, 24.4 ft-lb)

C: INSPECTION
Inspect for cracks and loose connections.

IN(S0HC)-8
MECHANICAL

ME(S0HC)
Page
1. General Description .................................................................................... 2
2. Compression ............................................................................................. 23
3. Idle Speed ................................................................................................. 24
4. Ignition Timing ........................................................................................... 25
5. Intake Manifold Vacuum ............................................................................ 26
6. Engine Oil Pressure .................................................................................. 27
7. Fuel Pressure ............................................................................................ 28
8. Valve Clearance ........................................................................................ 29
9. Engine Assembly ...................................................................................... 33
10. Engine Mounting ....................................................................................... 41
11. Preparation for Overhaul ........................................................................... 42
12. V-belt ......................................................................................................... 43
13. Crankshaft Pulley ...................................................................................... 45
14. Belt Cover ................................................................................................. 46
15. Timing Belt Assembly ................................................................................ 47
16. Camshaft Sprocket.................................................................................... 52
17. Crankshaft Sprocket .................................................................................. 54
18. Valve Rocker Assembly ............................................................................ 55
19. Camshaft ................................................................................................... 57
20 . Cylinder Head Assembly ........................................................................... 61
21 . Cylinder Block ........................................................................................... 69
22 . Engine Trouble in General ........................................................................ 89
23 . Engine Noise ............................................................................................. 95
 GENERAL DESCRIPTION

1. General Description
A: SPECIFICATIONS
T.nm
IYP=
I Horizontallyopposed, liquid cooled, 4-cylinder,4-stroke gasoline
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 3.1 10)
Displacement cm3 (cu in) 2,457 (150)

Compression pres-
sure (at 200 - 300 kPa ( kgf/cm2, psi) 1,079-1,275 (11.0-13.0, 156-185)
rpm)
Number of Diston rinas - 2, Oil ring: 1
Pressure ring:
Opening 1" BTDC
Engine Intake valve timing
Closing 51 ABDC
O

Opening 50" BBDC

Exhaust valve timing Closina 6" ATDC
u

Intake mm (in) 0.20f0.02 (0.0079kO.0008)

Valve clearance
Exhaust mm (in) 0.25f0.02 (0.0098k0.0008)
Idling speed [At neutral position MT: 650+100 (No load)
on MT, or "P" or "N" position on rPm AT: 700f100 (No load)
AT1 850k100 (NC switch ON)
Firina
u order I
1+3-+2+4
MT: 10"+8"/650
Ignition timing BTDC/rpm
AT: 15"f8"/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)
Va Ive STD 0.020 - 0.054 mm (0.0008 - 0.0021 in)
Clearance between shaft and arm
rocker arm I
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 0.1 1 mm (0.0043in)
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(SOHC)-2
 GENERAL DESCRIPTION
MECHANICAL

Surface wamaae limit 0.05 mm (0.0020 in)

Surface grinding limit 0.1 mm (0.004 in)
Standard height 98.3 mm (3.870 in)
Refacing angle 90"
STD 1.O mm (0.039 in)
Intake
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 I 6.000 - 6.012 mm (0.2362 - 0.2367 in)
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)

Intake
I STD 1.O mm (0.039 in)
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
Exhaust 5.945 - 5.960 "(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)
I Limit I- I 0.15 mm (0.0059 in)
I Intake I 120.6 mm (4.75 in)
Overall length
I Exhaust I 121.7 mm (4.79 in)
Free length 54.30 mm (2.1378 in)
Squareness 2.5", 2.4 mm (0.094 in)
214.8-246.2N (21.9-25.1 kgf,48.3-55.3Ib)/
Tensionlspring height
1 45.0 mm (1.772 in)
526.6 - 581.6 N (53.7 - 59.3 kgf, 118.4 - 130.8 Ib)/
34.7 mm (1.366 in)
Surface warpage limit (mating with cylinder head) 0.05 mm (0.0020 in)
Surface arindina limit 0.1 mm (0.004 in)
~

A 99.505 - 99.515 mm (3.9175 - 3.9179 in)

Cylinder bore
B 99.495 - 99.505 mm (3.9171 - 3.9175 in)
STD 0.015 mm (0.0006 in)
Taper
Limit 0.050 mm (0.0020 in)
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
I
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
I
B 99.475 - 99.485 mm (3.9163 - 3.9167 in)
Outer diameter 0.25 mm (0.0098 in)
99.725 - 99.735 mm (3.9262 - 3.9266 in)
os
I os
0.50 mm (0.0197 in)
-~

Standard inner diameter of piston pin hole

I 99.975 - 99.985 mm (3.9360 - 3.9364 in)

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)
ton
Piston pin must be fitted into position with thumb at
Degree of fit
20°C (68°F).

ME(S0HC)-3
 GENERAL DESCRIPTION
MECHANICAL

I Top ring
STD
Limit
I 0.20- 0.35mm (0.0079- 0.0138 in)
1 .O mm (0.039in)
Piston ring gap
I Second
ring
STD
Limit
0.35- 0.50mm (0.0138- 0.0197 in)
1 .O mm (0.039in)
Piston ring I oil ring
STD
Limit I
0.20- 0.70mm (0.0079- 0.0276in)
1.5mm (0.059in)
STD 0.040- 0.080mm (0.0016- 0.0031 in)
Clearance Top ring
between piston Limit 0.15 mm (0.0059in)
STD 0.030- 0.070 mm (0.0012- 0.0028in)
Limit 0.15 mm (0.0059in)
Bend twist per 100 mm (3.94
Limit 0.10 mm (0.0039in)
Connecting in) in lenqth
rod
Side clearance
STD I 0.070- 0.330mm (0.0028- 0.0130 in)
Limit 0.4mm (0.016 in)
STD 0.020- 0.046mm (0.0008- 0.0018in)
Oil clearance
Limit 0.05mm (0.0020in)
STD 1.486- 1.498mm (0.0585- 0.0590in)
0.03 mm (0.0012in)
Connecting 1.504- 1.512mm (0.0592- 0.0595in)
rod bearing
us
Thickness at center portion 0.05 mm (0.0020in)
1.514 - 1.522mm (0.0596- 0.0599in)
us
0.25 mm (0.0098in)
1.614 - 1.622mm (0.0635- 0.0639in)
us
Connecting Clearance between piston pin STD 0 - 0.022mm (0- 0.0009in)
rod bushing and bushing Limit 0.030mm (0.0012in)
Bend limit 0.035mm (0.0014in)
Crank pin and Out-Of -roundness 0.020mm (0.0008in) or less
crank journal Grinding limit 0.250mm (0.0098in)
STD I 51.984- 52.000 mm (2.0466- 2.0472in)

Crank pin outer diameter

0.03mm (0.0012in)
us
~~

0.05 mm (0.0020in)
I 51.954- 51.970mm (2.0454- 2.0461 in)

51.934- 51.950mm (2.0446- 2.0453in)

us
0.25 mm (0.0098in)
51.734- 51.750mm (2.0368- 2.0374in)
us
STD 59.992- 60.008mm (2.3619 - 2.3625in)
0.03mm (0.0012in)
59.962- 59.978mm (2.3607- 2.3613in)
us
Crankshaft
#I, #5,#3 0.05mm (0.0020in)
us
0.25mm (0.0098in)
1 59.942- 59.958mm (2.3599- 2.3605in)

59.742- 59.758mm (2.3520- 2.3527in)

Crank journal us
outer diameter STD 59.992- 60.008mm (2.3619 - 2.3625in)

#2,#4
0.03mm (0.0012in)
us
0.05mm (0.0020in)
I 59.962- 59.978mm (2.3607- 2.3613in)

59.942- 59.958mm (2.3599- 2.3605in)

us
0.25mm (0.0098in)
59.742- 59.758mm (2.3520- 2.3527in)
us
Thrust clearance
STD I 0.030- 0.115 mm (0.0012- 0.0045 in)
Limit 0.25mm (0.0098in)
STD 0.010- 0.030mm (0.0004- 0.0012in)
Oil clearance
Limit 0.040mm (0.0016 in)

ME(S0HC)-4
 GENERAL DESCRIPTION
MECHANICAL

STD 1.998 - 2.01 1 mm (0.0787 - 0.0792 in)

0.03 mm (0.0012 in)
2.01 7 - 2.020 mm (0.0794 - 0.0795 in)
us
# I , #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 - 2.01 3 mm (0.0787 - 0.0793 in)
0.03 mm (0.0012 in)
2.01 9 - 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(S0HC)-5
 GENERAL DESCRIPTION
MECHANICAL

B: COMPONENT
1. TIMING BELT

S2M1786A

Belt cover No. 2 (RH) (9) Automatic belt tension adjuster Tightening torque: N-m (kgf-m, ft-lb)
Timing belt guide (MT vehicles ASSY T1: 5 (0.5, 3.6)
only) (10) Belt idler No. 2 T2: 9.8 (7.0, 7.2)
Crankshaft sprocket (11) Camshaft sprocket No. 2 T3: 25 (2.5, 18.1)
Belt cover No. 2 (LH) (12) Timing belt T4: 39 (4.0, 28.9)
Camshaft sprocket No. 1 (13) Front belt cover T5: 78 (8.0, 57.9)
Belt idler (No. 1) (14) Belt cover (LH) T6: <Ref. to ME(S0HC)-45,
Tensioner bracket (15) Crankshaft pulley INSTALLATION, Crankshaft
Pulley.>
Belt idler (No. 2)

ME(SOHC)-6
 GENERAL DESCRIPTION
MECHANICAL

2. CYLINDER HEAD AND CAMSHAFT

I I

Rocker cover (RH) Cylinder head (LH) Tightening torque: N.m (kgf-m, ft-lb)
Intake valve rocker ASSY Camshaft (LH) T1: <Ref. to ME(SOHC)81,
Camshaft cap (LH) INSTALLATION, Cylinder Head
Exhaust valve rocker ASSY
Assembly.>
Camshaft cap (RH) Oil filler cap
Oil seal Gasket T2: 5 (0.5, 3.6)
Camshaft (RH) Oil filler pipe T3: 10 (1.0, 7.2)
Plug O-ring T4: 18 (1.8, 13.0)
Spark plug pipe gasket Rocker cover (LH) T5: 25 (2.5, 18.1)
Cylinder head (RH) Stud bolt T6: 6.4 (0.65, 4.7)
Cylinder head gasket

ME(SOHC)-7
 GENERAL DESCRIPTION
MECHANICAL

3. VALVE ROCKER ASSEMBLY

’ ‘\
/
/

Ea B2M1956A

(1) Intake valve rocker arm (6) Intake rocker shaft Tightening torque: N-m (kgf-m, ff-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: lO(1.0, 7.2)
(4) Spring T3: 25 (2.5, 18.1)
(5) Rocker shaft support

ME(SOHC)-8
 GENERAL DESCRIPTION
MECHANICAL

4. CYLINDER HEAD AND VALVE ASSEM-

BLY

A
- -

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 (1 1) Exhaust valve oil seal
(4) Intake valve spring seat (8) Retainer key

ME(S0HC)-9
 GENERAL DESCRIPTION
MECHANICAL

5. CYLINDER BLOCK

Oil pressure switch Baffle plate Tightening torque: N.m (kgf-m, ft-lb)
Cylinder block (RH) Oil filter connector T1: 5 (0.5, 3.6)
Service hole plug Oil strainer T2: 6.4 (0.65, 4.7)
Gasket Gasket T3: lO(1.0, 7)
Oil separator cover Oil pan T4: 25 (2.5, 18.1)
Water by-pass pipe Drain plug T5: 47 (4.8, 34.7)
Oil pump Metal gasket T6: 69 (7.0, 50.6)
Front oil seal Oil level gauge guide T7: First 12 (1.2, 8.7)
Rear oil seal Water pump sealing Second 12 (1.2, 8.7)
(10) O-ring (23) Oil filter T8: 16 (1.6, 11.6)
(11) Service hole cover (24) Gasket T9: 44 (4.5, 33)
(12) Cylinder block (LH) (25) Water DumD hose T10: 25f2.5. 18.1)
(13) Water pump

ME(S0HC)-10
GENERAL DESCRIPTION
MECHANICAL

ME(S0HC)-I 1
 im
GENERAL DESCRIPTION
MECHANICAL

6. CRANKSHAFT AND PISTON

B2M3429A

ME(S0HC)-12
 GENERAL DESCRIPTION
a
MECHANICAL

Flywheel (MT) Circlip (17) Crankshaft bearing #2, #4

Reinforcement (AT) Connecting rod bolt (18) Crankshaft bearing #5
Drive plate (AT) Connecting rod
Top ring Connecting rod bearing Tightening torque: N.m (kgf-m, ft-lb)
Second ring Connecting rod cap T1: 44.6 (4.55,32.9)
Oil ring Crankshaft T2: 72 (7.3,52.8)
Piston Woodruff key
Piston pin Crankshaft bearing # I , #3

ME(S0HC)-13
 GENERAL DESCRIPTION
MECHANICAL
7. ENGINE MOUNTING
9, I
(1) Front cushion rubber (2) Front engine mounting bracket
C: CAUTION
Wear working clothing, including a cap, protec-
tive goggles, and protective shoes during opera-
tion.
Remove contamination including dirt and corro-
sion before removal, installation or disassembly.
Keep the disassembled parts in order and pro-
tect them from dust or dirt.
Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary re-
moval, installation, disassembly, and replacement.
Be careful not to burn your hands, because each
part in the vehicle is hot after running.
Be sure to tighten fasteners including bolts and
nuts to the specified torque.
Place shop jacks or safety stands at the specified
points.
Before disconnecting electrical connectors of
sensors or units, be sure to disconnect the negative
terminal from battery.
All parts should be thoroughly cleaned, paying
special attention to the engine oil passages, pis-
ME(S0HC)-14
EN1005
Tightening torque: N.m (kgf-m, ft-lb)
T I : 35 (3.6, 25.8)
T2: 42 (4.3, 31.0)
T3: 85 (8.7, 63)
tons and bearings.
Rotating parts and sliding parts such as piston,
bearing and gear should be coated with oil prior to
assembly.
Be careful not to let oil, grease or coolant contact
the timing belt, clutch disc and flywheel.
All removed parts, if to be reused, should be re-
installed in the original positions and directions.
Bolts, nuts and washers should be replaced with
new ones as required.
Even if necessary inspections have been made
in advance, proceed with assembly work while
making rechecks.
Remove or install the engine in an area where
chain hoists, lifting devices, etc. are available for
ready use.
Be sure not to damage coated surfaces of body
panels with tools or stain seats and windows with
coolant or oil. Place a cover over fenders, as re-
quired, for protection.
 GENERAL DESCRIPTION
MECHANICAL

Prior to starting work, prepare the following: Lift-up or lower the vehicle when necessary.
Service tools, clean cloth, containers to catch cool- Make sure to support the correct positions.
ant and oil, wire ropes, chain hoist, transmission
jacks, etc.

D: PREPARATION TOOL
1. SPECIAL TOOLS
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
498267800 ZYLINDER Used for replacing valve guides.
i E A D TABLE 1 Used for removing and installing valve springs.

498457000 ENGINE STAND Used with ENGINE STAND (499817000).

ADAPTER RH

t------ B2M3051
498457100 ENGINE STAND
ADAPTER LH
Used with ENGINE STAND (499817000).

498497100 CRANKSHAFT Used for stopping rotation of flywheel when loos-

STOPPER ening and tightening crankshaft pulley bolt, etc.

I B2M3053

ME(S0HC)-15
 GENERAL DESCRIPTION
MECHANICAL

m ILLUSTRATION TOOL NUMBER

498747300
DESCRIPTION
PISTON GUIDE
REMARKS
Used for installing piston in cylinder for 2500 cc
engine.

498857100 VALVE OIL SEAL Used for press-fitting of intake and exhaust valve
GUIDE guide oil seals.

499017100 PISTON PIN Used for installing piston pin, piston and connect-
GUIDE ing rod.

499037100 CONNECTING Used for removing and installing connecting rod

ROD BUSHING bushing.
REMOVER &
INSTALLER

ME(S0HC)-I 6
 GENERAL DESCRIPTION
MECHANICAL

TOOL NUMBER DESCRIPTION REMARKS

499097700 'ISTON PIN Jsed for removing piston pin.
3EMOVER
9SSY

B2M3858
~

499207100 :AM S HAFT Jsed for removing and installing camshaft

3 PROCKET sprocket. (LH side)
URENCH

~~

499207400 CAMSHAFT Used for removing and installing camshaft

SPROCKET sprocket. (RH side)
WRENCH

499587700 CAMSHAFT OIL Used for installing cylinder head plug.

SEAL
INSTALLER

I B2M3860

ME(S0HC)-17
 GENERAL DESCRIPTION
MECHANICAL

ILLUSTRATION TOOL NUMBER DESCRlPTlON REMARKS

499587200 CRANKSHAFT Used for installing crankshaft oil seal.
OIL SEAL Used with CRANKSHAFT OIL SEAL GUIDE
INSTALLER (499597100).

B2M3861
499597000 OIL SEAL GUIDE Used for installing camshaft oil seal.
Used with CAMSHAFT OIL SEAL INSTALLER
(499587100).

B2M3862
499597100 CRANKSHAFT Used for installing crankshaft oil seal.
OIL SEAL GUIDE Used with CRANKSHAFT OIL SEAL
INSTALLER (499587200).

82M3863
499718000 VALVE SPRING Used for removing and installing valve spring.
REMOVER

82M3864

ME(S0HC)-18
 GENERAL DESCRIPTION
MECHANICAL

I ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

499767700 VALVE GUIDE Used for installing valve guides.
(Intake side) ADJUSTER
499767800
(Exhaust side)

499767200 VALVE GUIDE Jsed for removing valve guides.

3 EMOVER

I 02M3067
499767400 4ALVE GUIDE Jsed for reaming valve guides.
3EAMER

m B2M3068
499817100 INGINE STAND I Stand used for engine disassembly and assem-
,ly.
1 Used with ENGINE STAND ADAPTER RH
498457000) & LH (498457100).

I 82M3869

ME(S0HC)-19
 GENERAL DESCRIPTION
MECHANICAL

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

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
499497000 rORX PLUS Jsed for removing and installing camshaft cap.

82M3873

ME(SOHC)-2O
 GENERAL DESCRIPTION
MECHANICAL

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

499587500 31L SEAL Jsed for installing front camshaft oil seal.
NSTALLER

B2M3874
499587100 31L SEAL Jsed for installing oil pump oil seal.
INSTALLER

B2M3875
498277200 STOPPER SET Used for installing automatic transmission assem-
bly to engine.

B2M2043
24082AA150 CARTRIDGE Troubleshootingfor electrical systems.
(Newly adopted
tool)

B2M3876

ME(S0HC)-21
 GENERAL DESCRIPTION
MECHANICAL

ILLUSTRATION I TOOL NUMBER DESCRIPTION REMARKS

I 22771AA030 SELECT MONI- Troubleshootingfor electrical systems.
TOR KIT English: 22771AA030 (Without printer)
German: 22771AA070 (Without printer)
French: 22771AA080 (Without printer)
Spanish: 22771AA090 (Without printer)

2. GENERAL PURPOSE TOOLS

TOOL NAME REMARKS

Compression Gauge Used for measuring compression.
Tachometer (Secondarv pick-up tvpe) Used for measuring idle speed.
Timing Light I Used for measuring ignition timing.

E: PROCEDURE
It is possible to conduct the following service proce-
dures with engine on the vehicle, however, the pro-
cedures described in this section are based on the
condition that the engine is removed from the vehi-
cle.
V-belt
Timing Belt
Valve Rocker Assembly
Camshaft
Cylinder Head

ME(S0HC)-22
 COMPRESSION
MECHANICAL

2. Compression
A: INSPECTION
CAUTION:
After warming-up, engine becomes very hot. Be
careful not to burn yourself during measure-
ment.
1) After warming-up the engine, turn the ignition
switch to OFF.
2) Make sure that the battery is fully charged.
3) Release fuel pressure. <Ref. to FU(S0HC)-50,
RELEASING OF FUEL PRESSURE, OPERA-
TION, Fuel.>
4) Remove all the spark plugs. <Ref. to IG(S0HC)-
4, REMOVAL, Spark Plug.>
5) Fully open the 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.

9) Perform at least two measurements per cylinder,

and make sure that the values are correct.
Compression (350 rpm and fully open throttle):
Standard;
1,275 kPa (13.0 kgf/cd, 185 psi)
Limit;
1,020 kPa (10.4 kgf/cn?, 148psi)
Difference between cylinders;
49 kPa (0.5 kgf/cd, 7psi), or less

ME(S0HC)-23
 IDLE SPEED
3. Idle Speed
A: INSPECTION
1) Before checking the idle speed, check the follow-
ing:
(1) Ensure the 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 the malfunction indicator light
(CHECK ENGINE light) does not illuminate.
2) Warm-up the engine.
3) Stop the engine, and turn the ignition switch to
OFF.
4) When using the SUBARU SELECT MONITOR:
<Ref. to ME(S0HC)-15, SPECIAL TOOLS, PREP-
ARATION TOOL, General Description.>
(1) Insert the cartridge to the SUBARU SE-
LECT MONITOR.
(2) Connect the SUBARU SELECT MONITOR
to the data link connector.
(3) Turn the ignition switch to ON, and SUBA-
RU SELECT MONITOR switch to ON.
(4) Select (2. Each System Check} in Main
Menu.
(5) Select {Engine Control System} in Selection
Menu.
(6) Select (1. Current Data Display & Save} in
Engine Control System Diagnosis.
(7) Select {I . I 2 Data Display} in Data Display
Menu.
(8) Start the engine, and read engine idle
speed.
ME(S0HC)-24
5 ) When using the tachometer (Secondary pick-up
type):
(1) Attach the pick-up clip to No. 1 cylinder
spark plug cord.
(2) Start the engine, and read engine idle
speed.
NOTE:
When using the general scan tool, carefully read
its operation manual.
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 en-
gine speed.
6) Check the idle speed when unloaded. (With
headlights, heater fan, rear defroster, radiator fan,
air conditioning, etc. OFF)
Idle speed (No load and gears in neutral (MT), or
N or P (AT) position):
MT vehicle: 6502100 rpm
AT vehicle: 700f100rpm
7) Check the idle speed when loaded. (Turn the air
conditioning switch to “ON” and operate the com-
pressor for at least one minute before measure-
ment.)
Idle speed [A/C“ON”, no load and gears in neu-
tral (MT) or N or P (AT) position]:
8502100 rpm
CAUTION:
Never rotate the idle adjusting screw. If the idle
speed is out of specifications, refer to General
On-board Diagnosis Table under “Engine Con-
trol System”. <Ref. to EN(S0HC)-2, Basic Diag-
nostic Procedure.>
 IGNITION TIMING
MECHANICAL

4. Ignition Timing
A: INSPECTION
CAUTION:
After warming-up, engine becomesvery hot. Be
careful not to burn yourself during measure-
ment.
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 ig-
nition timing.
Ignition timing [BTDC/rpm]:
MT vehicle: 1Oof8O/650
AT vehicle: 1 5°f80R00

If the timing is not correct, check the ignition control

system.
Refer to Engine Control System. <Ref. to EN(S0-
HC)-2, Basic Diagnostic Procedure.>

ME(S0HC)-25
 INTAKE MANIFOLD VACUUM
MECHANICAL

5. Intake Manifold Vacuum 3) Keep the engine at the idle speed and read the
vacuum gauge indication.
A: INSPECTION By observing the gauge needle movement, the in-
1) Warm-up the engine. ternal condition of the engine can be diagnosed as
2) Disconn.ect the brake vacuum hose and install described below.
the vacuum gauge to the hose fitting on the mani-
fold.

Vacuum pressure (at idling, A/C c 6 0 F F ) :

Less than -60.0 kPa (-450 mmHg, -17.72 in-
Hg)
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
dencv 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(S0HC)-26
 ENGINE OIL PRESSURE
6. Engine Oil Pressure
A: INSPECTION
1) Disconnect the ground terminal from battery.
2) Remove the generator from bracket.
(1) Loosen the lock bolt and slider bolt, and re-
move the front side V-belt. <Ref. to ME(S0HC)-
43, REMOVAL, V-belt.>
(2) Remove the generator lock bolt.
(3) Remove the bolt which installs the generator
on bracket.
3) Disconnect the connector from oil pressure
switch.
4) Remove the oil pressure switch from engine cyl-
inder block. <Ref. to LU-22, REMOVAL, Oil Pres-
sure Switch.>
5) Connect the oil pressure gauge hose to cylinder
block.
6) Connect the battery ground terminal to battery.
ME(S0HC)-27
MECHANICAL
7) Start the engine, and measure oil pressure.
Oil pressure:
98 kPa (1.0 kgf/cd, 14 psi) or more at 800
rPm
294 kPa (3.0 kgflcd, 43 psi) or more at 5,000
rpm
CAUTION:
If the oil pressure is out of specification,
check oil pump, oil filter and lubrication line.
<Ref. to LU-28, INSPECTION, Engine Lubrica-
tion System Trouble in General.>
If the oil pressure warning light is turned ON
and oil pressure is in specification, replace the
oil pressure switch. <Ref. to LU-28, INSPEC-
TION, Engine Lubrication System Trouble in
General.>
NOTE:
The specified data is based on an engine oil tem-
perature of 80°C (176°F).
8) After measuring the oil pressure, install the oil
pressure switch. <Ref. to LU-23, INSTALLATION,
Oil Pressure Switch.>
Tightening torque:
25 N.m (2.5 kgf-m, 18.1 ff-lb)
9) Install the generator and V-belt in the reverse or-
der of removal, and adjust the V-belt deflection.
<Ref. to ME(S0HC)-43, INSTALLATION, V-belt.>
 FUEL PRESSURE
MECHANICAL

7. Fuel Pressure 6) Measure fuel pressure while disconnecting the

pressure regulator vacuum hose from intake man-
A: INSPECTION ifold.
WARNING: Fuel pressure:
Before removing the fuel pressure gauge, re- Standard; 284 - 314 kPa (2.9 - 3.2 kgf/cn?,
lease the fuel pressure. 41 - 46 psi)
NOTE:
If out of specification, check or replace the pressure
regulator and pressure regulator vacuum hose.
1) Release the fuel pressure. <Ref. to FU(S0HC)-
50, RELEASING OF FUEL PRESSURE, OPERA-
TION, Fuel.>
2) Open the fuel flap lid, and remove the fuel filler
cap.

7) After connecting the pressure regulator vacuum

hose, measure fuel pressure.
Fuel pressure:
Standard; 206 - 235 kPa (2.1 -2.4 kgvcn?,
30 - 34 psi)

3) Disconnect the fuel delivery hoses from fuel fil-

ter, and connect the fuel pressure gauge.

NOTE:
The fuel pressure gauge registers 10 to 20 kPa (0.1
to 0.2 kgf/cm2, 1 to 3 psi) higher than standard Val-
ues during high-altitude operations.
~

4) Connect the connector of fuel pump relay.

5) Start the engine.

ME(S0HC)-28
 VALVE CLEARANCE
8. Valve Clearance
A: INSPECTION
CAUTION:
Inspection and adjustment of valve clearance
should be performed while engine is cold.
1) Set the vehicle onto the lift.
2) Lift-up the vehicle.
3) Remove the under cover.
4) Disconnect the ground terminal from battery.
8) When inspecting #2 and #4 cylinders:
5 ) Lower the vehicle.
6) Remove the timing belt cover (LH).
7) When inspecting #1 and #3 cylinders:
(1) Remove the air intake duct as a unit.
ME(S0HC)-29
MECHANICAL
(2) Rmove the resonator chamber.
(3) Disconnect the spark plug cords from spark
plugs RH side. <Ref. to IG(S0HC)-4, RH SIDE,
REMOVAL, Spark Plug.>
(4) Disconnect the PCV hose from rocker cover
(RH).
(5) Remove the bolts, then remove the rocker
cover ( RH).
(1) Remove the battery and battery carrier.
(2) Disconnect the window washer motor con-
nectors.
(3) Remove the two bolts which hold washer
tank, then secure the tank away from working
area.
(4) Disconnect the spark plug cords from spark
plugs (LH Side) <Ref. to IG(S0HC)-4, LH SIDE,
REMOVAL, Spark Plug.>
(5) Disconnect the PCV hose from rocker cover
(LH).
(6) Remove the bolts, then remove the rocker
cover (LH).
 VALVE CLEARANCE

9) Set #1 cylinder piston to top dead center of com- 12) Similar to measurement procedures used for
pression stroke by rotating the crankshaft pulley #1 cylinder, measure #2, #3 and #4 cylinder valve
clockwise using ST. clearances.
ST 499977100 CRANKSHAFT PULLEY NOTE:
WRENCH Be sure to set the cylinder pistons to their re-
NOTE: spective top dead centers on compression stroke
When the arrow mark (A) on camshaft sprocket before measuring valve clearances.
(LH) comes exactly to the top, #1 cylinder piston is To set #3, #2 and #4 cylinder pistons to their top
brought to the top dead center of compression dead centers on compression stroke, turn the
stroke. crankshaft pulley clockwise 90" at a time starting
with arrow mark on left-hand camshaft sprocket
facing up.

#4
#3

B2M2027B

10) Measure #1 cylinder valve clearance by using B2M2029E

thickness gauge (A).
13) After inspection, install the related parts in the
CAUTION: reverse order of removal.
Insert the thickness gauge in as horizontal a
direction as possible with respect to the valve Tightening torque:
stem end face. Resonator chamber;
Measure the exhaust valve clearances while 33 N-m (3.4kgf-m, 24 ff-lb)
lifting-up the vehicle.
Valve clearance:
Intake;
0.20M.02 mm (0.0079M.0008in)
Exhaust;
0.25-20.02 mm (0.0098M.0008in)

11) If necessary, adjust the valve clearance. <Ref.

to ME(S0HC)-31, ADJUSTMENT, Valve Clear-
ance.>

ME(S0HC)-30
 VALVE CLEARANCE
MECHANICAL

B: ADJUSTMENT 2) Adjust the #1 cylinder valve clearance.

(1) Loosen the valve rocker nut and screw.
CAUTION: (2) Place suitable thickness gauge.
Adjustment of valve clearance should be per-
(3) While noting the valve clearance, tighten the
formed while engine is cold.
valve rocker adjust screw.
1) Set #1 cylinder piston to top dead center of com- (4) When the specified valve clearance is ob-
pression stroke by rotating the crankshaft pulley tained, tighten the valve rocker nut.
clockwise using ST.
ST 499977100 CRANKSHAFT PULLEY Tightening torque:
WRENCH 10 N.m (1.0 kgf-m, 7.2 ff-lb)
NOTE: CAUTION:
When the arrow mark (A) on camshaft sprocket Insert the thickness gauge in as horizontal a
(LH) comes exactly to the top, #1 cylinder piston is direction as possible with respect to the valve
brought to the top dead center of compression stem end face.
stroke. Adjust the exhaust valve clearances while
lifting-up the vehicle.
Valve clearance:
Intake;
0.20M.02mm (0.0079-M.0008in)
Exhaust;
0.25M.02mm (0.0098_+.0008 in)

B2M20276

3) Ensure the valve clearances are within specifica-

tions.
4) Turn the crankshaft two complete rotations until
#1 cylinder piston is again set to top dead center on
compression stroke.
5 ) Ensure the valve clearances are within specifica-
tions. If necessary, readjust the valve clearances.

ME(S0 HC)-31
 VALVE CLEARANCE
MECHANICAL

6) Similar to adjustment procedures used for #1

cylinder, adjust #2, #3 and #4 cylinder valve clear-
ances.
NOTE:
Be sure to set the cylinder pistons to their re-
spective top dead centers on compression stroke
before adjusting valve clearances.
To set #3, #2 and #4 cylinder pistons to their top
dead centers on compression stroke, turn the
crankshaft pulley clockwise 90" at a time starting
with arrow mark on left-hand camshaft sprocket
facing up.

#3

02M20290

ME(S0HC)-32
 ENGINE ASSEMBLY
MECHANICAL

9. Engine Assembly 11) Remove the air cleaner case stay.

MTmodel
A: REMOVAL
1) Set the vehicle on lift arms.
2) Open the front hood fully and support with stay.
3) Release the fuel pressure. <Ref. to FU(S0HC)-
50, RELEASING OF FUEL PRESSURE, OPERA-
TION, Fuel.>
4) Remove the filler cap.
5) Disconnect the battery ground terminal.

ATmodel

6) Remove the air intake duct and air cleaner case.

<Ref. to IN(S0HC)-7, REMOVAL, Air Intake Duct.>
and <Ref. to IN(S0HC)-6, REMOVAL, Air Cleaner
Case.>
7) Remove the under cover. 12) Disconnect the following connectors and ca-
8) Remove the radiator from vehicle. <Ref. to CO- bles.
37, REMOVAL, Radiator.> (1) Front oxygen (NF) sensor connector
9) Remove ATF cooler pipe from cylinder head.
<Ref. to AT-47, REMOVAL, ATF Cooler Pipe and
Hose.>
10) Collect refrigerant, and remove the pressure
hoses. (With A/C)
(1) Place and connect the attachment hose to
the refrigerant recycle system.
(2) Collect the refrigerant from A/C system.
(3) Disconnect the A/C pressure hoses from
A/C compressor.

(2) Engine ground terminal

ME(SO HC)-33
 ENGINE ASSEMBLY
MECHANICAL

(3) Engine harness connectors (6) Pressure switch

13) Disconnect the following hoses.

(1) Brake booster vacuum hose

(4) Generator connector, terminal and A/C

compressor connector
(2) Heater inlet outlet hose

(A) Generator connector and terminal

(B) A/C compressor connector

(5) Accelerator cable and cruise control cable

(A) Accelerator cable

(B) Cruise control cable

ME(S0HC)-34
 ENGINE ASSEMBLY
MECHANICAL

14) Remove the power steering pump from brack- (6) Place the power steering pump on the right
et. side wheel apron.
(1) Remove the resonator chamber.
(2) Loosen the lock bolt and slider bolt, and re-
move the front side V-belt.<Ref. to ME(S0HC)-
43, FRONT SIDE BELT, REMOVAL, V-belt.>
(3) Remove the pipe with bracket.

15) Remove the front and center exhaust pipe.

<Ref. to EX(S0HC)-5, REMOVAL, Front Exhaust
Pipe.>
16) Remove the nuts which hold lower side of
transmission to engine.
(4) Remove the bolts which install the power
steering pump bracket.

17) Remove the nuts which install the front cushion

rubber onto front crossmember.
(5) Remove the power steering tank from the
bracket by pulling it upward.

ME(S0HC)-35
 ENGINE ASSEMBLY
MECHANICAL

18) Separate the torque converter clutch from drive 21) Support the engine with a lifting device and wire
plate. (AT model) ropes.
(1) Lower the vehicle.
(2) Remove the service hole plug.
(3) Remove the bolts which hold torque con-
verter clutch to drive plate.
(4) Remove the other bolts while rotating the
engine using ST.
ST 499977100 CRANK PULLEY WRENCH

22) Support the transmission with a garage jack.

CAUTION:
Before moving the engine away from transmis-
sion, check to be sure no work has been over-
looked. Doing this is very important in order t o
facilitate re-installation and because transmis-
sion lowers under its own weight.
19) Remove the pitching stopper.

S2M 1928
H3M1839
23) Separation of engine and transmission.
20) Disconnect the fuel delivery hose, return hose (1) Remove the starter. <Ref. to SC-6, RE-
and evaporation hose. MOVAL, Starter.>
CAUTION: (2) Remove the bolts which hold upper side of
Disconnect the hose with its end wrapped transmission to engine.
with cloth t o prevent fuel from splashing.
Catch fuel from hose into container.

I)O

ME(S0HC)-36
 ENGINE ASSEMBLY
MECHANICAL

24) Install the ST to torque converter clutch case. B: INSTALLATION

(AT model) 1) Install the front cushion rubbers.
ST 498277200 STOPPER SET
Tightening torque:
34 N-m (3.5 kgf-m, 25.3 ft-16)
2) Install the engine onto transmission.
(1) Position the 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.

25) Remove the engine from vehicle.

(1) Slightly raise the engine.
(2) Raise the transmission with garage jack.
(3) Move the engine horizontally until main
shaft is withdrawn from clutch cover.
(4) Slowly move the engine away from engine
compartment.
CAUTION:
Be careful not to damage adjacent parts or
body panels with crank pulley, oil level gauge, (2) Apply a small amount of grease to spline of
etc. main shaft. (MT model)
3) Tighten the bolts which hold upper side of trans-
mission to engine.
Tightening torque:
50 N.m (5.7 kgf-m, 36.9 ft-16)

26) Remove the front cushion rubbers.

I 83M2044

4) Remove the lifting device and wire ropes.

5 ) Remove the garage jack.

ME(S0HC)-37
 ENGINE ASSEMBLY
MECHANICAL
6) Install the pitching stopper. 10) Install the power steering pump on bracket.
Tightening torque: (1) Install the power steering tank on bracket.
T I : 50 N-m (5.1kgf-m, 36.9 ft-16)
T2: 58 N-m (5.9kgf-m, 42.8 ft-16)

(2) Install the power steering pump on bracket,

and tighten the bolts.
7) Remove the ST from torque converter clutch Tightening torque:
case. (AT model) 20.1 N-m (2.05kgf-m, 14.8 f?-16)
NOTE:
Be careful not to drop the ST into the torque con-
verter clutch case when removing ST.
ST 498277200 STOPPER SET
8) Install the starter. <Ref. to SC-7, INSTALLA-
TION, Starter.>
9) Install the torque converter clutch onto drive
plate. (AT model)
(1) Tighten the bolts which hold torque convert-
er clutch to drive plate.
(2) Tighten other bolts while rotating the engine
by using ST. (3) Tighten the bolt which installs the power
steering pump bracket, and install the spark plug
CAUTION:
codes.
Be careful not to drop bolts into the torque con-
verter clutch housing.
ST 499977100 CRANK PULLEY WRENCH
Tightening torque:
25 N-m (2.5kgf-m, 18.I ft-16)

(4) Connect the power steering switch connec-

tor.

(3) Clog the service hole with plug.

ME(S0HC)-38
 ENGINE ASSEMBLY
(5) Install the front side V-belt, and adjust it.
<Ref. to ME(S0HC)-43, FRONT SIDE BELT,
INSTALLATION, V-belt .>
(6) Install the resonator chamber.
Tightening torque:
33 N-m (3.4 kgf-m, 24.6 ft-lb)
11) Tighten the nuts which hold lower side of trans-
mission to engine.
Tightening torque:
50 N-m (5.1 kgf-m, 36.9 ft-lb)
12) Tighten the nuts which install the front cushion
rubber onto crossmember.
Tightening torque:
85 N-m (8.7 kgf-m, 63 ft-lb)
CAUTION:
Make sure the front cushion rubber mounting
bolts (A) and locator (B) are securely installed.
I B2M3880A
ME(S0HC)-39
MECHANICAL
13) Install the front and center exhaust pipe.
<Ref. to EX(S0HC)-6, INSTALLATION, Front Ex-
haust Pipe.>
14) Connect the following hoses:
(1) Fuel delivery hose, return hose and evapo-
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) Generator connector and terminal
(4) A/C compressor connectors
(5) Power steering pressure switch
16) Connect the following cables:
(1) Accelerator cable
(2) Cruise control cables (With cruise control)
CAUTION:
After connecting each cable, adjust them.
17) Install the air cleaner case stay.
Tightening torque:
16 N.m (1.6 kgf-m, 11.6 ft-lb)
18) Install the A/C pressure hoses.
<Ref. to AC-30, INSTALLATION, Hose and Tube.>
CAUTION:
Use new O-rings.
Tightening torque:
25 N.m (2.5 kgf-m, 18.I ft-lb)
19) Install the radiator to vehicle. <Ref. to CO-41,
INSTALLAT10N, Radiator.>
20) Install the ATF cooler pipe. <Ref. to AT-49, IN-
STALLATION, ATF Cooler Pipe and Hose.>.
21) Install the under cover.
22) Install the battery in the vehicle, and connect
cables.
 ENGINE ASSEMBLY
MECHANICAL

23) Fill coolant. C: INSPECTION

<Ref. to CO-25, FILLING OF ENGINE COOLANT, 1) Make sure pipes and hoses are installed correct-
REPLACEMENT, Engine Coolant.> lY-
24) Check the ATF level and correct if necessary. 2) Make sure the engine coolant and ATF are at
(AT model) specified levels.
<Ref. to AT-9, INSPECTION, Automatic Transmis-
sion Fluid.>
25) Charge the A/C system with refrigerant.
<Ref. to AC-17, OPERATION, Refrigerant Charg-
ing Procedure.>
26) Install the air intake duct and air cleaner case.
<Ref. to IN(S0HC)-7, INSTALLATION, Air Intake
Duct.> and <Ref. to IN(S0HC)-6, INSTALLATION,
Air Cleaner Case.>
27) Remove the front hood stay, and close the front
hood.
28) Take off the vehicle from lift arms.

ME(S0HC)-40
 ENGINE MOUNTING
MECHANICAL

10.Engine Mounting
A: REMOVAL
1) Remove the engine assembly. <Ref. to ME(S0-
HC)-33, REMOVAL, Engine Assembly.>
2) Remove the engine mounting from engine as-
sembly.
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
Engine mounting;
35 N.m (3.6 kgf-m, 25.8 ff-lb)
C: INSPECTION
Make sure there are no cracks or other damage.

ME(S0HC)-41
 PREPARATION FOR OVERHAUL
MECHANICAL

11.Preparation for Overhaul

A: PROCEDURE
1) After removing the engine from the body, secure
it in the ST shown below.
ST1 498457000 ENGINE STAND ADAPTER
RH
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(S0HC)-42
 V-BELT
MECHANICAL

4) Remove the A/C belt tensioner.

12.V-belt
A: REMOVAL
1. FRONT SIDE BELT
NOTE:
Perform the following procedures 1) to 4) with the
engine installed to the body.
1) Remove the V-belt cover.

2) Loosen the lock bolt (A).
3) Loosen the slider bolt (B).
4) Remove the front side belt (C).
B: INSTALLATION
1. FRONT SIDE BELT
CAUTION:
Wipe off any oil or water on the belt and pulley.
1) Install a belt, and tighten the slider bolt so as to
obtain the.specified belt tension <Ref. to ME(S0-
HC)-44, INSPECTION, V-belt.>
2) Tighten the lock bolt (A)
3) Tighten the slider bolt (B).
Tightening torque:
Lock bolt through bolt:
25 N*m (2.5 kgf-m, 18 ft-lb)
Slider bolt:
8 N.m (0.8 kgf-m, 5.5 ft-lb)

2. REAR SIDE BELT

1) Loosen the lock nut (A).
2) Loosen the slider bolt (B).

3) Remove the A/C belt.

ME(S0HC)-43
 V-BELT
MECHANICAL

2. REAR SIDE BELT C: INSPECTION

1) Install a belt, and tighten the slider bolt (B) so as
to obtain the specified belt tension. <Ref. to
ME(S0HC)-44, INSPECTION, V-belt.>
2) Tighten the lock nut (A).
Tightening torque:
Lock nut (A);
22.6 N.m (2.3 kgf-m, 16.6 ff-lb)
1) Replace the belts, if cracks, fraying or wear is
found.
2) Check the drive belt tension and adjust it if nec-
essary by changing generator installing position
and/or idler pulley installing position.
Belt tension
(A)
replaced: 7 - 9 mm (0.276 - 0.354 in)
reused: 9 - 11 mm (0.354 - 0.433 in)
(B)*
replaced: 7.5 - 8.5 mm (0.295 - 0.335 in)
reused: 9.0 - 10.0 mm (0.354 - 0.394 in)
*: With Air conditioner
98 N (10 kg, 22 Ib)
-

C/P Crankshaft pulley

GEN Generator
P/S Power steering oil pump pulley
A/C Air conditioning compressor pulley
I/P Idler pulley

ME(S0HC)-44
 CRANKSHAFT PULLEY ma
MECHANICAL

13.Crankshaft Pulley 3) Confirm that the tightening angle of the crank-

shaft pulley bolt is 65 degrees or more. If not, con-
A: REMOVAL duct the following procedures (1) through (4):
1) Remove the V-belt. <Ref. to ME(S0HC)-43, RE- (1) Replace the crankshaft pulley bolts and
MOVAL, V-belt.> clean them.
2) Remove the crankshaft pulley bolt. To lock Crankshaft pulley bolt:
crankshaft, use ST. 12369AA011
ST 499977100
( 2 ) Clean the crankshaft thread using an air
CRANKSHAFT PULLEY WRENCH
gun.
(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 keeping
them in an angle between 45 degrees and 60
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 the A/C belt tensioner.
3) Remove the crankshaft pulley.
B: INSTALLATION
1) Install the crankshaft pulley.
2) Install the pulley bolt.
To lock the crankshaft, use ST.
ST 499977100 CRANKSHAFT PULLEY
WRENCH
(1) Clean the crankshaft pulley thread using an
air gun.
(2) Apply engine oil to the crankshaft pulley bolt
seat and thread.
(3) Tighten the bolts temporarily with tightening 5) Install the A/C belt.
torque of 44 N-m (4.5 kgf-m, 33 ft-lb).
(4) Tighten the crankshaft pulley bolts.
Tightening torque:
177 N.m (18 kgf-m, 130.2 ff-lb)

C: INSPECTION
1) Make sure the V-belt is not worn or otherwise
damaged.
2) Check the tension of the belt. <Ref. to ME(S0-
- I

HC)-44, INSPECTION, V-belt.>

ME(SOHC)-45
 BELT COVER
MECHANICAL

14.Belt Cover
A: REMOVAL
1) Remove the V-belt. <Ref. to ME(S0HC)-43, RE-
MOVAL, V-belt.>
2) Remove the crankshaft pulley. <Ref. to ME(S0-
HC)-45, REMOVAL, Crankshaft Pulley.>
3) Remove the belt cover (LH).
4) Remove the front belt cover.

B: INSTALLATION
1) Install the front belt cover.
Tightening torque:
5 Nom(0.5 kgf-m, 3.6 ft-lb)
2) Install the belt cover (LH).
Tightening torque:
5 N-m (0.5 kgf-m, 3.6 ft-lb)

3) Install the crankshaft pulley. <Ref. to ME(S0-

HC)-45, I NSTALLATION, Crankshaft PuIley.>
4) Install the V-belt. <Ref. to ME(S0HC)-43, IN-
STALLATION, V-belt.>
C: INSPECTION
Make sure the cover is not damaged.

ME(S0 HC)-46
 TIMING BELT ASSEMBLY
MECHANICAL

15.Timing Belt Assembly

A: REMOVAL
1. TIMING BELT
1) Remove the V-belt. <Ref. to ME(S0HC)-43, RE-
MOVAL, V-belt.>
2) Remove the crankshaft pulley. <Ref. to ME(S0-
HC)-45, REMOVAL, Crankshaft Pulley.>
3) Remove the belt cover. <Ref. to ME(S0HC)-46,
REMOVAL, Belt Cover.>
4) Remove the timing belt guide. (MT vehicle only)

(2) Using white paint, put alignment and/or ar-

5 ) If the alignment mark (a) and/or arrow mark row marks on the timing belts in relation to the
(which indicates rotation direction) on timing belt crank sprocket and cam sprockets.
fade away, put new marks before removing the tim-
ing belt as shown in procedures below:
(1) Turn the crankshaft using ST. Align mark (a)
of sprocket to cylinder block notch (b) and en-
sure that right side cam sprocket mark (c), cam
cap and cylinder head matching surface (d) and/
or left side cam sprocket mark (e) and belt cover
notch (f) are properly adjusted.
ST 499987500 CRANKSHAFT SOCKET
I

Specified data:
Z,: 44 tooth length
Z,: 40.5 tooth length

6) Remove the belt idler (No. 2).

ME(SO HC)-47
 TIMING BELT ASSEMBLY
MECHANICAL
7) Remove the belt idler No. 2.
I \
8) Remove the timing belt.
I B2M2594 I
2. BELT IDLER AND AUTOMATIC BELT
TENSION ADJUSTER ASSEMBLY
1) Remove the belt idler (No.1).
2) Remove the automatic belt tension adjuster as-
sembly.
B: INSTALLATION
1. AUTOMATIC BELT TENSION ADJUST-
ER ASSEMBLY AND BELT IDLER
1) Preparation for installation of automatic belt ten-
sion adjuster assembly:
CAUTION:
Always use a vertical type pressing tool to
move the adjuster rod down.
Do not use a lateral type vise.
S2M1008l
Push the adjuster rod vertically.
Be sure to slowly move the adjuster rod down
applying a pressure of 294 N (30 kgf, 66 Ib).
Press-in the push adjuster rod gradually tak-
ing more than three minutes.
Do not allow press pressure to exceed 9,807
N (1,000 kgf, 2,205 Ib).
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.
Do not release the press pressure until stop-
per pin is completely inserted.
(1) Attach the automatic belt tension adjuster
assembly to the vertical pressing tool.
(2) Slowly move the adjuster rod down with a
pressure of 294 N (30 kgf, 66 Ib) until the adjust-
er rod is aligned with the stopper pin hole in the
cylinder.
l+l
(3) With a 2 mm (0.08 in) dia. stopper pin or a 2
mm (0.08 in) (nominal) dia. hex bar wrench in-
serted into the stopper pin hole in the cylinder,
secure the adjuster rod.
Stopper pin
11 H2M2383A
ME(S0HC)-48
 TIMING BELT ASSEMBLY
MECHANICAL

2) Install the automatic belt tension adjuster as- 2. TIMING BELT

sembly.
1) Preparation for installation of automatic belt ten-
Tightening torque: sion adjuster assembly. <Ref. to ME(S0HC)-48,
25 N-m (2.5 kgf-m, 18.4 ff-lb) AUTOMATIC BELT TENSION ADJUSTER AS-
SEMBLY AND BELT IDLER, INSTALLATION,
Timing Belt Assembly.>
2) Installation of timing belt:
(1) Turn the camshaft sprocket No. 2 using
ST1, and turn the camshaft sprocket No. 1 using
ST2 so that their alignment marks (A) come to
top positions.
ST1 4992071 00 CAMSHAFT SPROCKET
WRENCH
ST2 499207400 CAMSHAFT SPROCKET
WRENCH
3) Install the belt idler (No. 1).
Tightening torque:
39 N.m (4.0 kgf-m, 28.9 ff-lb)

(2) While aligning alignment mark (B) on the

timing belt with marks (A) on sprockets, position
the timing belt properly.
CAUTION:
Ensure the belt's rotating direction is correct.

3) Install the belt idler No. 2.

Tightening torque:
39 N-m (4.0 kgf-m, 28.9 ff-lb)

ME(S0HC)-49
 TIMING BELT ASSEMBLY
MECHANICAL

4) Install the belt idler (No. 2). (2) Check and adjust the clearance between
timing belt and timing belt guide by using thick-
Tightening torque:
ness gauge.
39 N-m (4.0kgf-m, 28.9 ft-lb)
Clearance:
5 mm (0.039M.020 in)
1.0-M.

\S2M1008I

5) After ensuring that the marks on the timing belt

and camshaft sprockets are aligned, remove the
stopper pin from belt tensioner adjuster. (3) Tighten the remaining bolts.
Tightening torque:
9.8 N-m (1.0 kgf-m, 7.2 ft-lb)

6) Install the timing belt guide. (MT vehicles only)

(1) Temporarily tighten the remaining bolts
7) Install the belt cover. <Ref. to ME(S0HC)-46, IN-
STALLATION, Belt Cover.>
8) Install the crankshaft pulley. <Ref. to ME(S0-
HC)-45, REMOVAL, Crankshaft Pulley.>
9) Install the V-belt. <Ref. to ME(S0HC)-43, IN-
STALLATION, V-belt.>

ME(S0HC)-50
 TIMING BELT ASSEMBLY
C: INSPECTION
1. TIMING BELT
1) Check the timing belt teeth for breaks, cracks,
and wear. If any fault is found, replace the belt.
2) Check the condition of back side of belt; if any
crack is found, replace the belt.
CAUTION:
Be careful not to let oil, grease or coolant
contact the belt. Remove quickly and thorough-
ly if this happens.
Do not bend the belt sharply.
Bending radius: h
60 mm (2.36 in) or more
G2M011E
2. AUTOMATIC BELT TENSION ADJUST-
ER
1) Visually check the oil seals for leaks, and rod
ends for abnormal wear or scratches. If necessary,
replace the faulty parts.
CAUTION:
Slight traces of oil at rod's oil seal does not in-
dicate a problem.
2) Check that the adjuster rod does not move when
a pressure of 294 N (30 kgf, 66 Ib) is applied to it.
This is to check adjuster rod stiffness.
3) If the adjuster rod is not stiff and moves freely
when applying 294 N (30 kgf, 66 Ib), check it using
the following procedures:
(1) Slowly press the adjuster rod down to the
end surface of the cylinder. Repeat this motion 2
or 3 times.
(2) With the adjuster rod moved all the way up,
apply a pressure of 294 N (30 kgf, 66 Ib) to it.
Check the adjuster rod stiffness.
(3) If the adjuster rod is not stiff and moves
down, replace the automatic belt tension adjust-
er assembly with a new one.
ME(SO HC)-51
MECHANICAL
CAUTION:
Always use a vertical type pressing tool to
move the adjuster rod down.
Do not use a lateral type vise.
Push the adjuster rod vertically.
Press-in the push adjuster rod gradually tak-
ing more than three minutes.
Do not allow press pressure to exceed 9,807
N (1,000 kgf, 2,205 Ib).
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-M.5 mm (0.224-M.
020 in)
3. BELT TENSION PULLEY
1) Check the mating surfaces of timing belt and
contact point of adjuster rod for abnormal wear or
scratches. Replace the automatic belt tension ad-
juster assembly if faulty.
2) Check the tension pulley for smooth rotation. Re-
place if noise or excessive play is noted.
3) Check the tension pulley for grease leakage.
4. BELTIDLER
1) Check the belt idler for smooth rotation. Replace
if noise or excessive play is noted.
2) Check the belt outer contacting surfaces of idler
pulley for abnormal wear and scratches.
3) Check the belt idler for grease leakage.
 CAMSHAFT SPROCKET
MECHANICAL

16.Camshaft Sprocket B: INSTALLATION

1) Install the camshaft sprocket No. 1. To lock the
A: REMOVAL camshaft, use ST.
1. REMOVAL ST 499207400 CAMSHAFT SPROCKET
WRENCH
1) Remove the V-belt. <Ref. to ME(S0HC)-43, RE-
MOVAL, V-belt.> Tightening torque:
2) Remove the crankshaft pulley. <Ref. to ME(S0- 78 N-m (8.0 kgf-m, 57.9 fi-lb)
HC)-45, REMOVAL, Crankshaft Pulley.> CAUTION:
3) Remove the belt cover. <Ref. to ME(S0HC)-46, Do not confuse left and right side camshaft
REMOVAL, Belt Cover.> sprockets during installation. The camshaft
4) Remove the timing belt assembly. <Ref. to sprocket No. 2 is identified by a projection used
ME(S0HC)-47, REMOVAL, Timing Belt Assem- to monitor camshaft position sensor.
bly.>
5 ) Remove the camshaft position sensor. <Ref. to
FU(S0HC)-29, REMOVAL, Camshaft Position
Sensor .>
6) Remove the camshaft sprocket No. 2. To lock
the camshaft, use ST.
ST 499207100 CAMSHAFT SPROCKET
WRENCH

2) Install the camshaft sprocket No. 2. To lock the

camshaft, use ST.
ST 4992071 00 CAMSHAFT SPROCKET
WRENCH
Tighfening torque:
78 N-m (8.0 kgf-m, 57.9 fi-lb)
H2M2377A

7) Remove the camshaft sprocket No. 1. To lock

the camshaft, use ST.
ST 499207400 CAMSHAFT SPROCKET
WRENCH

H2M2377A

3) Install the camshaft position sensor. <Ref. to

FU(S0HC)-29, INSTALLATION, Camshaft. Posi-
tion Sensor.>
4) Install the timing belt assembly. <Ref. to ME(S0-
HC)-48, INSTALLATION, Timing Belt Assembly.>
5) Install the belt cover. <Ref. to ME(S0HC)-46, IN-
STALLATION, Belt Cover.>
6) Install the crankshaft pulley. <Ref. to ME(S0-
HC)-45, INSTALLATION, Crankshaft PuIley.>
7) install the V-belt. <Ref. to ME(S0HC)-43, IN-
STALLATION, V-belt.>

ME(S0HC)-52
 CAMSHAFT SPROCKET
MECHANICAL

C: INSPECTION
1) Check the sprocket teeth for abnormal wear and
scratches.
2) Make sure there is no free play between sprock-
et and key.
3) Check the camshaft sprocket notch used for
sensor for damage and contamination of foreign
matter.

ME(S0HC)-53
 CRANKSHAFT SPROCKET
MECHANICAL

17.Crankshaft Sprocket B: INSTALLATION

A: REMOVAL
1) Remove the V-belt. <Ref. to ME(S0HC)-43, RE-
MOVAL, V-belt.>
2) Remove the crankshaft pulley. <Ref. to ME(S0-
HC)-45, REMOVAL, Crankshaft Pulley.>
3) Remove the belt cover. <Ref. to ME(S0HC)-46,
REMOVAL, Belt Cover.>
4) Remove the timing belt assembly. <Ref. to
ME(S0HC)-47, REMOVAL, Timing Belt Assem-
bly.>
5) Remove the camshaft sprocket. <Ref. to
ME(S0HC)-52, REMOVAL, Camshaft Sprocket.>
6) Remove the crankshaft sprocket.
1) Install the crankshaft sprocket.
2) Install the camshaft sprocket. <Ref. to ME(S0-
HC)-52, INSTALLATION, Camshaft Sprocket.>
3) Install the timing belt assembly. <Ref. to ME(S0-
HC)-48, INSTALLATION, Timing Belt Assembly.>
4) Install the belt cover. <Ref. to ME(S0HC)-46,IN-
STALLATION, Belt Cover.>
5) Install the crankshaft pulley. <Ref. to ME(S0-
HC)-45, INSTALLATION, Crankshaft PuIley .>
6) Install the V-belt. <Ref. to ME(S0HC)-43, IN-
STALLATION, V-belt. >
C: INSPECTION
1) Check the sprocket teeth for abnormal wear and
scratches.
2) Make sure there is no free play between sprock-
et and key.
3) Check the crankshaft sprocket notch used for
sensor for damage and contamination of foreign
matter.

ME(S0HC)-54
 VALVE ROCKER ASSEMBLY
18.Valve Rocker Assembly
A: REMOVAL
1) Remove the V-belt. <Ref. to ME(S0HC)-43, RE-
MOVAL, V-belt.>
2) Remove the crankshaft pulley. <Ref. to ME(S0-
HC)-45, REMOVAL, Crankshaft Pulley.>
3) Remove the belt cover. <Ref. to ME(S0HC)-46,
REMOVAL, Belt Cover.>
4) Remove the timing belt assembly. <Ref. to
ME(S0HC)-47, REMOVAL, Timing Belt Assem-
bly.>
5) Remove the camshaft sprocket. <Ref. to
ME(S0HC)-52, REMOVAL, Camshaft Sprocket.>
6) Disconnect the PCV hose and remove the rocker
cover.
7) Removal of valve rocker assembly:
(1) Remove the bolts (a) through (h) in alpha-
betical sequence.
CAUTION:
Leave two or three threads of bolts (g and h) en-
gaged to retain the valve rocker assembly.
d STALLATION, V-belt.>
(2) Remove the valve rocker assembly.
I B2M2606 I rocker shaft.
B: INSTALLATION
1) Installation of valve rocker assembly:
(1) Temporarily tighten the bolts (a) through (d)
equally as shown in figure.
CAUTION:
Do not allow the valve rocker assembly to
gouge knock pins.
(2) Tighten the bolts (e) through (h) to specified
torque.
ME(S0HC)-55
MECHANICAL
(3) Tighten the bolts (a) through (d) to specified
torque.
Tightening torque:
25 N-m (2.5 kgf-m, 18.1 ft-lb)
d
2) Adjust the valve clearances. <Ref. to ME(S0-
HC)-31, ADJUSTMENT, Valve Clearance.>
3) Install the rocker cover and connect PCV hose.
4) Install the camshaft sprocket. <Ref. to ME(S0-
HC)-52, INSTALLATION, Camshaft Sprocket.>
5) Install the timing belt assembly. <Ref. to ME(S0-
HC)-48, INSTALLATION, Timing Belt Assembly.>
6) Install the belt cover. <Ref. to ME(S0HC)-46, IN-
STALLATION, Belt Cover.>
7) Install the crankshaft pulley. <Ref. to ME(S0-
HC)-45, INSTALLATION, Crankshaft Pulley.>
8) Install the V-belt. <Ref. to ME(S0HC)-43, IN-
C: DISASSEMBLY
1) Remove the bolts which secure the rocker shaft.
2) Extract the rocker shaft. Remove the valve rock-
er arms, springs and shaft supports from rocker
shaft.
CAUTION:
Arrange all removed parts in order so that they
can be installed in their original positions.
3) Remove the nut and adjuster screw from valve
rocker.
D: ASSEMBLY
1) Install the adjuster screw and nut to valve rocker.
2) Arrange the valve rocker arms, springs and shaft
supports in assembly order and insert the valve
Tightening torque (Shaft supports installing
bolts):
5 N-m (0.5 kgf-m, 3.6 ft-lb)
CAUTION:
Valve rocker arms, rocker shaft and shaft sup-
ports have identification marks. Ensure the
parts with same markings are properly assem-
bled.
3) Install the valve rocker shaft securing bolts.
 VALVE ROCKER ASSEMBLY
MECHANICAL

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

rocker shaft support or shaft, whichever shows
1. VALVE ROCKER ARM greater amount of wear.
1) Measure the inside diameter of valve rocker arm Rocker shaft support inside diameter:
and outside diameter of valve rocker shaft, and de- 22.005 -22.026 mm (0,8663 - 0.8672 in)
termine the difference between the two (= oil clear-
ance). Rocker shaft diameter:
21.987 -22.000 mm (0.8656 - 0.8661 in)
Clearance between arm and shaft: 5 ) If the cam or valve contact surface of valve rock-
Standard er arm is worn or dented excessively, replace the
0.020 - 0.054 mm (0.0008 - 0.0021 in) valve rocker arm.
Limit 6) Check that the valve rocker arm roller rotates
0.10 mm (0.0039 in) smoothly. If not, replace the valve rocker arm.
2. INTAKE AND EXHAUST VALVE ROCK-
ER SHAFT
Visually check the oil relief valve of shaft end for
any of the following abnormalities:
Breaks in check ball body
Foreign particles caught in valve spring
Oil leakage at check ball
CAUTION:
// B2M0072 Repair or replace the valve rocker shaft as nec-
essary.

2) If the oil clearance exceeds the limit, replace the

valve rocker arm or shaft, whichever shows greater
amount of wear.
Rocker arm inside diameter:
22.020 -22.041 mm (0.8669 - 0.8678 in)
Rocker shaft diameter:
-
21.987 -22.000 mm (0.8656 0.8661 in)
3 ) Measure the inside diameter of rocker shaft 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(S0HC)-56
 CAMSHAFT
MECHANICAL

19.Camshaft 13) Remove the camshaft cap.

(1) Remove the bolts (a) through (b) in alpha-
A: REMOVAL betical sequence.
1) Remove the V-belt. <Ref. to ME(S0HC)-43, IN-
STALLATION, V-belt.>
2) Remove the crankshaft pulley. <Ref. to ME(S0-
HC)-45, REMOVAL, Crankshaft Pulley.>
3) Remove the belt cover. <Ref. to ME(S0HC)-46,
REMOVAL, Belt Cover.>
4) Remove the timing belt assembly. <Ref. to
ME(S0HC)-47, REMOVAL, Timing Belt Assem-
bly.>
5) Remove the camshaft sprocket. <Ref. to
ME(S0HC)-52, REMOVAL, Camshaft Sprocket.> I B2M2612E

6) Remove the crankshaft sprocket. <Ref. to (2) Equally loosen the bolts (c) through (j) all the
ME(S0HC)-54, REMOVAL, Crankshaft Sprocket.> way in alphabetical sequence.
7) Remove the belt cover No. 2 (RH).
8) Remove the tensioner bracket.

I B2M2612C

H2M2380
(3) Remove the bolts (k) through (p) in alpha-
betical sequence using ST.
9) Remove the belt cover No. 2 (LH). ST 499497000 TORX PLUS
CAUTION:
Do not damage or lose the seal rubber when re-
moving the belt covers.

(4) Remove the camshaft cap.

I O ) Remove the camshaft position sensor support.

(LH side only)
11) Remove the oil level gauge guide. (LH side
only) .
12) Remove the valve rocker assembly. <Ref. to
ME(S0HC)-55, REMOVAL, Valve Rocker Assem-
bly.>
B2M2613

14) Remove the camshaft.

15) Remove the oil seal.

ME(S0HC)-57
 CAMSHAFT
MECHANICAL

16) Remove the plug from rear side of camshaft. (3) Install the valve rocker assembly.
CAUTION:
Do not remove the oil seal unless necessary.
Do not scratch the journal surface when re-
moving the oil seal. \
B: INSTALLATION
1) Apply a coat of engine oil to camshaft journals
and install the camshaft.
2) Install the camshaft cap.
(1) Apply liquid gasket on the periphery of cam-
shaft cap. - \ B2M261f

Liquid gasket: (4) Tighten the bolts (a) through (h) in alphabet-
THREE BOND 12808 ical sequence.
P/N KO877YAO18 Tightening torque:
25 N.m (2.5 kgf-m, 18.1 fi-lb)

NOTE: (b) B2M2621B

Apply a coat of 3 mm (0.12 in) dia. (A): liquid ghor,et
along edge (B) of camshaft cap (C) mating surface. (5) Tighten the TORX bolts (i) through (n) in al-
phabetical sequence using ST.
ST 499427000 TORX PLUS
Tightening torque:
18 N.m (1.8 kgf-m, 13.0 ff-lb)

S2M1199B

(2) Temporarily tighten the bolts (9) through (j)

in alphabetical sequence.
-( I

(i) B2M2621C

B2M2612E

ME(S0HC)-58
 CAMSHAFT
MECHANICAL

(6) Tighten the bolts (0)through (v) in alphabet- 8) Install the camshaft position sensor support. (LH
ical sequence. side only)
9) Install the belt cover No. 2 (RH).
Tightening torque:
10 N.m (1.0 kgf-m, 7.2 ft-lb) Tightening torque:
5 N-m (0.5kgf-m, 3.6 ft-lb)
10) Install the belt cover No. 2 (LH).
Tightening torque:
5 N.m (0.5 kgf-m, 3.6 ft-lb)

I (b) B2M2621D

(7) Tighten the bolts (w) through (x) in alphabet-

ical sequence.
Tightening torque:
10 N.m (1.0 kgf-m, 7.2 ft-lb)
11) Install the tensioner bracket.
I I
Tightening torque:
25 N.m (2.5 kgf-m, 18.1 ft-lb)

B2M2621E

3) Apply a coat of grease to oil seal lips and install

the oil seal (A) on camshaft using ST1 and ST2.
CAUTION:
Use a new oil seal.
ST1 499597000 OIL SEAL GUIDE
ST2 499587500 OIL SEAL INSTALLER
4) Install the plug using ST.
ST 499587700 OIL SEAL INSTALLER
5) Adjust the valve clearance. <Ref. to ME(S0HC)-
31, ADJUSTMENT, Valve Clearance.>
6) Install the rocker cover and connect PCV hose.
7) Install the oil level gauge guide. (LH side only)
H2M2380 I
Install the crankshaft sprocket. <Ref. to
ME(SOHC)-54, INSTALLATI0N, Crankshaft
Sprocket.>
13) Install the camshaft sprocket. <Ref. to ME(S0-
HC)-52, INSTALLATION, Camshaft Sprocket.>
14) Install the timing belt assembly. <Ref. to
ME(S0HC)-48, INSTALLATION, Timing Belt As-
sembly.>
15) Install the belt cover. <Ref. to ME(S0HC)-46,
INSTALLATION, Belt Cover.>
16) Install the crankshaft pulley. <Ref. to ME(S0-
HC)-45, INSTALLATION, Crankshaft Pulley.>
17) Install the V-belt. <Ref. to ME(S0HC)-43, IN-
STALLATION, V- belt .>

ME(S0HC)-59
 CAMSHAFT
MECHANICAL

C: INSPECTION 4) Check the cam face condition; remove the minor

faults by grinding with oil stone. Measure the cam
1. CAMSHAFT height H; replace if the limit has been exceeded.
1) Measure the bend, and repair or replace if nec-

I---:
Cam height: H
essary.
I Item I Unit: mm (in)
Limit: 39.485- 39.585
0.025 mm (0.0010 in) , Intake (1.5545- 1.5585)
Limit 39.385(1.5506)
39.257- 39.357
(1.5455 1.5495)
Exhaust

Cam base circle diameter A:

IN: 34.00 mm (1.3386 in)
EX: 34.00 mm (1.3386 in)

2) Check the journal for damage and wear. Re-

place if fqulty.
3) Measure the outside diameter of camshaft jour-
nal and inside diameter of cylinder head journal,
and determine the difference between the two (= oil
clearance). If the oil clearance exceeds specifica-
tions, replace the camshaft or cylinder head as A
necessary. B2M1209A

Unit: mm (in) 2. CAMSHAFT SUPPORT

Tear- I Standard I 0.055- 0.090(0.0022- 0.0035) Measure the thrust clearance of camshaft with dial
ance at gauge. If the clearance exceeds the limit, replace
Limit 0.10 (0.0039)
journal
the camshaft support.
31.928- 31.945 (1.2570-
Camshaft journal O.D.
1.2577) Standard:
0.030 -
0.090 mm (0.0012 - 0.0035 in)
Journal hole I.D.
I 32.000- 32.018 (1.2598-
1.2605)
Limit:
0.10 mm (0.0039 in)

ME(S0HC)-60
 CYLINDER HEAD ASSEMBLY
20.Cylinder Head Assembly
A: REMOVAL
1) Remove the V-belt. <Ref. to ME(S0HC)-43, RE-
MOVAL, V-belt.>
2) Remove the crankshaft pulley. <Ref. to ME(S0-
HC)-45, REMOVAL, Crankshaft Pulley.>
3) Remove the belt cover. <Ref. to ME(S0HC)-46,
REMOVAL, Belt Cover.>
4) Remove the timing belt assembly. <Ref. to
ME(S0HC)-47, REMOVAL, Timing Belt Assem-
bly.>
5) Remove the camshaft sprocket. <Ref. to
ME(S0HC)-52, REMOVAL, Camshaft Sprocket.>
6) Remove the intake manifold. <Ref. to FU(S0-
HC)-15, REMOVAL, Intake Manifold.>
7) Remove the bolt which installs the N C compres-
sor bracket on cylinder head.
8) Remove the valve rocker assembly. <Ref. to
ME(S0HC)-55, REMOVAL, Valve Rocker Assem-
bly.> . Ib) in alphabetical sequence.
9) Remove the camshaft. <Ref. to ME(S0HC)-57,
REMOVAL, Camshaft.>
10) Remove the cylinder head bolts in alphabetical
sequence shown in figure.
CAUTION:
Leave bolts (a) and (c) engaged by three or four
threads to prevent the cylinder head from fall-
ing.
11) While tapping the cylinder head with a plastic
hammer, separate it from cylinder block.
12) Remove the bolts (a) and (b) to remove the cyl-
inder head.
ME(S0HC)-61
MECHANICAL
13) Remove the cylinder head gasket.
CAUTION:
Do not scratch the mating surface of cylinder
head and cylinder block.
14) Similarly, remove the right side cylinder head.
B: INSTALLATION
1) Install the cylinder head and gaskets on cylinder
block.
CAUTION:
Use new cylinder head gaskets.
Be careful not to scratch the mating surface
of cylinder block and cylinder head.
2) Tighten the cylinder head bolts.
(1) Apply a coat of engine oil to washers and
bolt threads.
(2) Tighten all bolts to 29 N.m (3.0 kgf-m, 22 ft-
Ib) in alphabetical sequence.
Then tighten all bolts to 69 N.m (7.0 kgf-m, 51 ft-
(3) Back off all bolts by 180" first; back them off
by 180" again.
(4) Tighten the bolts (a) and (b) to 34 N-m (3.5
kgf-m, 25 ft-lb).
(5) Tighten the 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 the bolts more than 90".
(7) Further tighten all bolts by 80 to 90" in al-
phabetical sequence shown in the figure below.
CAUTION:
Ensure the total "re-tightening angle" [in the
former two steps], do not exceed 180".
(C)
S2M1589B
3) Install the camshaft. <Ref. to ME(S0HC)-58, IN-
STALLAT10N, Camshaft.>
4) Install the valve rocker assembly. <Ref. to
ME(S0HC)-55, INSTALLATION,Valve Rocker As-
sembly.>
5 ) Install the N C compressor bracket on cylinder
head.
 CYLINDER HEAD ASSEMBLY
MECHANICAL

6) Install the intake manifold. <Ref. to FU(S0HC)- C: DISASSEMBLY

17, INSTALLATION, Intake Manifold.>
7) Install the camshaft sprocket. <Ref. to ME(S0-
HC)-52, INSTALLATION, Camshaft Sprocket.>
8) Install the timing belt assembly. <Ref. to ME(S0-
HC)-48, INSTALLATION, Timing Belt Assembly.>
9) Install the belt cover. <Ref. to ME(S0HC)-46, IN-
STALLATION, Belt Cover.>
10) Install the crankshaft pulley. <Ref. to ME(S0-
HC)-45, INSTALLATI ON, Crankshaft PuIIey.>
11) Install the V-belt. <Ref. to ME(S0HC)-43, IN-
STALLATION, V-belt.>
1) Place the cylinder head on ST.
ST 498267800 CYLINDER HEAD TABLE
2) Set the ST on valve spring. Compress the valve
spring and remove the valve spring retainer key.
Remove each valve and valve spring.
ST 499718000 VALVE SPRING REMOVER
CAUTION:
Mark each valve to prevent confusion.
Use extreme care not to damage the lips of
the intake valve oil seals and exhaust valve oil
seals.

ME(S0HC)-62
 CYLINDER HEAD ASSEMBLY
MECHANICAL

D: ASSEMBLY

B2M2629E

(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 (IO) Oil seal
1) Installation of valve spring and valve: (4) Set the ST on valve spring.
(1) Place the cylinder head on ST. ST 499718000 VALVE SPRING REMOVER
ST 498267800 CYLINDER HEAD TABLE
(2) Coat the stem of each valve with engine oil
and insert the valve into valve guide.
CAUTION:
When inserting the valve into valve guide, use
special care not to damage the oil seal lip.
(3) Install the valve spring and retainer.
CAUTION:
Be sure to install the valve springs with their
close-coiled end facing the seat on the cylinder
head.

ME(S0HC)-63
 CYLINDER HEAD ASSEMBLY
MECHANICAL

(5) Compress the valve spring and fit the valve
spring retainer key.
W B2M26348
(A) Retainer key
(6) Painted face
(6) After installing, tap the valve spring retainers
lightly with wooden hammer for better seating.
E: INSPECTION
1. VALVE SPRING
1) Check the valve springs for damage, free length,
and tension. Replace the valve spring if it is not to
the specifications presented below.
2) To measure the squareness of the valve spring,
stand the spring on a surface plate and measure its
deflection at the top using a try square.
I 54.30mm (2.1378in)
~ ~~
2. INTAKE AND EXHAUST VALVE OIL
SEAL
Replace the oil seal with a new one, if the lip is
damaged or spring out of place, or when the surfac-
es of intake valve and valve seat are reconditioned
or intake valve guide is replaced. Use pliers to
pinch and remove the oil seal from valve.
1) Place the cylinder head on ST1.
2) Press-fit the oil seal to the specified dimension
indicated in the figure using ST2.
CAUTION:
Apply engine oil to oil seal before press-fit-
ting.
When press-fitting the oil seal, do not use a
hammer or strike in.
Differentiate between the intake valve oil seal
and exhaust valve oil seal by noting their differ-
ence in color.
ST1 498267800 CYLINDER HEAD TABLE
ST2 498857100 VALVE OIL SEAL GUIDE
Color of rubber part:
Intake [Black]
Exhaust [Brown]
Color of spring part:
Intake [Silver]
Exhaust [Silver]

Free lenqth I
Squareness 2.5",2.4mm (0.094in)
214.8- 246.2N
(21.9- 25.1 kgf, 48.3- 55.3Ib)/
Tensiodspring 45.0mm (1.772in)
height 526.6- 581.6 N
-
(53.7- 59.3 kgf, 1 18.4 130.8Ib)/
34.7 mm (1.366in)

ME(S0HC)-64
 CYLINDER HEAD ASSEMBLY
MECHANICP I

F: ADJUSTMENT 2. VALVESEAT
1. CYLINDER HEAD Inspect the intake and exhaust valve seats, and
correct the contact surfaces with a valve seat cutter
1) Make sure that no crack or other damage do not if they are defective or when valve guides are re-
exists. In addition to visual inspection, inspect im- placed.
portant areas by means of red lead check.
Also make sure the gasket installing surface shows Valve seat width: W
no trace of gas and water leaks. Intake
2) Place the cylinder head on ST. Standard 1.0 mm (0.039 in)
ST 498267800 CYLINDER HEAD TABLE Limit 1.7 mm (0.067 in)
3) Measure the warping of the cylinder head sur- Exhaust
face that mates with crankcase using a straight Standard 1.4 mm (0.055 in)
edge (A) and thickness gauge (B). Limit 2.1 mm (0.083 in)
If the warping exceeds 0.05 mm (0.0020 in), re-
grind the surface with a surface grinder.
Warping limit:
0.05 mm (0.0020 in)
Grinding limit:
0.1 mm (0.004 in)
Standardheight of cylinder head:
97.5 mm (3.839 in)
CAUTION: G2M0149
Uneven torque for the cylinder head bolts can
cause warping. When reassembling, pay spe-
cial attention to the torque so as to tighten
evenly.

(B)

S2M1817A

ME(S0HC)-65
 CYLINDER HEAD ASSEMBLY
MECHANICAL

3. VALVE GUIDE (2) Insert ST2 into the valve guide and press it
1) Check the clearance between valve guide and down to remove the valve guide.
stem. The clearance can be checked by measuring ST1 498267800 CYLINDER HEAD TABLE
the outside diameter of valve stem and the inside ST2 499767200 VALVE GUIDE REMOVER
diameter of valve guide with outside and inside mi-
crometers respectively.
Clearance between the valve guide and valve (STZ)
stem:
Standard
Intake 0.035 - 0.062 mm (0.0014 -0.0024
in)
Exhaust 0.040 - 0.067 mm (0.0016 - 0.0026
in)
Limit
0.15 mm (0.0059 in)
(3) Turn the cylinder head upside down and
place the ST as shown in the figure.
Intake side:
ST 499767700 VALVE GUIDE ADJUSTER
Exhaust side:

1
ST 499767800 VALVE GUIDE ADJUSTER

Valve guide
B2M0387A I

%-
B2M0077D

(A) Valve guide

(4) Before installing a new oversize valve guide,

A 02M0076B
make sure that neither scratches nor damages
exist on the inside surface of the valve guide
holes in cylinder head.
2) If the clearance between valve guide and stem
exceeds the limit, replace the valve guide or valve
itself whichever shows greater amount of wear.
See the following procedure for valve guide re-
placement:
Valve guide inner diameter:
6.000 - 6.012 mm (0.2362 - 0.2367 in)
Valve stem outer diameters:
Intake
5.950 - 5.965 mm (0.2343 - 0.2348 in)
Exhaust
5.945 - 5.960 mm (0.2341 - 0.2346 in)
(1) Place the cylinder head on STl with the
combustion chamber upward so that valve
guides enter the holes in STl.

ME(S0HC)-66
 CYLINDER HEAD ASSEMBLY
( 5 ) Put a new valve guide, coated with sufficient
oil, in cylinder, and insert the ST1 into valve
guide. Press in until the valve guide upper end is
flush with the upper surface of ST2.
STI 499767200 VALVE GUIDE REMOVER
Intake side:
ST2 499767700 VALVE GUIDE ADJUSTER
Exhaust side:
ST2 499767800 VALVE GUIDE ADJUSTER
(6) Check the valve guide protrusion.
Valve guide protrusion: L
Intake
20.0 -20.5 mm (0.787 - 0.807 in)
Exhaust
-
16.5 - 77.0 mm (0.650 0.669 in)
(A) Valve guide
ME(S0HC)-67
MECHANICAL
(7) Ream the inside of valve guide with ST.
Gently rotate the reamer clockwise while press-
ing it lightly into the valve guide, and return it
also rotating clockwise. After reaming, clean the
valve guide to remove chips.
CAUTION:
Apply engine oil to the reamer when reaming.
If the inner surface of the valve guide is torn,
the edge of the reamer should be slightly
ground with an oil stone.
If the inner surface of the valve guide be-
comes lustrous and the reamer does not chip,
use a new reamer or remedy the reamer.
ST 499767400 VALVE GUIDE REAMER
(8) Recheck the contact condition between
valve and valve seat after replacing the valve
guide.
 CYLINDER HEAD ASSEMBLY
MECHANICAL

4. INTAKE AND EXHAUST VALVE

1) Inspect the flange and stem of the valve, and re-
place if damaged, worn, or deformed, or if “H” is
less than the specified limit.
H:
Intake
Standard 1.0 mm (0.039 in)
Limit 0.6 mm (0.024 in)
Exhaust
Standard 1.2 mm (0.047 in)
Limit 0.6 mm (0.024 in)
Valve overall length:
Intake
120.6 mm (4.75 in)
Exhaust
121.7 mm (4.79 in)

G2M0153

2) Put a small amount of grinding compound on the

seat surface and lap the valve and seat surface.
<Ref. to ME(S0HC)-65, VALVE SEAT, ADJUST-
MENT, Cylinder Head Assembly.> Install a new in-
take valve oil seal after lapping.

ME(S0HC)-68
 CYLINDER BLOCK
MECHANICAL

21.Cylinder Block 12) Remove the bolts (a) and (b) to remove the cyl-
inder head.
A: REMOVAL
NOTE:
Before conducting this procedure, drain the engine
oil completely if applicable.
Front
1) Remove the intake manifold. <Ref. to FU(S0-
HC)-15, REMOVAL, Intake Manifold.>
2) Remove the V-belt. <Ref. to ME(S0HC)-43, RE-
c7 U
MOVAL, V-belt.>
3) Remove the crankshaft pulley. <Ref. to ME(S0-
HC)-45, REMOVAL, Crankshaft Pulley.>
4) Remove the belt cover. <Ref. to ME(S0HC)-46,
REMOVAL, Belt Cover.> 13) Remove the cylinder head gasket.
5 ) Remove the timing belt assembly. <Ref. to CAUTION:
ME(S0HC)-47, REMOVAL, Timing Belt Assem- Do not scratch the mating surface of cylinder
bly.> head and cylinder block.
6) Remove the camshaft sprocket. <Ref. to 14) Similarly, remove the right side cylinder head.
ME(S0HC)-52, REMOVAL, Camshaft Sprocket.> 15) Remove the clutch housing cover (MT vehicles
7) Remove the crankshaft sprocket. <Ref. to only).
ME(SOW)-54, REMOVAL, Crankshaft Sprocket.> 16) Remove the flywheel (MT vehicles only) or
8 ) Remove the generator and A/C compressor with drive plate (AT vehicles only).
their brackets. Using the ST, lock crankshaft.
9) Remove the rocker cover. ST 498497100 CRANKSHAFT STOPPER
10) Remove the cylinder head bolts in alphabetical MT MODEL
sequence shown in the figure.
CAUTION:
Leave bolts (a) and (b) engaged by three or four
threads to prevent the cylinder head from fall-
ing.

Front

0U
- EN1177

ATMODEL

11) While tapping the cylinder head with a plastic

hammer, separate it from cylinder block.

17) Remove the oil separator cover.

18) Remove the water by-pass pipe for heater
19) Remove the water pump.

ME(S0HC)-69
 CYLINDER BLOCK
MECHANICAL

20) Remove the oil pump from cylinder block. 26) Remove the water pipe.
Use a flat-bladed screwdriver as shown in the fig-
ure when removing the oil pump.
CAUTION:
Be careful not to scratch the mating surface of
cylinder block and oil pump.

2 ) Removal of oil pan:

(1) Turn the cylinder block with #2 and #4 piston
sides facing upward.
(2) Remove the bolts which secure oil pan to
cylinder block.
(3) Insert a oil pan cutter blade between cylin-
der block-to-oil pan clearance and remove the
oil pan.
CAUTION:
Do not use a screwdriver or similar tool in place
of oil pan cutter.

22) Remove the oil strainer stay.

23) Remove the oil strainer.
24) Remove the baffle plate.
25) Remove the oil filter using ST.
ST 498547000 OIL FILTER WRENCH

1 B2M2611A

ME(S0HC)-70
 CYLINDER BLOCK
MECHANICAL

SZM15906

(1) Service hole plug (3) Circlip (5) Service hole cover
. , Gasket
(2) (4) Piston pin (6) O-ring
27) Remove the service hole cover and service 28) Rotate the crankshaft to bring #1 and #2 pis-
hole plugs using a hexagon wrench [14 mm (0.55 tons to bottom dead center position, then remove
in)]. the piston circlip through service hole of #1 and #2
cylinders.

ME(S0HC)-71
 CYLINDER BLOCK
MECHANICAL

29) Draw out the piston pin from #1 and #2 pistons 30) Similarly remove the piston pins from #3 and #4
using ST. pistons.
ST 499097700 PISTON PIN REMOVER 31) Remove the bolts which connect cylinder block
CAUTION: on the side of #2 and #4 cylinders.
Be careful not to confuse the original combina- 32) Back off the bolts which connect cylinder block
tion of piston, piston pin and cylinder. on the side of #1 and #3 cylinders two or three
turns.
33) Set up the cylinder block so that #1 and #3 cyl-
inders are on the upper side, then remove the cyl-
inder block connecting bolts.
34) Separate the left-hand and right-hand cylinder
blocks.
CAUTION:
When separating the cylinder block, do not al-
low the connecting rod to fall and damage the
cylinder block.
\ - G2M0166

,! ’

B2M2408r

(1) Cylinder block (3) Crankshaft (5) Piston

(2) Rear oil seal (4) Crankshaft bearing
35) Remove the rear oil seal. 38) Draw out each piston from cylinder block using
36) Remove the crankshaft together with connect- a wooden bar or hammer handle.
ing rod. . CAUTION:
37) Remove the crankshaft bearings from cylinder D~ not confuse the combination of piston and
block using a hammer handle. cylinder.
CAUTION:
Do not confuse the combination of crankshaft
bearings. Press the bearing at the end opposite
to locking lip.

ME(S0HC)-72
 CYLINDER BLOCK
MECHANICAL

B: INSTALLATION

(1) Crankshaft bearing (4) Rear oil seal Tightening torque: N.m (kgf-m, ft-lb)
(2) Crankshaft T1: 25 (2.5, 18.1)
(31
\ I
Cvlinder block T2: 47 (4.8, 34.7)
CAUTION: 2) Apply fluid packing to the mating surface of #1
Remove oil in the mating surface of bearing and and #3 cylinder block, and position it on #2 and #4
cylinder block before installation. Also apply a cylinder block.
coat of engine oil to crankshaft pins. Fluid packing:
1) Positionthe crankshaft on the #2 and #4 cylinder THREE BOND 7275 or equivalent
block.
CAUTION:
Do not allow fluid packing to jut into O-ring
grooves, oil passages, bearing grooves, etc.

ME(SOHC)-73
 CYLINDER BLOCK
MECHANICAL

3) Temporarily tighten the 10 mm cylinder block 6) Install the rear oil seal using STI and ST2.
connecting bolts in alphabetical sequence shown in ST1 499597100 OIL SEAL GUIDE
the figure. ST2 499587200 OIL SEAL INSTALLER

B2M0088D
- S2M1827A

4) Tighten the 10 mm cylinder block connecting

(A) Rear oil seal
bolts in alphabetical sequence.
(B) Flywheel attaching bolt
Tightening torque:
47 N.m (4.8 kgf-m, 34.7 ff-lb) 7) Position the top ring gap at (A) or (B) in the fig-
ure.

B2M0088D
I B2M3722A
5 ) Tighten the 8 mm and 6 mm cylinder block con-
necting bolts in alphabetical sequence shown in the 8) Position the second ring gap at 180" on the re-
figure. verse side for the top ring gap.
9) Position the upper rail gap at (C) or (D) in the fig-
Tightening torque: ure.
(A) -(G): 25 N-m (2.5 kgf-m, 18.1 ff-lb)
(H): 6.4 N-m (0.65 kgf-m, 4.7 ff-lb)

B2M3723A I
B2M0089F
10) Position the expander gap at 180" of the re-
verse side for the upper rail gap.

ME(S0HC)-74
 CYLINDER BLOCK
MECHANICAL
~~

11) Positionthe lower rail gap at (E) or (F) in the fig- CAUTION:
ure. Use new circlips.
CAUTION:
Ensure ring gaps do not face the same direc-
tion.
Ensure ring gaps are not within the piston
skirt area.
Q”

Front side #2
B2M1403A

CAUTION:
Piston front mark faces towards the front of the
engine.
I 1

12) Installing the circlip:

Install the circlips in piston holes located opposite
of serviceholes in cylinder block, when positioning
all pistons in the corresponding cylinders.
Front mark

B2M3724A

(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

ME(SOHC)-75
 CYLINDER BLOCK
MECHANICAL

13) Installing the piston: (3) Install the circlip.

(1) Turn the cylinder block so that #1 and #2 cyl-
inders face upward. CAUTION:
Use new circlips.
(2) Using STI, turn the crankshaft so that #1
and #2 connecting rods are set at bottom dead
center.
STI 499987500 CRANKSHAFT SOCKET
(3) Apply a coat of engine oil to the pistons and
cylinders and insert pistons in their cylinders us-
ing ST2.
ST2 498747300 PISTON GUIDE

(4) Apply fluid packing around the service hole

Plug.
Fluid packing:
THREE BOND 1215 or equivalent

14) Installing piston pin:

(1) Insert ST3 into the service hole to align pis-
ton pin hole with connecting rod small end.
CAUTION:
Apply a coat of engine oil to ST3 before inser-
tion.
ST3 499017100 PISTON PIN GUIDE
82M2625
I

(5) Install the service hole plug and gasket.

CAUTION:
Use a new gasket.

(2) Apply a coat of engine oil to the piston pin

and insert piston pin into piston and connecting
rod through service hole.

ME(S0HC)-76
 CYLINDER BLOCK
MECHANICAL

B2M1323h

(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 the cylinder block so that #3 and #4 cyl- 18) Install the oil strainer stay.
inders face upward. Using the same procedures 19) Apply fluid packing to matching surfaces and
as used for #1 and #2 cylinders, install the pis- install the oil pan.
tons and piston pins. Fluid packing:
15) Install the water pipe. THREE BOND 1215 or equivalent

S2M18331
16) Install the baffle plate.
Tightening torque:
6.4 N.m (0.65 kgf-m, 4.7 ff-lb)
17) Install the oil strainer and O-ring
Tightening torque:
10 N.m (1.0 kgf-m, 7 ft-lb)

ME(S0HC)-77
 CYLINDER BLOCK
MECHANICAL~~

20) Apply fluid packing to matching

- surfaces and 23) Installation of oil pump:
install the oil separator-cover. (1) Discard the front oil seal after removal. Re-
Fluid packing: place with a new one using ST.
THREE BOND 1215 or equivalent ST 499587100 OIL SEAL INSTALLER

S2M1834A S2M0235

21) Install the flywheel or drive plate. (2) Apply fluid packing to the matching surface
To lock the crankshaft, use ST. of oil pump.
ST 498497100 CRANKSHAFT STOPPER Fluid packing:
Tightening torque: THREE BOND 1215 or equivalent
72 N.m (7.3 kgf-m, 52.8 tl-lb)

S2M0739B

(A) O-ring

(3) Apply a coat of engine oil to the inside of the

oil seal.

22) Install the housing cover.

1 S2M0118B

ME(S0HC)-78
 CYLINDER BLOCK
(4) Install the oil pump on cylinder block. Be
careful not to damage the oil seal during instal-
lation.
Tightening torque:
6.4 N-m (0.65 kgf-m, 4.7 ft-lb)
CAUTION:
Do not forget to install the O-ring and seal
when installing the oil pump.
Align the flat surface of oil pump's inner rotor
with crankshaft before installation.
24) Install the water pump and gasket.
Tightening torque:
First; 72 N-m (7.2 kgf-m, 8.7 ft-lb)
Second; 72 N m (7.2 kgf-m, 8.7 ft-lb)
CAUTION:
Be sure to use a new gasket.
When installing the water pump, tighten bolts
in two stages in alphabetical sequence as
shown in the figure.
H2M1568B
25) Install the water by-pass pipe for heater
26) Install the oil filter usina ST.
ST 498547000 OIL FrLTER WRENCH
ww
B2M2611f
27) Tighten the cylinder head bolts.
(1) Apply a coat of engine oil to washers and
bolt threads.
(2) Tighten all bolts to 29 N-m (3.0 kgf-m, 22 ft-
Ib) in alphabetical sequence.
Then tighten all bolts to 69 N.m (7.0 kgf-m, 51 ft-
Ib) in alphabetical sequence.
(3) Back off all bolts by 180" first; back them off
by 180" again.
ME(S0HC)-79
MECHANICAL
(4) Tighten the bolts (a) and (b) to 34 N-m (3.5
kgf-m, 25 ft-lb).
(5) Tighten the 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 the bolts more than 90".
(7) Further tighten all bolts by 80 to 90" in al-
phabetical sequence.
CAUTION:
Ensure the total "re-tightening angle" [in the
former two steps], do not exceed 180".
Front
0
28) Install the oil level gauge guide and tighten the
attaching bolt (left side only).
29) Install the rocker cover.
30) Install the crankshaft sprocket. <Ref. to
ME(S0HC)-54, INSTALLATION, Crankshaft
Sprocket.>
31) Install the camshaft sprocket. <Ref. to ME(S0-
HC)-52, INSTALLATION, Camshaft Sprocket.>
32) Install the timing belt assembly. <Ref. to
ME(S0HC)-48, INSTALLATION, Timing Belt As-
sembly.>
33) Install the belt cover. <Ref. to ME(S0HC)-46,
INSTALLATION, Belt Cover.>
34) Install the crankshaft pulley. <Ref. to ME(S0-
HC)-45, INSTALLAT ION, Crankshaft PuIley.>
35) Install the generator and A/C compressor
brackets on cylinder head.
36) Install the intake manifold. <Ref. to FU(S0HC)-
17, INSTALLATION, Intake Manifold.>
37) Install the V-belt. <Ref. to ME(S0HC)-43, IN-
STALLATION, V-belt.>
 CYLINDER BLOCK
MECHANICAL

C: DISASSEMBLY

(1) Connecting rod cap (3) Top ring (5) Oil ring
(2) Connecting rod bearing (4) Second ring (6) Circlip
1) Remove the connecting rod cap.
2) Remove the connecting rod bearing.
CAUTION:
Arrange the removed connecting rod, connect-
ing rod cap and bearing in order to prevent con-
fusion.
3) Remove the piston rings using the piston ring ex-
pander.
4) Remove the oil ring by hand.
CAUTION:
Arrange the removed piston rings in proper or-
der to prevent confusion.
5) Remove the circlip.

ME(S0HC)-80
 CYLINDER BLOCK
MECHANICAL

D: ASSEMBLY

B2M1320J

(1) Connecting rod bearing (5) Second ring Tightening torque: N-m (kgf-m, ft-Ib)
(2) Connecting rod (6) Top ring Tr 44.6 (4.55. 32.9)
(3) Connecting rod cap (7) Circlip
(4) Oil ring
1) Install the connecting rod bearings on connect- E: INSPECTION
ing rods and connecting rod caps.
1. CYLINDER BLOCK
CAUTION:
Apply oil to the surfaces of the connecting rod 1) Visually check for cracks and damage. Especial-
bearings. ly, inspect the important parts by means of red lead
check.
2) Install the connecting rod on crankshaft.
2) Check the oil passages for clogging.
CAUTION: 3) Inspect the crankcase surface that mates with
Position each connecting rod with the side cylinder head for warping by using a straight edge,
marked facing forward. and correct by grinding if necessary.
3) Install the connecting rod cap with connecting
Warping limit:
rod nut.
0.05 mm (0.0020 in)
Ensure the arrow on connecting rod cap faces the
front during installation. Grinding limit:
CAUTION: 0.1 mm (0.004 in)
Each connecting rod has its own mating cap. Standard height of cylinder block:
Make sure that they are assembled correctly by 201.0 mm (7.91 in)
checking their matching number.
When tightening the connecting rod nuts, ap-
ply oil on the threads.
4) Install the oil ring spacer, upper rail and lower rail
in this order by hand. Then install the second ring
and topring with a piston ring expander.

ME(SOHC)-81
 CYLINDER BLOCK
MECHANICAL

2. CYLINDER AND PISTON 2) How to measure the inner diameter of each cyl-
inder:
1) The cylinder bore size is stamped on the cylinder
Measure the inner diameter of each cylinder in both
block’s front upper surface.
the thrust and piston pin directions at the heights
CAUTION: shown in the figure, using a cylinder bore gauge.
Measurement should be performed at a temper-
CAUTION:
ature of 20°C (68°F).
Measurement should be performed at a temper-
NOTE: ature of 20°C (68°F).
Standard sized pistons are classified into two
grades, “ A and “6”.These grades should be used Taper:
as a guide line in selecting a standard piston. Standard
0.015 mm (0.0006 in)
Standard diameter; Limit
A: 99.505 - 99.515 mm (3.9175 - 3.91 79 in) 0.050 mm (0.0020 in)
B: 99.495 - 99.515 mm (3.9171 - 3.91 75 in)
Out-of-roundness:
Standard
0.010 mm (0.0004 in)
Limit
0.050 mm (0.0020 in)

k 1 0 (0.39)

45 (1.77)

80 (3.15)

H2M1732C 115 (4.53)

(A) Main journal size mark

(B) Cylinder block RH-LH combination mark
W
(C) #1 cylinder bore size mark Unit: mm (in)
S2M1821A
(D) #2 cylinder bore size mark
(E) #3 cylinder bore size mark
(A) Piston pin direction
(F) #4 cylinder bore size mark
(B) Thrust direction

3) When the piston is to be replaced due to general

or cylinder wear, determine a suitable sized piston
by measuring the piston clearance.

ME(S0HC)-82
 CYLINDER BLOCK
MECHANICAL

4) How to measure the outer diameter of each pis- 6) Boring and honing:
ton: (1) If the value of taper, out-of-roundness, or
Measure the outer diameter of each piston at the cylinder-to-piston clearance measured exceeds
height shown in the figure. (Thrust direction) the specified limit or if there is any damage on
CAUTION: the cylinder wall, rebore it to use an oversize pis-
Measurement should be performed at a temper- ton.
ature of 20°C (68°F). CAUTION:
When any of the cylinders needs reboring, all
Piston grade point H: other cylinders must be bored at the same time,
37.0 mm (1.457 in) and use oversize pistons. Do not perform bor-
Piston outer diameter: ing on one cylinder only, nor use an oversize
Standard piston for one cylinder only.
A: 99.485 - 99.495 mm (2) If the cylinder inner diameter exceeds the
(3.9167 - 3.9171 in) limit after boring and honing, replace the crank-
B: 99.475 - 99.485 mm case.
(3.9163 - 3.9167 in) CAUTION:
0.25 mm (0.0098 in) oversize Immediately after reboring, the cylinder diame-
99.725 - 99.735 mm ter may differ from its real diameter due to tem-
(3.9262 - 3.9266 in) perature rise. Thus, pay attention to this when
0.50 mm (0.0197 in) oversize measuring the cylinder diameter.
99.975 - 99.985 mm
-
(3.9360 3.9364 in) Limit of cylinder enlarging (boring):
0.5 mm (0.020 in)

-- /-
3. PISTON AND PISTON PIN
1) Check the pistons and piston pins for damage,
cracks, and wear and the piston ring grooves for
wear and damage. Replace if defective.
2) Measure the piston-to-cylinder clearance at
each cylinder. <Ref. to ME(S0HC)-82, CYLINDER
AND PISTON, INSPECTION, Cylinder Block.> If
any of the clearances is not within specification, re-
place the piston or bore the cylinder to use an over-
size piston.
5) Calculate the clearance between cylinder and
piston.
CAUTION:
Measurement should be performed at a temper-
ature 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)
Limit
0.050 mm (0.0020 in)

ME(S0HC)-83
 CYLINDER BLOCK
MECHANICAL

3) Make sure that the piston pin can be inserted into 4. PISTON RING
the piston pin hole with a thumb at 20°C (68°F). Re-
1) If the piston ring is broken, damaged, or worn, or
place if defective.
if its tension is insufficient, or when the piston is re-
Standard clearance between piston pin and placed, replace the piston ring with a new one of
hole in piston: the same size as the piston.
Standard CAUTION:
0.004 - 0.008 mm (0.0002 - 0.0003 in) "R" is marked on the end of the top and sec-
Limit ond rings. When installing the rings to the pis-
0.020 mm (0.0008 in) ton, face these marks upward.

B2M1401 G2M0623

The oil ring is a combined ring consisting of

two rails and a spacer in between. When install-
ing, be careful to assemble correctly.

i/
B2M008~

4) Check the circlip installationgroove on the piston

for burr (A). If necessary, remove burr from the
groove so that the piston pin can lightly move.

(A) Top ring

(B) Second ring
(C) Oil ring
(a) R mark
(b) Upper rail
(c) Spacer
(d) Lower rail

5) Check the piston pin circlip for distortion, cracks

and wear.

ME(S0HC)-84
 CYLINDER BLOCK
MECHANICAL

2) Squarely place the piston ring and oil ring in cyl- 5. CONNECTING ROD
inder, and measure the piston ring gap with a thick- 1) Replace the connecting rod, if the large or small
ness gauge. end thrust surface is damaged.
I Unit: mm (in) I 2) Check for bend or twist using a connecting rod
I I Standard 1 Limit I aligner. Replace the connecting rod if the bend or

Top ring 1 0.20- 0.35

10.0079- 0.0138)
I 1.0(0.039) I twist exceeds the limit.
Limit of bend or twist per 100 mm (3.94 in) in
Piston Second 0.35- 0.50 length:
1 .O(0.039)
ring gap rina (0.0138 - 0.0197) 0.10 mm (0.0039 in)
Oil ring 0.20- 0.70
1.5(0.059)
rail (0.0079- 0.0276)

3) Measure the clearance between piston ring and

piston ring groove with a thickness gauge.
CAUTION:
Before measuring the clearance, clean the pis-
ton ring groove and piston ring.

Standard Limit
B2M11848
0.040- 0.080
(0.0016- 0.15 (0.0059)
between pis- (A) Thickness gauge
ton ring and (B) Connecting rod
0.030- 0.070
groove ring
0.0028) 3) Install the connecting rod fitted with bearing to
crankshaft and measure the side clearance (thrust
clearance). Replace the connecting rod if the side
clearance exceeds the specified limit.
Connecting rod side clearance:
Standard
0.070 - 0.330 mm (0.0028 - 0.0130 in)
Limit
0.4 mm (0.016 in)

EN0335

ME(SOHC)-85
 CYLINDER BLOCK
MECHANICAL

4) Inspect the connecting rod bearing for scar, 6) Inspect the bushing at connecting rod small end,
peeling, seizure, melting, wear, etc. and replace if worn or damaged. Also measure the
5) Measure the oil clearance on individual connect- piston pin clearance at the connecting rod small
ing rod bearings by means of plastigauge. If any oil end.
clearance is not within specification, replace the Clearance between piston pin and bushing:
defective bearing with a new one of standard size Standard
or undersize as necessary. (See the table below.)
0 - 0.022 mm (0 - 0.0009 in)
Connecting rod oil clearance: Limit
Standard 0.030 mm (0.0012 in)
0.020 - 0.046 mm (0.0008 - 0.0018 in)
Limit
0.05 mm (0.0020 in)
I Unit: mm (in)
Bearing size

\
Outer diameter of
Bearing (Thickness at cen-
crank pin
ter)

1 Standard

(0.0012)
undersize'
1.486 - 1.498
(0.0585 - 0.0599)
1.504 - 1.512
(0.0592 - 0.0595)
51.984 - 52.000
(2.0466 - 2.0472)
51.954 - 51.970
(2.0454 - 2.0461)
B2M0085

1.514 - 1.522 51.934 - 51.950

(0.0020)
(0.0596 - 0.0599) (2.0446 - 2.0453)
undersize
1.614 - 1.622 51.734 - 51.750
(0.0098)
(0.0635 - 0.0639) (2.0368 - 2.0374)
I undersize

W
EN0337

7) Replacement procedure is as follows:

(1) Remove the bushing from connecting rod
with ST and press.
(2) Press the bushing with ST after applying oil
on the periphery of bushing.
ST 499037100 CONNECTING ROD BUSH-
ING REMOVER AND IN-
STALLER

i ,
I / I \, G2M0177

(3) Make two 3 mm (0.12 in) holes in bushing.

Ream the inside of bushing.
(4) After completion of reaming, clean the bush-
ing to remove chips.

ME(S0HC)-86
 CYLINDER BLOCK
MECHANICAL

6. CRANKSHAFT AND CRANKSHAFT 3) Inspect the crank journal and crank pin for wear.
BEARING If they are not within the specifications, replace the
bearing with a suitable (undersize) one, and re-
i) clean the crankshaft completely and check for place or recondition crankshaft as necessary.
cracks by Of red leadcheck etc.9 and re- When grinding the crank journal or crank pin, finish
place if defective. them to the specified dimensions according to the
2) Measure the crankshaft bend, and correct or re- undersize bearina " to be used.
place if it exceeds the limit.
Crank pin and crank journal:
CAUTION:
Out-of-roundness
If a suitable V-block is not available, install #1
0.020 mm (0.0008 in) or less
and #5 crankshaft bearing on cylinder block,
position crankshaft on these bearings and mea- Taper limit
sure the crankshaft bend using a dial gauge. 0.07 mm (0.0028 in)
Grinding limit
Crankshaft bend limit: 0.250 mm (0.0098 in)
0.035 mm (0.0014 in)

G2M0179
I I

Unit: mm (in)
Crank journal diameter
Crank pin diameter
#I, #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 (0.0787- 0.0792) (0.0787- 0.0793) (0.0587- 0.0591)
terl
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)
Bearing size
undersize 2.017- 2.020 2.019- 2.022 1.510- 1.513
(Thickness at
(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 (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) 42.3520- 2.3527) (2.0368- 2.0374)
0.25(0.0098)
undersize Bearing size 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

ME(S0HC)-87
 CYLINDER BLOCK
MECHANICAL

4) Measure the thrust clearance of crankshaft at

center bearing. If the clearance exceeds the limit,
replace the bearing.
Crankshaft thrust clearance:
Standard
0.030 - 0.115 mm (0.0012 - 0.0045 in)
Limit
0.25 mm (0.0098 in)
r

EN0341

5) Inspect individual crankshaft bearings for signs

of flaking, ‘seizure, melting, and wear.
6) Measure the oil clearance on each crankshaft
bearing by means of plastigauge. If the measure-
ment is not within the specification, replace the de-
fective bearing with an undersize one, and replace
or recondition the crankshaft as necessary.
I Unit: mm (in) 1

Standard 0.010 - 0.030(0.0004-

0.0012)
Limit 0.040(0.0016)

ME(S0HC)-88
 ENGINE TROUBLE IN GENERAL
MECHANICAL

22.Engine Trouble in General

A: INSPECTION
NOTE:
“RANK’ shown in the chart refers to the possibility of reason for the trouble in order (“Very often” to “Rarely”)
A - Very often
B - Sometimes
C - Rarely

TROUBLE PROBLEM PARTS, ETC. I POSSIBLE CAUSE I RANK I

1. Engine will not start.
1) Starter does not turn. 8 Starter Defective battery-to-starter harness B
Defective starter switch C
Defective inhibitor switch or neutral switch C
I Defective starter l B 1
Battery I Poor terminal connection / A I
I Run-down battery I A I
Defective charging system B
b Friction Seizure of crankshaft and connecting rod bearing C
Seized camshaft C
1 Seized or stuck piston and cvlinder I c l
2) Initial combustion does b Starter I Defective starter I C
not occur. Engine control system <Ref. to EN(S0HC)-2, Basic Diagnostic Procedure.> ] A
1 Fuel line I Defective fuel pump and relay
] A I
Lack of or insufficient fuel B
Belt Defective B
Defective timina B
b Compression I Incorrect valve clearance I C 1
I Loosened spark plugs or defective gasket I C 1
I Loosened cylinder head bolts or defective gasket 1 C I
Improper valve seating C
Defective valve stem C
Worn or broken valve sprina B
I Worn or stuck piston rings, cvlinder and piston I C 1
I Incorrect valve timing 1 B 1
1 Improper engine oil (low viscosity)
I B I

ME(S0HC)-89
 ENGINE TROUBLE IN GENERAL
MECHANICAL

TROUBLE PROBLEM PARTS. ETC. I POSSIBLE CAUSE I RANK

3) Initial combustion occur. Enaine control svstem <Ref. to EN(SOHC)-2, Basic Diaqnostic Procedure.> I A
Intake system I Defective intake manifold gasket I B
Defective throttle body gasket B
Fuel line Defective fuel pump and relay C
Clogged fuel line C
Lack of or insufficient fuel B
Belt Defective B
I Defective timing I B
Compression I Incorrect valve clearance I C
Loosened spark plugs or defective gasket C
Loosened cylinder head bolts or defective gasket C
ImDroDer valve seatina C
I Defective valve stem I C
I Worn or broken valve spring I B
I Worn or stuck piston rings, cylinder and piston I C
Incorrect valve timing B
Improper engine oil (low viscosity) B
4) Engine stalls after initial Engine control system <Ref. to EN(SOHC)Q, Basic Diagnostic Procedure.> A
:ombustion. Intake system Loosened or cracked intake duct B
Loosened or cracked PCV hose C
I Loosened or cracked vacuum hose I C
Defective intake manifold gasket B
Defective throttle body gasket B
Dirty air cleaner element C
Fuel line Cloaaed fuel line C
I Lack of or insufficient fuel I B
Belt I Defective I B
I Defective timing I B
Compression Incorrect valve clearance C
Loosened spark plugs or defective gasket C
Loosened cvlinder head bolts or defective aasket C
Improper valve seating C
Defective valve stem C
Worn or broken valve spring B
Worn or stuck piston rings, cylinder and piston C
Incorrect valve timing B
Improper engine oil (low viscosity) B

ME(S0HC)-90
 ENGINE TROUBLE IN GENERAL
MECHANICAL

TROUBLE PROBLEM PARTS, ETC: I POSSIBLE CAUSE I RANK

2. Rough idle and engine Engine control system <Ref. to EN(S0HC)-2, Basic Diagnostic Procedure.> I A
stall Intake system Loosened or cracked intake duct A
Loosened or cracked PCV hose A
Loosened or cracked vacuum hose A
Defective intake manifold aasket B
1 Defective throttle body gasket I B
I Defective PCV valve I C
I Loosened oil filler cap I B
Dirty air cleaner element C
Fuel line Defective fuel pump and relay C
Cloaaed fuel line C
I Lack of or insufficient fuel I B
Belt I Defective timing I C
Compression I incorrect valve clearance I B
Loosened spark plugs or defective gasket B
Loosened cylinder head bolts or defective gasket B
ImDroDer valve seatina B
I Defective valve stem I C
I Worn or broken valve spring I B
I Worn or stuck piston rings, cylinder and piston I B
Incorrect valve timing A
Improper engine oil (low viscosity) B
Lubrication system Incorrect oil pressure B
Defective rocker cover aasket C
Coolina system I Overheating I C
Others I Malfunction of evaporative emission control system I A
Stuck or damaged throttle valve B
Accelerator cable out of adjustment C

ME(S0HC)-91
 ENGINE TROUBLE IN GENERAL
MECHANICAL

TROUBLE -PROBLEM PARTS, ETC. I POSSIBLE CAUSE I RANK I

3. Low output, hesitation and Engine control system <Ref. to EN(S0HC)-2, Basic Diagnostic Procedure.> I A
ioor acceleration Intake system Loosened or cracked intake duct I A
Loosened or cracked PCV hose I A
I*Loosened or cracked vacuum hose 1 B 1
I Defective intake manifold gasket 1 B 1
Defective throttle body gasket B
Defective PCV valve B
Loosened oil filler cap B
Dirty air cleaner element A
Fuel line Defective fuel pump and relav B
I Clogged fuel line 1 B 1
I Lack of or insufficient fuel I C 1
Belt Defective timing B
Compression Incorrect valve clearance B
Loosened spark plugs or defective gasket B
Loosened cvlinder head bolts or defective aasket B
I Improper valve seating 1 B 1
I Defective valve stem I C 1
I Worn or broken valve spring 1 B 1
Worn or stuck piston rings, cylinder and piston C
Incorrect valve timing A
Improper engine oil (low viscosity) B
Lubrication svstem Incorrect oil pressure B
Cooling system Overheating I C
Over coolina I C
Others I Malfunction of evaporative emission control system A
4. Surging Engine control system <Ref. to EN(SOHC)Q, Basic Diagnostic Procedure.> A
Intake system Loosened or cracked intake duct A
Loosened or cracked PCV hose A
I Loosened or cracked vacuum hose I A I
I Defective intake manifold gasket 1 B 1
Defective throttle body gasket B
Defective PCV valve B
Loosened oil filler caD B
I Dirty air cleaner element I B
Fuel line I Defective fuel pump and relav I B
I Clogged fuel line 1 B 1
Lack of or insufficient fuel C
Belt Defective timing B
Compression Incorrect valve clearance B
Loosened spark Dluas or defective aasket C
r* Loosened cvlinder head bolts or defective gasket I C I
I Improper valve seating I C 1
Defective valve stem C
Worn or broken valve spring C
Worn or stuck piston rings, cylinder and piston C
Incorrect valve timina A
I Improperengine oil (low viscosity) I B
Coolina svstem I Overheating I B
Others I Malfunction of evaporative emission control system I C I

ME(S0HC)-92
 ENGINE TROUBLE IN GENERAL
MECHANICAL

TROUBLE PROBLEM PARTS, ETC. [ POSSIBLE CAUSE I RANK

5. Engine does not return to Enaine control svstem <Ref. to ENC3OHC)Q. Basic Diaanostic Procedure.> I A
idle. .Intake svsxm I Loosened or cracked vacuum hose ] A I
Others I Stuck or damaned throttle valve \ A I
I Accelerator cable out of adjustment I B
6. Dieseling (Run-on) Engine control system <Ref. to EN(SOHC)Q, Basic Diagnostic Procedure.> I A
Cooling system Overheating B
Others Malfunction of evaporative emission control system B
7. After burning in exhaust Enaine control svstem <Ref. to EN(SOHC)-2, Basic Diaanostic Procedure.> A
system Intake system I Loosened or cracked intake duct I C 1
I Loosened or cracked PCV hose I C 1
I Loosened or cracked vacuum hose B
Defective PCV valve B
Loosened oil filler cap C
Belt Defective timina B
0 Compression I Incorrect valve clearance 1 B 1
I Loosened spark plugs or defective gasket I C 1
I Loosened cylinder head bolts or defective gasket I C I
Improper valve seating B
Defective valve stem C
Worn or broken valve spring C
Worn or stuck Diston rinas, cvlinder and Diston C
I Incorrect valve timing I A I
Lubrication system I Incorrect oil pressure I C 1
Cooling system Over cooling C
Others Malfunction of evaporative emission control system C
8. Knocking Engine control system <Ref. to EN(SOHC)Q, Basic Diagnostic Procedure.> A
Intake svstem I Loosened oil filler caD B
Belt I Defective timina 1 B 1
Compression I Incorrect valve clearance I C 1
I Incorrect valve timing 1 B 1
Cooling system Overheating A
9. Excessive engine oil con- Intake system Loosened or cracked PCV hose A
sumption Defective PCV valve B
I Loosened oil filler cap I C 1
Compression Defective valve stem I A I
Worn or stuck piston rings, cylinder and piston A
Lubrication system Loosened oil pump attaching bolts and defective B
gasket
Defective oil filter o-rina B
I Defective crankshaft oil seal 1 B 1
Defective rocker cover gasket B
Loosened oil drain plug or defective gasket B
Loosened oil pan fitting bolts or defective oil pan B

ME(S0HC)-93
 ENGINE TROUBLE IN GENERAL

TROUBLE PROBLEM PARTS. ETC. I POSSIBLE CAUSE I RANK 1

10. Excessive fuel consump- 1 Enaine control svstem <Ref. to EN(SOHC)-2, Basic Diaqnostic Procedure.> I A I
1 Intake svstem I Dirty air cleaner element I A I
1 Belt 1 Defective timing 1 B 1
1 Compression Incorrect valve clearance B
Loosened spark plugs or defective gasket C
Loosened cvlinder head bolts or defective gasket C
I ImDroDer valve seating 1 B 1
I Defective valve stem I C 1
Worn or broken valve spring C
Worn or stuck piston rings, cylinder and piston B
Incorrect valve timing B
Lubrication system Incorrect oil Dressure C
1 Cooling system Over coolina I C 1
Others Accelerator cable out of adjustment I B I

ME(S0HC)-94
 ENGINE NOISE
MECHANICAL

23.Engine Noise
A: INSPECTION
Type of sound Condition Possible cause
Valve mechanism is defective.
Incorrect valve clearance
Sound increases as engine
Regular clicking sound Worn valve rocker
speed increases.
Worn camshaft
Broken valve sDrina
Worn crankshaft main bearing
Oil pressure is low.
Worn connecting rod bearing (big end)
Heavy and dull clank
Loose flywheel mounting bolts
Oil pressure is normal.
Damaged engine mounting
Ignition timing advanced
High-pitchedclank (Spark Sound is noticeable when Accumulation of carbon inside combustion chamber
knock) acceleratingwith an overload. Wrong spark plug
Improper gasoline
Sound is reduced when fuel Worn crankshaft main bearing
Clank when engine speed is injector connector of noisy cyl- Worn bearing at crankshaft end of connecting rod
medium (1,000 to 2,000 rpm). inder is disconnected.
(NOTE*)
Sound is reduced when fuel Worn cylinder liner and piston ring
injector connector of noisy cyl- Broken or stuck piston ring
Knocking sound when engine inder is disconnected. 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 Unusually worn valve lifter
fuel injector connector is dis- Worn cam gear
connected in turn. (NOTE*) Worn camshaft journal bore in crankcase
Geakrsound Insufficient generator lubrication
RubbinQ sound Defective generator brush and rotor contact
Gear scream when starting Defective ignition starter switch
engine Worn aear and starter Dinion
Sound like polishing glass with Loose drive belt
a drv cloth Defective water pump shaft
Loss of compression
Hissing sound Air leakage in air intake system, hoses, connections or mani-
folds
Loose timing belt
Timing belt noise Belt contacting case/adjacent part
Valve tappet noise Incorrect valve clearance
NOTE*:
When disconnecting the fuel injector connector, Malfunction Indicator Light (CHECK ENGINE light) illuminates and trouble code
is stored in ECM memory.
Therefore, carry out the CLEAR MEMORY MODE <Ref. to EN(S0HC)-43, OPERATION, Clear Memory Mode.> and INSPEC-
TION MODE <Ref. to EN(S0HC)-40, OPERATION, Inspection Mode.> after connecting the fuel injector connector.

ME(SOHC)-SS
 ENGINE NOISE
MECHANICAL

ME(SOHC)196
EXHAUST
EX(S0HC)
Page
1. General Description .................................................................................... 2
2. Front Exhaust Pipe...................................................................................... 5
3. Center Exhaust Pipe ..........................................................
4. Rear Exhaust Pipe ...................................................................................... 9
5.

a
Muffler ....................................................................................................... 11
 GENERAL DESCRIPTION
EXHAUST

1. General Description
A: COMPONENT

I /-

EN1048

EX(SOHC)-2
 GENERAL DESCRIPTION
EXHAUST

Upper front exhaust pipe cover Muffler (29) Upper rear catalytic converter
CTR Cushion rubber cover
Lower front exhaust pipe cover Rear exhaust pipe (30) Lower rear catalytic converter
CTR Clamp cover
Clamp Upper center exhaust pipe cover (31) Rear catalytic converter
Upper front exhaust pipe cover LH Lower center exhaust pipe cover
Lower front exhaust pipe cover LH Protector Tighfening torque: N-m (kgf-m, fi-lb)
Front exhaust pipe Gasket T l : 8 (0.8, 5.8)
Lower front exhaust pipe cover RH Front oxygen (NF) sensor T2: 13 (1.3, 9.4)
Upper front exhaust pipe cover RH Front catalytic converter T3: 18 (1.8, 13.0)
Gasket Center exhaust pipe T4: 30 (3. 1, 22.4)
Spring Lower front catalytic converter T5: 35 (3.6,26.0)
Chamber cover T6: 48 (4.9, 35.4)
Rear exhaust pipe cover Upper front catalytic converter
Gasket cover
Self-locking nut Rear oxygen sensor

EX(S0HC)-3
 GENERAL DESCRIPTION
EXHAUST

B: CAUTION
Wear working clothing, including a cap, protec-
tive goggles, and protective shoes during opera-
tion.
Remove contamination including dirt and corro-
sion before removal, installation or disassembly.
Keep the disassembled parts in order and pro-
tect them from dust or dirt.
Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary re-
moval, installation, disassembly, and replacement.
Be careful not to burn your hands, because each
part on the vehicle is hot after running.
Be sure to tighten fasteners including bolts and
nuts to the specified torque.
Place shop jacks or safety stands at the specified
points.
Before disconnecting electrical connectors of
sensors or units, be sure to disconnect negative
terminal from battery.

EX(S0HC)-4
 FRONT EXHAUST PIPE
EXHAUST

2. Front Exhaust Pipe 4) Lift-up the vehicle.

5) SeDarate the front and center exhaust pipe as-
A: REMOVAL sembiy from rear exhaust pipe.
1) Disconnect the battery ground cable. WARNING:
Be careful, the exhaust pipe is hot.

I I

2) Disconnect the front oxygen (NF)sensor con- B2M3109

nector. 6 ) Remove the under cover.
I
7) Remove the bolts which hold front exhaust pipe
onto cylinder heads.
CAUTION:
Be careful not to pull down the front and center
exhaust pipe assembly.

3) Disconnect the rear oxygen sensor connector.

1

8) Remove the bolt which installs front and center

exhaust pipe assembly to hanger bracket.

EX(SOHC)-5
 FRONT EXHAUST PIPE
EXHAUST

9) Remove the front and center exhaust pipe as- B: INSTALLATION

sembly from the vehicle. 1) Install the front exhaust pipe to center exhaust
CAUTION: pipe.
Be careful not to let the front and center ex- NOTE:
haust pipe assembly fall off when removing as Replace the gaskets with new ones.
it is quite heavy.
After removing the front and center exhaust Tightening torque:
assembly, do not apply excessive pulling force 30 N.m (3.1 kgf-m, 22.4 ft-lb)
on the rear exhaust pipe.
10) Separate the front exhaust pipe from center ex-
haust pipe.

\\' S2M0923

2) Install the front and center exhaust pipe assem-

bly to the vehicle.
3) Temporarily tighten the bolt which installs front
and center exhaust pipe assembly to hanger brack-
et.
I

B2M3111

4) Tighten the bolts which hold front exhaust pipe

onto cylinder heads.
Tightening torque:
30 N-m (3.1 kgf-m, 22.4 ft-lb)

5 ) Install the under cover.

EX(S0HC)-6
 FRONT EXHAUST PIPE
-
EXHAUST

6) Tighten the bolts which install front and center 10) Connect the front oxygen (NF) sensor connec-
exhaust pipe assembly to rear exhaust pipe. tor.
Tightening torque:
78 N.m (7.8 kgf-m, 73.0 ft-lb)
I

11) Connect the battery ground cable.

B2M3109 1
7 ) Tiahten the bolt which holds front and center ex-
haus pipe assembly to hanger bracket.
Tightening torque:
35 N-m (3.6 kgf-m, 26.0 ft-lb)

C: INSPECTION
1) Make sure there are no exhaust leaks from con-
nections and welds.
2) Make sure there are no holes or rusting.
B2M3111

8) Lower the vehicle.

9) Connect the rear oxygen sensor connector.

EX(SOHC)-7
 CENTER EXHAUST PIPE
EXHAUST

3. Center Exhaust Pipe

A: REMOVAL
After removing the center and front exhaust pipes
as one unit, separate them. Refer to the procedure
for removing the front exhaust pipe. <Ref. to
EX(SOHC)d, REMOVAL, Front Exhaust Pipe.>
B: INSTALLATION
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(S0HC)-6,
INSTALLATION, Front Exhaust Pipe.>
C: INSPECTION
1) Make sure there are no exhaust leaks from con-
nections and welds.
2) Make sure there are no holes or rusting.

EX(S0HC)-8
 REAR EXHAUST PIPE
EXHAUST

4. Rear Exhaust Pipe B: INSTALLATION

NOTE:
A: REMOVAL Replace the gaskets with new ones.
1) Lift-up the vehicle.
1) Install rear exhaust pipe bracket to rubber cush-
2) Separate the rear exhaust pipe from center ex- ion.
haust pipe.
NOTE:
CAUTION:
To facilitate installation, apply a coat of SUBARU
Be careful, the exhaust pipe is hot. CRC to mating area of rubber cushion in advance.
SUBARU CRC (Part No. 004301003)

B2M310E

3) Separate the rear exhaust pipe from muffler.

CAUTION:
Be careful not to pull down rear the exhaust 2) Install the rear exhaust pipe to muffler
pipe. Tightening torque:
48 N.m (4.9 kgf-m, 35.4 ft-lb)

4) Remove rear exhaust pipe bracket from rubber

cushion. 3) Install the rear exhaust pipe to center exhaust
NOTE: pipe.
To facilitate removal, apply a coat of SUBARU Tightening torque:
CRC to pipe bracket in advance. 18 N.m (1.8 kgf-m, 13.0 ft-lb)
SUBARU CRC (Part No. 004301003)

B2M310S
/
S2M056C

EX(S0HC)-9
 REAR EXHAUST PIPE
EXHAUST

C: INSPECTION
1) Make sure there are no exhaust leaks from con-
nections and welds.
2) Make sure there are no holes or rusting.
3) Make sure the cushion rubber is not worn or
cracked.

EX(S0HC)-10
 MUFFLER
EXHAUST

5. Muffler B: INSTALLATION
1) Install in the reverse order of removal.
A: REMOVAL NOTE:
1) Separate the muffler from rear exhaust pipe. Replace the gasket with a new one.
CAUTION:
Be careful, the exhaust pipe is hot. Tightening torque:
48 Nom(4.9 kgf-m, 35.4 ft-lb)

2) Apply a coat of SUBARU CRC to mating area of

rubber cushions in advance.
SUBARU. CRC (Part No. 004301003)
C: INSPECTION
1) Make sure there are no exhaust leaks from con-
nections and welds.
2) Make sure there are no holes or rusting.
3) Make sure the cushion rubber is not worn or
cracked.

G2M0385 I
3) Remove the front, left and right rubber cushion,
and detach muffler assembly.

EX(SOHC)-lI
 MUFFLER
EXHAUST

EX(SOHC)-12
COOLING
co Page
1. General Description .................................................................................... 2
2. Radiator Main Fan System.......................................................................... 9
3. Radiator Sub Fan System ......................................................................... 17
4. Engine Coolant.......................................................................................... 25
5. Water Pump .............................................................................................. 27
6. Thermostat ................................................................................................ 35
7. Radiator..................................................................................................... 37
8. Radiator Cap ............................................................................................. 45
9. Radiator Main Fan and Fan Motor ............................................................ 46
10. Radiator Sub Fan and Fan Motor.............................................................. 48
11. Reservoir Tank .......................................................................................... 50
12. Coolant Filler Tank .................................................................................... 51
13. Engine Cooling System Trouble in General .............................................. 52
 GENERAL DESCRIPTION
COOLING

1. General Description
A: SPECIFICATIONS
Model I Non-turbo I Turbo
Electric fan + Forced engine coolant circulation sys-
Zooling system
tem

rota1 engine coolant capacity

MT: Approx. 7
1 MT: Approx. 7.7
(8.14; 6.78)
AT: Approx. 7.6
(7.29, 6.07) (8.03, 6.69)
TvDe Centrifuaal imDeller type
I Discharge I 20 12 (5.3 US gal, 4.4 Imp qal)/min.
Discharge performance I I Pump speed-total engine
coolant
~~. head
~.
700 rpm - 0.3 mAq (1.O ftAq)
Engine coolant temperature 85°C (185°F)
Discharae 100 8 (26.4 US aal. 22.0 ImD aal)/min.

Discharge performance II
I Pump speed-total engine
coolant head
Engine coolant temperature
I 3,000 rpm - 5.0 mAq (16.4 ftAq)

85°C (185°F)
iNater pump Discharge 200 8 (52.8 US gal, 44.0 Imp gal)/min.
Pump speed-total engine
Discharge performance Ill 6,000 rpm - 23.0 mAq (75.5 ftAq)
coolant head
1 Engine coolant temperature 1 85°C (185°F)
Impeller diameter I 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.O mm (0.039 in)
"Thrust" runout of impeller end I 0.5 mm (0.020 in)
Type I 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)
Main fan 70 W 120 w
Motor
Sub fan 70 W 120 w
qadiator fan
320 mm (12.60 in) x 5 (main fan)
Fan diameter x Blade
320 mm (12.60 in) x 7 (sub fan)
TvDe Down flow. Dressure tvDe
'1 691.5x340x16mm *2 691.5x340x27mm
Core dimensions
(27.22 x 13.39 x 0.63 in) (27.22 x 13.39 x 1.06 in)
Above: 108f15 kPa
3adiator
(1.1+_0.15kg/cm2, 16-12 psi)
Pressure range in which cap valve is open
Below: -1 .O to -4.9 kPa
(-0.01 to -0.05 kdcm', -0.1 to -0.7 psi)
Fins I Corrugated fin type
qeservoir
Capacity 0.5 8 (0.5 US qt, 0.4 Imp qt)
,ank .
'1: Non-turl
*2: Turbo MT model

co-2
 GENERAL DESCRIPTION
COOLING

B: COMPONENT
1. WATER PUMP
NON-TURBO MODEL

H2M2354f

(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)
13) Heater bV-DaSS hose Second 12 (1.2, 8.7)
\ I < .

(4) Thermostat T2: 6.4 (0.65, 4.7)

CO-3
 GENERAL DESCRIPTION
COOLING

TURBO MODEL

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

CO-4
 GENERAL DESCRIPTION
COOLING

2. RADIATOR AND RADIATOR FAN

NON-TURBO MODEL

EN1181

Radiator lower cushion (13) Main fan shroud (23) Radiator lower bracket
Radiator (14) Radiator main fan (24) Radiator drain plug
Radiator upper cushion (15) Main fan motor
Radiator upper bracket (16) ATF hose clamp (AT vehicles only) Tightening torque: “I (kgf-m, ff-lb)
Clamp (17) ATF inlet hose A (AT vehicles only) T7: 3.4 (0.35, 2.5)
Radiator inlet hose (18) ATF outlet hose A (AT vehicles T2: 4.5 (0.46, 3.3)
Engine coolant reservoir tank cap only) T3: 5.0 (0.51, 3.7)
Over flow hose (19) ATF pipe (AT vehicles only) T4: 7.5 (0.76, 5.5)
Engine coolant reservoir tank (20) ATF inlet hose B (AT vehicles only) T5: 72 (7.2, 8.7)
Sub fan shroud (21) ATF outlet hose B (AT vehicles
Radiator sub fan only)
Sub fan motor (22) Radiator outlet hose

CO-5
 GENERAL DESCRIPTION
COOLING

TURBO MODEL

(1) Radiator lower cushion (14) Main fan shroud (26) ATF pipe (AT vehicles only)
(2) Radiator (1 5) Radiator main fan (27) ATF inlet hose B (AT vehicles only)
(3) Radiator upper cushion (16) Radiator main fan motor (28) ATF outlet hose 6 (AT vehicles
(4) Radiator upper bracket (17) Radiator outlet hose only)
(5) Clamp (1 8) Radiator drain plug (29) Radiator under cover
(6) Radiator inlet hose (19) Engine coolant filler tank
(7) Engine coolant reservoir tank cap (20) Engine coolant filler tank cap
(8) Over flow hose (21) Engine coolant hose Tightening torque: N.m (kgf-m, ft-lb)
(9) Engine coolant reservoir tank (22) Radiator lower bracket T I : 3.4 (0.35, 2.5)
(IO) Over flow pipe (23) ATF hose clamp (AT vehicles only) T2: 4.5 (0.46, 3.3)
(11) Sub fan shroud (24) ATF inlet hose A (AT vehicles only) T3: 5.0 (0.51, 3.7)
(12) Radiator sub fan (25) ATF outlet hose A (AT vehicles T4: 7.5 (0.76, 5.5)
(13 ) Radiator sub fan motor only) T5: 12 (1.2, 8.7)

CO-6
 GENERAL DESCRIPTION
COOLING

C: CAUTION
Wear working clothing, including a cap, protec-
tive goggles, and protective shoes during opera-
tion.
Remove contamination including dirt and corro-
sion before removal, installation or disassembly.
Keep the disassembled parts in order and pro-
tect them from dust or dirt.
Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary re-
moval, installation, disassembly, and replacement.
Be careful not to burn your hands, because each
part in the vehicle is hot after running.
Be sure to tighten fasteners including bolts and
nuts to the specified torque.
Place shop jacks or safety stands at the specified
points.
Before disconnecting electrical connectors of
sensors or units, be sure to disconnect negative
terminal from battery.

CO-7
 GENERAL DESCRIPTION
COOLING

D: PREPARATION TOOL
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
499977300 :RANK PULLEY Used for stopping crankshaft pulley when
JVRENCH loosening and tightening crankshaft pulley
bolts. (Turbo model)

82M4157
499977100 X A N K PULLEY Used for stopping crankshaft pulley when
NRENCH loosening and tightening crankshaft pulley
bolts. (Non-turbo model)

82M3870
499207100 ;AMSHAFT Used for removing and installing camshaft
SPROCKET sprocket. (Non-turbo LH side only)
NRENCH

B2M3859
499207400 2AMSHA FT Jsed for removing and installing camshaft
SPROCKET sprocket.
NRENCH

B2M4158

CO-8
 RADIATOR MAIN FAN SYSTEM
COOLING

2. Radiator Main Fan System

A: SCHEMATIC
1. NON-TURBO MODEL

BATTERY
N0.3
T
IGN"
SWlTCH

I AlRC0ND"lNG

EN1061

co-9
 RADIATOR MAIN FAN SYSTEM
COOLING

2. TURBO MODEL

BATTERY

3 -
e SBF-1
-

7 1 1r
N0.17

I in

-
- MOTOR MOTOR
0 0
SUB FAN
RELAYP
@
SUB FAN
RELAYl
@
0

@
O U
MAIN FAN MAIN FAN
RELAYP RELAYl
@ @
i
AIR CONDITIONING RELAY HOLDER

EN1062

co-10
 RADIATOR MAIN FAN SYSTEM
COOLING

B: INSPECTION Vehicle speed is below 19 km/h (12 MPH).

TROUBLE SYMPTOM:
1. NON-TURBO MODEL Radiator main fan does not rotate under the
DETECTING CONDITION: above conditions.
Condition:
Engine coolant temperature is above 95°C
(203°F).

Step Check Yes No

1 CHECK POWER SUPPLY TO MAIN FAN MO- s the voltage more than 10 V? 30 to step 2. i o to step 5.
TOR.
CAUTION:
Be careful not to overheat engine during re-
pair.
1)Turnthe ignition switch to OFF.
2)Disconnectthe connector from the 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 the ignition switch
to ON.
5)Measure the voltage between main fan
motor connector and chassis ground.
Connector & terminal
(F17) No. 2 (+) - Chassis ground (-):
2 CHECK GROUND CIRCUIT OF MAIN FAN s the resistance less than 5 30 to step 3. 3epair the open
MOTOR. 2? :ircuit in harness
1)Turn the ignition switch to OFF. )etween main fan
2)Measure the resistance between main fan notor connector
motor connector and chassis ground. md chassis
Connector & terminal jround.
(F17) No. 1 - Chassis ground:
3 CHECK POOR CONTACT. s there poor contact in main Repair the poor 20 to step 4.
Check poor contact in main fan motor connec- 'an motor connector? :ontact in main fan
tor. motor connector.
4 CHECK MAIN FAN MOTOR. 3oes the main fan rotate? Repair the poor 3eplace the main
Connect the battery positive (+) terminal toter, contact in main fan an motor with a
minal No. 2, and the negative (-) terminal to motor connector. iew one.
terminal No. 1 of main fan motor connector.
5 CHECK POWER SUPPLY TO MAIN FAN RE. s the voltage more than 10 V? Go to step 6. 30 to step 7.
LAY.
1)Turnthe ignition switch to OFF.
2)Remove the main fan relay from A/C relay
holder.
3)Measure the voltage between main fan relay
terminal and chassis ground.
Connector & terminal
(F66) No. 26 (- i )Chassis ground (-):
6 CHECK POWER SUPPLY TO MAIN FAN RE, Is the voltage more than 10 V? Go to step 10. 30 to step 9.
LAY.
. 1)Turn the ignition switch to ON.
2)Measure the voltage between main fan relay
terminal and chassis ground.
Connector & terminal
(F66) No. 28 (+) - Chassis ground (-):
7 CHECK 20 A FUSE. Is the fuse blown-out? Replace the fuse. 30 to step 8.
1)Remove 20 A fuse from A/C relay holder.
2)Check condition of fuse.

co-11
 i

RADIATOR MAIN FAN SYSTEM

COOLING

Step Check Yes No

B CHECK POWER SUPPLY TO A/C RELAY Is the voltage more than 10 V? ?epair the open Repair the open
HOLDER 20 A FUSE TERMINAL. :ircuit in harness circuit in harness
Measure the voltage of harness between A/C 2etween 20 A fuse between main fuse
relay holder 20 A fuse terminal and chassis and main fan relay box connector and
ground. :erminal. 20 A fuse terminal.
Connector & terminal
(F27) No. 1 (+) - Chassis ground (-):
9 CHECK FUSE. Is the fuse blown-out? Replace the fuse. Repair the open
1)Turn the ignition switch to OFF. circuit in harness
2)Remove the fuse No. 18 from joint box. between main fan
3)Check condition of fuse. relay and ignition
switch.
10 CHECK MAIN FAN RELAY. Is the resistance more than 1 So to step 11. Replace the main
1)Turn the ignition switch to OFF. MR? fan relay.
2)Remove the main fan relay.
3)Measure the resistance of main fan relay.
Terminal
NO. 26 - NO. 25:
11 CHECK MAIN FAN RELAY. Is the resistance less than 1 Go to step 12. Replace the main
1)Connect the battery to terminals No. 27 and R? fan relay.
No. 28 of main fan relay.
2)Measure the resistance of main fan relay.
Terminal
NO. 26 - NO.25:
12 CHECK HARNESS BETWEEN MAIN FAN Is the resistance less than 1 Go to step 13. Repair the open
RELAY TERMINAL AND MAIN FAN MOTOR R? circuit in harness
CONNECTOR. between main fan
Measure the resistance of harness between motor connector
main fan motor connector and main fan relay and main fan relay
terminal. terminal.
Connector & terminal
(F17) NO. 2 - (F66) NO. 25:
13 CHECK HARNESS BETWEEN MAIN FAN Is the resistance less than 1 Go to step 14. Repair the open
RELAY AND ECM. R? circuit in harness
1)Turn the ignition switch to OFF. between main fan
2)Disconnect the connector from ECM. relay and ECM.
3)Measure the resistance of harness between
main fan relay connector and ECM connector.
Connector & terminal
(F66) NO. 27 - (8134) NO. 3:
14 CHECK POOR CONTACT. Is there poor contact in con- Repair the poor Contact with SOA
Check poor contact in connector between main nector between main fan motor contact connector. service.
fan and ECM. and ECM?

NOTE:
Inspection by SOA service is required, because
probable cause is deterioration of multiple parts.

co-12
 RADIATOR MAIN FAN SYSTEM
COOLING

2. TURBO MODEL TROUBLE SYMPTOM:

Radiator main fan does not rotate under the
DETECTING CONDITION: above conditions.
Condition: Radiator main fan does not rotate at high speed
Engine coolant temperature is above 96"c when the following conditions are both met:
(205°F). (1) Engine coolant temperature is above 90°C
A/C compressor is rotated. (194°F)
Vehicle speed is below 19 km/h (12 MPH). (2) A/C is ON

Step No
CHECK OPERATION OF RADIATOR. 30 to step 3.
1)Run the engine at idle. (Vehicle stationary) otate?
2)Turn the A/C switch to OFF.
3)Warm the engine coolant temperature over
96°C (205°F).
CHECK OPERATION OF RADIATOR. )oes the main radiator fan Radiator main fan 30 to step 17.
1)Turnthe A/C switch ON at condition of step otate faster when A/C com- system is okay.
1. )ressor is operated?
CHECK POWER SUPPLY TO MAIN FAN MO- s the voltage more than 10 V? Go to step 4. 30 to step 7.
TOR.
CAUTION:
Be careful not to overheat engine during re-
pair.
1)Turn the ignition switch to OFF.
2)Disconnect the connector from main fan
motor.
3)Start the engine, and warm it up until engine
coolant temperature increases over 96°C
(205"F).
4)Stop the engine and turn ignition switch to
ON.
5)Measure the voltage between main fan
motor connector and chassis ground.
Connector & terminal
(F17) No. 3 (+) - Chassis ground (-):
I CHECK GROUND CIRCUIT OF MAIN FAN s the resistance less than 5 Go to step 5. Repair the open
MOTOR. 3? circuit in harness
1)Turn the ignition switch to OFF. between main fan
2)Measure the resistance between main fan motor connector
motor connector and chassis ground. and chassis
Connector & terminal ground.
(F17) No. 1 - Chassis ground:
1 CHECK POOR CONTACT. s there poor contact in main Repair the poor Go to step 6.
Check poor contact in main fan motor connec- :an motor connector? contact in main fan
tor. motor connector.
i CHECK MAIN FAN MOTOR. Ioes the main fan rotate? Repair the poor Replace the main
Connect the battery positive (+) terminal to ter. contact in main fan fan-motor with a
minal No. 3, and the negative (-) terminal to motor connector. new one.
terminal No. 1 of main fan motor connector.
r CHECK POWER SUPPLY TO MAIN FAN s the voltage more than 10 V? Go to step 8. Go to step 9.
RELAYl.
. 1)Turnthe ignition switch to OFF.
2)Remove the main fan relayl from A/C relay
holder.
3)Measure the voltage between main fan
relayl terminal and chassis ground.
Connector & terminal
(F66) No. 26 (+) - Chassis ground (-):

CO-13
 RADIATOR MAIN FAN SYSTEM
COOLING

Step Check Yes No

I
3 CHECK POWER SUPPLY TO MAIN FAN Is the voltage more than 10 V? Go to step 12. Go to step 11.
RELAYl.
1)Turnthe ignition switch to ON.
2)Measure the voltage between main fan
relayl terminal and chassis ground.
Connector & terminal
(F66) No. 28 (+) - Chassis ground (-):
3 CHECK 20 A FUSE. Is the fuse blown-out? Replace fuse. Go to step 10.
1)Removethe 20 A fuse from N C relay holder
2)Check the condition of fuse.
IO CHECK POWER SUPPLY TO A/C RELAY Is the voltage more than 10 V? Repair the open Repair the open
HOLDER 20 A FUSE TERMINAL. circuit in harness circuit in harness
Measure the voltage of harness between N C between 20 A fuse between main fuse
relay holder 20 A fuse terminal and chassis and main fan relay box connector and
ground. terminal. 20 A fuse terminal
Connector & terminal
(F27) No. 1 (+) - Chassis ground (-):
I1 CHECK FUSE. Is the fuse blown-out? Replace the fuse. Repair the open
1)Turnthe ignition switch to OFF. circuit in harness
2)Remove the fuse No. 18 from joint box. between main fan
3)Check the condition of fuse. relay and ignition
switch.
12 CHECK MAIN FAN RELAY1. Is the resistance more than 1 Go to step 13. Replace the main
1)Turnthe ignition switch to OFF. MR? fan relayl .
2)Remove the main fan relayl .
3)Measure the resistance of main fan relayl .
Terminal
NO. 26 - NO.25:
13 CHECK MAIN FAN RELAY. Is the resistance less than 1 Go to step 14. Replace the main
1)Connect the battery to terminals No. 27 and R? fan relayl .
No. 28 of main fan relayl .
2)Measure the resistance of main fan relayl.
Terminal
NO. 26 - NO. 25:
14 CHECK HARNESS BETWEEN MAIN FAN Is the resistance less than 1 Go to step 15. Repair the open
RELAYl TERMINAL AND MAIN FAN MOTOR R? circuit in harness
CONNECTOR. between main fan
Measure the resistance of harness between motor connector
main fan motor connector and main fan relayl and main fan
terminal. relayl terminal.
Connector & terminal
(F17) NO. 3 - (F66) NO. 25:
15 CHECK HARNESS BETWEEN MAIN FAN Is the resistance less than 1 Go to step 16. Repair the open
RELAY1 AND ECM. R? circuit in harness
1)Turnthe ignition switch to OFF. between main fan
2)Disconnect the connector from ECM. relayl and ECM.
3)Measure the resistance of harness between
main fan relayl connector and ECM connector
Connector & terminal
(F66) NO. 27 -(8137) NO. 17:
16 CHECK POOR CONTACT. Is there poor contact in con- Repair the poor Contact with SOA
. Check poor contact in connector between main nector between main fan motor contact connector. service.
fan and ECM. and ECM?

CO-14
 RADIATOR MAIN FAN SYSTEM
COOLING

Step Check Yes No

7 CHECK POWER SUPPLY TO MAIN FAN MO- ;the voltage more than 10 V? 30 to step 18. io to step 20.
TOR.
CAUTION:
Be careful not to overheat engine during re-
pair.
1)Turn the ignition switch to OFF.
2)Disconnect the connector from main fan
motor.
3)Start the engine, and warm it up until engine
coolant temperature increases over 96°C
(205°F).
4)Turn the AJC switch ON.
5)Measure the voltage while A/C compressor
is rotating.
6)Measure the voltage between main fan
motor connector and chassis ground.
Connector & terminal
(F17) No. 2 (+) - Chassis ground (-):
8 CHECK POOR CONTACT. j there poor contact in main 3epair the poor Go to step 19.
Check poor contact in main fan motor connec- i n motor connector? :ontact in main fan
tor. notor connector.
9 CHECK MAIN FAN MOTOR. bes the main fan rotate? Repair the poor 3eplace the main
Connect the battery positive (+)terminal toter. :ontact in main fan an motor with a
minal No. 2, and negative (-) terminal to termi- notor connector. iew one.
nal No. 1 of main fan motor connector.
!O CHECK POWER SUPPLY TO MAIN FAN j the voltage more than 10 V? So to step 21. o
; to step 22.
RELAY2.
1)Turn the ignition switch to OFF.
2)Remove the main fan relay2 from A/C relay
holder.
3)Measure the voltage between main fan
relay2 terminal and chassis ground.
Connector & terminal
(F30) No. 23 (+) - Chassis ground (-):
!1 CHECK POWER SUPPLY TO MAIN FAN the voltage more than 10 V? Go to step 25. 30 to step 24.
RELAY2.
1)Turn the ignition switch to ON.
2)Measure the voltage between main fan
relay2 terminal and chassis ground.
Connector & terminal
(F30) No. 21 (+) - Chassis ground (-):
!2 CHECK 20 A FUSE. s the fuse blown-out? Replace the fuse. 30 to step 23.
1)Removethe 20 A fuse from A/C relay holder
2)Check condition of fuse.
!3 CHECK POWER SUPPLY TO N C RELAY s the voltage more than 10 V? Repair the open 3epair the open
HOLDER 20 A FUSE TERMINAL. circuit in harness :ircuit in harness
Measure the voltage of harness between AJC between 20 A fuse letween main fuse
relay holder 20 A fuse terminal and chassis and main fan relay )ox connector and
ground. terminal. ?O A fuse terminal
Connector & terminal
(F27) No. 1 (+) - Chassis ground (-):
24 . CHECK FUSE. s the fuse blown-out? Replace the fuse. 3epair the open
1)Turn the ignition switch to OFF. :ircuit in harness
2)Remove the fuse No. 18 from joint box. 3etween main fan
3)Check the condition of fuse. 'elay and ignition
Switch.

CO-15
 RADIATOR MAIN FAN SYSTEM
COOLING

Step Check Yes No

25 CHECK MAIN FAN RELAYS. Is the resistance more than 1 30 to step 26. Replace the main
1)Turnthe ignition switch to OFF. MQ? fan relay2.
2)Remove the main fan relay2.
3)Measure the resistance of main fan relay2.
Terminal
NO.23 - NO. 24:
26 CHECK MAIN FAN RELAYS. Is the resistance less than 1 30 to step 27. Replace the main
1)Connectthe battery to terminals No. 21 and R? fan relay2.
No. 22 of main fan relayl.
2)Measure the resistance of main fan relay2.
Terminal
NO. 23 - NO. 24:
27 CHECK HARNESS BETWEEN MAIN FAN Is the resistance less than 1 30 to step 28. Repair the open
RELAY2TERMINAL AND MAIN FAN MOTOR R? circuit in harness
CONNECTOR. between main fan
Measure the resistance of harness between motor connector
main fan motor connector and main fan relay2 and main fan
terminal. relay2 terminal.
Connector & terminal
(F17) NO. 2 - (F30) NO. 24:
28 CHECK HARNESS BETWEEN MAIN FAN Is the resistance less than 1 Go to step 29. Repair the open
RELAY2 AND ECM. R? circuit in harness
1)Turnthe ignition switch to OFF. between main fan
2)Disconnect the connector from ECM. relay2 and ECM.
3)Measure the resistance of harness between
main fan relay2 connector and ECM connector
Connector & terminal
(F30) NO.22 - (8134) NO. 28:
29 CHECK POOR CONTACT. Is there poor contact in con- Repair poor con- Contact with SOA
Check poor contact in connector between main nector between main fan motor tact connector. service.
fan and ECM. and ECM?

NOTE:
Inspection by SOA service is required, because
probable cause is deterioration of multiple parts.

CO-16
 RADIATOR SUB FAN SYSTEM
COOLING

3. Radiator Sub Fan System

A: SCHEMATIC
1. NON-TURBO MODEL

I SUB FAN

EN1061

CO-17
 RADIATOR SUB FAN SYSTEM
COOLING

2. TURBO MODEL

SBF-1
3 03-

9
No.17

MOTOR AIR CONDITIONING RELAY HOLDER

EN1062

CO-18
 RADIATOR SUB FAN SYSTEM
COOLING
~~

6 : INSPECTION A/C switch is turned ON.

Vehicle speed is below 19 km/h (12 MPH).
1. NON-TURBO MODEL Condition (2):
NOTE: Engine coolant temperature is above 100°C
System for A/C equipped vehicles only. (212°F).
A/C switch is turned OFF.
DETECTING CONDITION: Vehicle speed is below 19 km/h (12 MPH).
Condition (1): TROUBLE SYMPTOM:
Engine coolant temperature is below 95°C Radiator sub fan does not rotate under condi-
(203" F). tions (1) and (2) above.
~~ ~

Step Check Yes No

I CHECK POWER SUPPLY TO SUB FAN MO- Is the voltage more than 10 V? 30 to step 2. 30 to step 5.
TOR.
CAUTION:
Be careful not to overheat engine during re-
pair.
1)Turnthe ignition switch to OFF.
2)Disconnect the connector from the sub fan
motor and main 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 the ignition switch
to ON.
5)Measure the voltage between sub fan motor
connector and chassis ground.
Connector & terminal
(F16) No. 2 (+) - Chassis ground (-):
2 CHECK GROUND CIRCUIT OF SUB FAN Is the resistance less than 5 30 to step 3. Repair the open
MOTOR. R? Zircuit in harness
1)Turnthe ignition switch to OFF. Detween sub fan
2)Measure the resistance between sub fan motor connector
motor connector and chassis ground. and chassis
Connector & terminal ground.
(F16) No. 1 - Chassis ground:
3 CHECK POOR CONTACT. Is there poor contact in sub fan 3epair the poor Go to step 4.
Check poor contact in sub fan motor connec- motor connector? :ontact in sub fan
tor. notor connector.
1 CHECK SUB FAN MOTOR. Does the sub fan rotate? Fiepair the poor Replace the sub
Connect the battery positive (+) terminal toter :ontact in sub fan fan motor with a
minal No. 2, and negative (-) terminal to termi- notor connector. new one.
nal No. 1 of sub fan motor connector.
5 CHECK POWER SUPPLY TO SUB FAN RE- Is the voltage more than 10 V? So to step 6. Go to step 7.
LAY.
1)Turn the ignition switch to OFF.
2)Remove the sub fan relay from A/C relay
holder.
3)Measure the voltage between sub fan relay
terminal and chassis ground.
Connector & terminal
~
(F28)No. 18 (+) - Chassis ground (-):
6 CHECK POWER SUPPLY TO SUB FAN RE- Is the voltage more than 10 V? Go to step 10. Go to step 9.
LAY.
1)Turnthe ignition switch to ON.
2)Measure the voltage between sub fan relay
terminal and chassis ground.
Connector & terminal
(F28)No. 20 (+) - Chassis ground (-):

co-19
 RADIATOR SUB FAN SYSTEM
COOLING
~ ~ ~

Step Check Yes No

7 CHECK 20 A FUSE. Is the fuse blown-out? Replace the fuse. Go to step 8.
1)Remove the 20 A fuse from N C relay holder.
2)Check the condition of fuse.
3 CHECK POWER SUPPLY TO A/C RELAY Is the voltage more than 10 V? Repair the open Repair the open
HOLDER 20 A FUSE TERMINAL. circuit in harness circuit in harness
Measure the voltage of harness between A/C between 20 A fuse between main fuse
relay holder 20 A fuse terminal and chassis and sub fan relay box connector and
ground. terminal. 20 A fuse terminal
Connector & terminal
(F27) No. 3 (+) - Chassis ground (-):
3 CHECK FUSE. Is the fuse blown-out? Replace the fuse. Repair the open
1)Turn the ignition switch to OFF. circuit in harness
2)Remove the fuse No. 17 from joint box. between sub fan
3)Check the condition of fuse. relay and ignition
switch.
IO CHECK SUB FAN RELAY. Is the resistance more than 1 Go to step 11. Replace the sub
1)Turn the ignition switch to OFF. MR? fan relay.
2)Measure the resistance of sub fan relay.
Terminal
NO. 17-NO. 18:
I1 CHECK SUB FAN RELAY. Is the resistance less than 1 Go to step 12. Replace the sub
4)Connect the battery to terminals No. 20 and Q? fan relay.
No. 19 of sub fan relay.
2)Measure the resistance of sub fan relay.
Terminal
No. 17-NO. 18:
12 CHECK HARNESS BETWEEN SUB FAN RE- Is the resistance less than 1 Go to step 13. Repair the open
LAY TERMINAL AND SUB FAN MOTOR Q? circuit in harness
CONNECTOR. between sub fan
Measure the resistance of harness between motor and sub fan
sub fan motor connector and sub fan relay ter- relay connector.
minal.
Connector & terminal
-
(F16) NO. 2 (F28) NO. 17:
13 CHECK HARNESS BETWEEN SUB FAN RE- Is the resistance less than 1 Go to step 14. Repair the open
LAY AND ECM. Q? circuit in harness
1)Turn the ignition switch to OFF. between sub fan
2)Disconnect the connector from ECM. relay and ECM.
3)Measure the resistance of harness between
sub fan relay connector and ECM connector.
Connector & terminal
(F28) NO. 19 - (8134) NO. 12:
14 CHECK POOR CONTACT. Is there poor contact in con- Repair poor con- Contact with SOA
Check poor contact in connnector between sub nector between sub fan motor tact connector. service.
fan and ECM. and ECM?

NOTE:
Inspection by SOA service is required, because
probable cause is deterioration of multiple parts.

co-20
 RADIATOR SUB FAN SYSTEM
COOLING
~~

2. TURBO MODEL TROUBLE SYMPTOM:

Radiator sub fan does not rotate under the above
DETECTING CONDITION: conditions.
Condition: Radiator sub fan does not rotate at high speed
Engine coolant temperature is above 96"c when the following conditions are both met:
(205°F). (1) Engine coolant temperature is above 90°C
A/C compressor is rotated. (194°F)
Vehicle speed is below 19 km/h (12 MPH).
(2) A/C is ON

Step Check Yes No

CHECK OPERATION OF RADIATOR. Ioes the radiator sub fan Go to step 2. $0to step 3.
1)Run the engine at idle. (Vehicle stationary) otate?
2)Turn the A/C switch to OFF.
3)Warm the engine coolant temperature over
96°C (205°F).
! CHECK OPERATION OF RADIATOR. Ioes the radiator sub fan Radiator main fan ;o to step 17.
1)Turnthe A/C switch ON at condition of step otate faster when A/C corn- system is okay.
1. iressor is operated?
I CHECK POWER SUPPLY TO SUB FAN MO- s the voltage more than 10 V? Go to step 4. ;o to step 7.
TOR.
CAUTION:
Be careful not to overheat engine during re-
pair.
1)Turn the ignition switch to OFF.
2)Disconnect the connector from sub fan
motor.
3)Start the engine, and warm it up until engine
coolant temperature increases over 96°C
(205°F).
4)Stop the engine and turn the ignition switch
to ON.
5)Measure the voltage between sub fan motor
connector and chassis ground.
Connector & terminal
(F16) No. 3 (+) - Chassis ground (-):
I CHECK GROUND CIRCUIT OF SUB FAN s the resistance less than 5 Go to step 5. 3epair the open
MOTOR. n? :ircuit in harness
1)Turnthe ignition switch to OFF. letween sub fan
2)Measure the resistance between sub fan notor connector
motor connector and chassis ground. ind chassis
Connector & terminal ]round.
(F16) No. 1 - Chassis ground:
CHECK POOR CONTACT. s there poor contact in sub fan Repair the poor 30 to step 6.
Check poor contact in sub fan motor connec- notor connector? contact in sub fan
tor. motor connector.
i CHECK MAIN FAN MOTOR. Ioes the main fan rotate? Repair the poor 3eplace the sub
Connect the battery positive (+) terminal to ter. contact in sub fan an motor with a
minal No. 3, and negative (-) terminal to termi- motor connector. iew one.
nal No. 1 of sub fan motor connector.
r CHECK POWER SUPPLY TO SUB FAN s the voltage more than 10 V? Go to step 8. 50 to step 9.
RELAYl.
. 1)Turn the ignition switch to OFF.
2)Remove the sub fan relayl from A/C relay
holder.
3)Measure the voltage between sub fan relayl
terminal and chassis ground.
Connector & terminal
(F28)No. 7 (+) - Chassis ground (-):

co-21
 E

RADIATOR SUB FAN SYSTEM

COOLING

Step Check Yes No

B CHECK POWER SUPPLY TO SUB FAN Is the voltage more than 10 V? i o to step 12. Go to step 11.
RELAYl.
1)Turn the ignition switch to ON.
2)Measure the voltage between sub fan relayl
terminal and chassis ground.
Connector & terminal
(F28) No. 5 (+) - Chassis ground (-):
9 CHECK 20 A FUSE. Is the fuse blown-out? leplace the fuse. Go to step 10.
1)Removethe 20 A fuse from AIC relay holder
2)Check the condition of fuse.
IO CHECK POWER SUPPLY TO A/C RELAY Is the voltage more than 10 V? lepair the open Repair the open
HOLDER 20 A FUSE TERMINAL. :ircuit in harness circuit in harness
Measure the voltage of harness between AIC ,etween 20 A fuse between sub fuse
relay holder 20 A fuse terminal and chassis md sub fan relay box connector and
ground. erminal. 20 A fuse terminal
Connector & terminal
(F27) No. 3 (+) - Chassis ground (-):
11 CHECK FUSE. Is the fuse blown-out? leplace the fuse. Repair the open
1)Turn the ignition switch to OFF. circuit in harness
2)Remove the fuse No. 17 from joint box. between sub fan
3)Check the condition of fuse. relayl and ignition
switch.
12 CHECK SUB FAN RELAYl. Is the resistance more than 1 i o to step 13. Replace the sub
1)Turn the ignition switch to OFF. MQ? fan relayl.
2)Remove the main fan relayl.
3)Measure the resistance of sub fan relayl .
Terminal
NO. 7 - NO. 8:
13 CHECK SUB FAN RELAYl . Is the resistance less than 1 i o to step 14. Replace the sub
1)Connect the battery to terminals No. 6 and R? fan relayl .
No. 5 of sub fan relayl.
2)Measure the resistance of sub fan relay.
Terminal
NO. 7- NO. 8:
14 CHECK HARNESS BETWEEN SUB FAN Is the resistance less than 1 $0to step 15. Repair the open
RELAYl TERMINAL AND SUB FAN MOTOR R? :ircuit in harness
CONNECTOR. between sub fan
Measure the resistance of harness between motor connector
sub fan motor connector and sub fan relayl m d sub fan relayl
terminal. terminal.
Connector & terminal
(F16) NO. 3 - (F28) NO. 8:
15 CHECK HARNESS BETWEEN SUB FAN Is the resistance less than 1 ;o to step 16. Repair the open
RELAYl AND ECM. R? :ircuit in harness
1)Turnthe ignition switch to OFF. Detween sub fan
2)Disconnect the connector from ECM. relayl and ECM.
3)Measure the resistance of harness between
sub fan relayl connector and ECM connector.
Connector & terminal
(F28) NO. 6 - (8137) NO. 17:
16 CHECK POOR CONTACT. Is there poor contact in con- lepair poor con- Sontact with SOA
. Check poor contact in connector between sub nector between sub fan motor 3Ct connector. service.
fan and ECM. and ECM?

co-22
 RADIATOR SUB FAN SYSTEM
COOLING

Step Check Yes No

7 CHECK POWER SUPPLY TO SUB FAN MO- s the voltage more than 10 V? 30 to step 18. 30 to step 20.
TOR.
CAUTION:
Be careful not to overheat engine during re
pair.
1)Turnthe ignition switch to OFF.
2)Disconnect the connector from sub fan
motor.
3)Start the engine, and warm it up until engine
coolant temperature increases over 96°C
(205°F).
4)Turn the A/C switch ON.
5)Measure the voltage while A/C compressor
is rotating.
6)Measure the voltage between sub fan motor
connector and chassis ground.
Connector & terminal
-
(F16) No. 2 (+) Chassis ground (-):

----I
8 CHECK POOR CONTACT. s there poor contact in sub fan Repair the poor 30 to step 19.
Check the poor contact in sub fan motor con- notor connector? contact in sub fan
nector. motor connector.
9 CHECK SUB FAN MOTOR. loes the main fan rotate? Repair the poor Replace the sub
Connect the battery positive (+) terminal toter contact in sub fan Ian motor with a
minal No. 2, and negative (-)terminal to termi motor connector. new one.

P
nal No. 1 of sub fan motor connector.
!O CHECK POWER SUPPLY TO SUB FAN s the voltage more than 10 V? Go to step 21. Go to step 22.
RELAY2.
1)Turnthe ignition switch to OFF.
2)Remove the sub fan relay2 from N C relay
holder.
3)Measure the voltage between sub fan relay2
terminal and chassis ground.
Connector & terminal
(F29) No. 18 (+) - Chassis ground (-):
!l CHECK POWER SUPPLY TO SUB FAN s the voltage more than 10 V? Go to step 23. Go to step 24.
RELAYS.
1)Turn the ignition switch to ON.
2)Measure the voltage between sub fan relay2
terminal and chassis ground.
Connector & terminal
(F29) No. 20 (+) - Chassis ground (-):
!2 CHECK 20 A FUSE. s the fuse blown-out? Replace fuse. Go to step 23.
1)Remove the 20 A fuse from A/C relay holdet

i
2)Check the condition of fuse.
!3 CHECK POWER SUPPLY TO A/C RELAY s the voltage more than 10 V? Repair the open Repair the open
HOLDER 30 A FUSE TERMINAL. circuit in harness circuit in harness
Measure the voltage of harness between A/C between 20 A fuse between sub fuse
relay holder 20 A fuse terminal and chassis and sub fan relay box connector ana
ground. terminal. 20 A fuse terminal
Connector & terminal
-
(F27) No. 3 (+) Chassis ground (-):
!4 . CHECKFUSE. s the fuse blown-out? Replace the fuse. Repair the open
1)Turnthe ignition switch to OFF. circuit in harness
2)Remove the fuse No. 17 from joint box. between sub fan
3)Check the condition of fuse. relay and ignition
switch.

CO-23
 RADIATOR SUB FAN SYSTEM
COOLING

Step Check Yes No

25 CHECK SUB FAN RELAY2. Is the resistance more than 1 So to step 26. Replace the sub
1)Turn the ignition switch to OFF. MR? fan relay2.
2)Remove the sub fan relay2.
3)Measure the resistance of sub fan relay2.
Terminal
NO. 18-N0. 17:
26 CHECK MAIN FAN RELAY2. Is the resistance less than 1 30 to step 27. Replace the sub
1)Connect the battery to terminals No. 19 and Q? fan relay2.
No. 20 of sub fan relay2.
2)Measure the resistance of sub fan relay2.
Terminal
NO. 18 - NO. 17:
27 CHECK HARNESS BETWEEN SUB FAN Is the resistance less than 1 30 to step 28. Repair the open
RELAY2 TERMINAL AND SUB FAN MOTOR ZZ? circuit in harness
CONNECTOR. between sub fan
Measure the resistance of harness between motor connector
sub fan motor connector and sub fan relay2 and sub fan relay2
terminal. terminal.
Connector & terminal
(F16) NO. 2 -(F29) NO. 17:
28 CHECK HARNESS BETWEEN SUB FAN Is the resistance less than 1 30 to step 29. Repair the open
*RELAY2 AND ECM. n? circuit in harness
1)Turn the ignition switch to OFF. between sub fan
2)Disconnect the connector from ECM. relay2 and ECM.
3)Measure the resistance of harness between
sub fan relay2 connector and ECM connector.
Connector & terminal
(F29) NO. 19 - (8137) NO. 28:
29 CHECK POOR CONTACT. Is there poor contact in con- 3epair the poor Contact with SOA
Check the poor contact in connector between nector between sub fan motor :ontact connector. service.
sub fan and ECM. and ECM?

NOTE:
Inspection by SOA service is required, because
probable cause is deterioration of multiple parts.

CO-24
 ENGINE COOLANT
COOLING

4. Engine Coolant 3) Warm-up engine completely for more than five

minutes at 2.000 to 3,000 rpm.
A: REPLACEMENT 4) If the engine coolant level drops in radiator, add
the engine coolant to filler neck position.
1. DRAINING OF ENGINE COOLANT 5) If the engine coolant level drops from upper level
1) Lift-up the vehicle. of reservoir tank, add the engine coolant to the up-
2) Remove the under cover. per level.
3) Remove the drain cock to drain engine coolant 6) Attach the radiator cap and f - e w ~ o itank
r cap
into container. properly.
NOTE:
Remove the radiator cap so that engine coolant will
drain faster.

2. FILLING OF ENGINE COOLANT

1) Fill engine coolant into radiator up to the filler
neck position.
Coolant capacity (fill up to “FULL” level):
Non-turbo AT model
Approx. 6.9 8 (7.29 US qt, 6.07 Imp qt)
Non-turbo MT model
Approx. 7 8 (7.4 US qt, 6.2 Imp qt)
Turbo AT model
Approx. 7.6 8 (8.03 US qt, 6.69 Imp qt)
Turbo MT model
Approx. 7.7 8 (8.74 US 9t, 6.78 Imp 9t)
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 Cool-
ant, since other coolant may cause corrosion.
2) Fill engine coolant into reservoir tank up to the
upper level.

CO-25
 ENGINE COOLANT
COOLING

B: INSPECTION 2. PROCEDURE TO ADJUST THE CON-

CENTRATION OF THE COOLANT
1. RELATIONSHIP OF SUBARU COOLANT
CONCENTRATION AND FREEZING TEM- To adjust the concentration of the coolant accord-
PERATURE ing to temperature, find the proper fluid concentra-
tion in the above diagram and replace the
The concentration and safe operating temperature necessary amount of coolant with an undiluted so-
of the SUBARU coolant is shown in the diagram. lution of SUBARU genuine coolant (concentration
Measuring the temperature and specific gravity of 50%).
the coolant will provide this information. The amount of coolant that should be replaced can
[Example] be determined using the diagram.
If the coolant temperature is 25°C (77°F) and its [Example]
specific gravity is 1.054, the concentration is 35% Assume that the coolant concentration must be in-
(point A), the safe operating temperature is -14°C creased from 25% to 40%. Find point A, where the
(7°F) (point B), and the freezing temperature is - 25% line of coolant concentration intersects with
20°C (-4°F) (point C). the 40% curve of the necessary coolant concentra-
-
x
._
> Safe operating temperature
tion, and read the scale on the vertical axis of the
graph at height A. The quantity of coolant to be
z drained is 2.1 liters (2.2 US qt, 1.8 Imp qt). Drain
CDE
0s
EO
Concentration 2.1 liters (2.2 US qt, 1.8 Imp qt) of coolant from the
$8 of coolant
cooling system and add 2.1 liters (2.2 US qt, 1.8
i%z Imp qt) of the undiluted solution of SUBARU cool-
1.100
ant.
1.090
If a coolant concentration of 50% is needed, drain
1.080 all the coolant and refill with the undiluted solution
1.070
only.
1.060

1.050

1.040

1.030

1.020
i4
- 3
0-
Necessary concentration
of coolant
1.010

1.000

Coolant temperature "C (OF) ~ 2 ~ 3 1 2 8 ~

Concentration of coolant in
the vehicle cooling system %

Concentration of coolant in vehicle

and quantity to be drained B2M3129A

CO-26
 WATER PUMP
COOLING

5. Water Pump 6) Disconnect the radiator outlet hose and heater

hose from the water pump.
A: REMOVAL
1. NON-TURBO MODEL
1) Disconnect the ground cable from the battery.

7) Lower the vehicle.

8) Remove the air intake duct.

2) Lift-up the vehicle.

3) Remove the under cover.
4) Drain the engine coolant completely.
<Ref. toCO-25, DRAINING OF ENGINE COOL-
ANT, REPLACEMENT, Engine Coolant.>
5) Disconnect the connectors from the radiator
main fan (A) and sub fan (B) motors.
I
\ w y / w EN0063

9) Disconnect the over flow hose.

10) Remove the reservoir tank.

 WATER PUMP
COOLING

11) Remove the radiator main fan and sub fan as- 17) Remove the tensioner bracket.
semblies. <Ref. to CO-46, REMOVAL, Radiator
Main Fan and Fan Motor.> and <Ref. to CO-48,
REMOVAL, Radiator Sub Fan and Fan Motor.>
12) Remove V-belts.
<Ref. to ME(S0HC)-43, REMOVAL, V-belt.>
13) Remove the timing belt.
<Ref. to ME(S0HC)-47, TIMING BELT, REMOV-
AL, Timing Belt Assembly.>
14) Remove the automatic belt tension adjuster.

H2M2380

18) Remove the left-hand belt cover No. 2.

15) Remobe the belt idler No. 2.

19) Disconnect the heater hose from the water

pump-
20) Remove the water pump.

16) Remove the left-hand camshaft sprocket by us-

ing ST.
ST 499207100 CAMSHAFT SPROCKET
WRENCH

CO-28
 WATER PUMP
COOLING

2. TURBO MODEL 12) Disconnect the over flow hose.

13) Remove the reservoir tank.
WARNING:
The radiator is pressurized. Wait until engine
cools down before working on the radiator.
1) Set the vehicle on the lift.
2) Disconnect the ground cable from the battery.

3) Lift-up the vehicle.
4) Remove the under cover.
5) Drain the engine coolant completely. <Ref. to
CO-25, DRAINING OF ENGINE COOLANT, RE-
PLACEMENT, Engine Coolant.>
6) Remove the radiator under cover.
7) Disconnect the connectors from the radiator
main fan and sub fan motors.
8) Remove the bolt which installs water by-pass
pipe of oil cooler onto oil pump.
14) Remove the radiator main fan and sub fan as-
sem-blies. <Ref. to CO-46, REMOVAL, Radiator
Main Fan and Fan Motor.> and <Ref. to CO-48,
REMOVAL, Radiator Sub Fan and Fan Motor.>
15) Remove the V-belts. <Ref. to ME(D0HC TUR-
BO)-44, REMOVAL, V-belt.>
16) Remove the timing belt. <Ref. to ME(D0HC
TURBO)-48, REMOVAL, Timing Belt Assembly.>
17) Remove the automatic belt tension adjuster
(A) *
18) Remove the belt idler (6).
19) Remove the belt idler No. 2 (C).

20) Remove the camshaft position sensor. <Ref. to

FU(D0HC TURBO)-31, REMOVAL, Camshaft Po-
/ - S2MQ02i
sition Sensor.>
9) Disconnect the radiator outlet hose (A) and heat-
er hose (B) from the water pump.
10) Disconnect the water by-pass hose (C) and oil
cooler hose (D).

11) Lower the vehicle.

CO-29
 WATER PUMP
COOLING

21) Remove the left-hand camshaft sprockets by 6: INSTALLATION

using ST.
ST 499207400 CAMSHAFT SPROCKET 1. NON-TURBO MODEL
WRENCH 1) Install the water pump onto the left-hand cylinder
head.
CAUTION:
Replace gasket with a new one.
When installing water pump, tighten bolts in
two stages in alphabetical sequence as shown
in figure.
Tightening torque:
First:
12 N.m (1.2 kgf-m, 8.7 ft-lb)
Second:
22) Remove the tensioner bracket. 12 N.m (1.2 kgf-m, 8.7 ft-lb)

S2M0760A

23) Remove the left-hand belt cover No. 2. 2) Install the tensioner bracket.
Tightening torque:
25 N.m (2.5 kgf-m, 18.1 ft-16)
I

24) Disconnect the heater hose from the water

pump.
25) Remove the water pump.

CO-30
 WATER PUMP
COOLING

3) Install the left-hand belt cover No. 2.
Tightening torque:
5 N-m (0.5 kgf-m, 3.6 ff-16)
8) Install V-belts. <Ref. to ME(S0HC)-43, INSTAL-
LATION, V-belt.>
9) Install the radiator main fan and sub fan motor
assemblies. <Ref. to CO-47, INSTALLATION, Ra-
diator Main Fan and Fan Motor.> and <Ref. to CO-
48, INSTALLATION, Radiator Sub Fan and Fan
Motor.>
10) Install the reservoir tank.

--.-
4) Install the left-hand camshaft sprockets by using
SI.
ST 4992707100 CAMSHAFT SPROCKET
WRENCH
Tightening torque: 11) Connect the over flow hose.
78 N m (8.0 kgf-m, 57.9 ff-lb)

12) Install the air intake duct.

5) Install the belt idler No. 2.
Tightening torque:
39 N.m (4.0 kgf-m, 28.9 ff-lb)

13) Lift-up the vehicle.

6) Install the automatic belt tension adjuster which

tension rod is holded with pin. <Ref. to ME(S0HC)-
48, AUTOMATIC BELT TENSION ADJUSTER AS-
SEMBLY AND BELT IDLER, INSTALLATION,
Timing Belt Assembly.>
7) Install the timing belt. <Ref. to ME(S0HC)-49,
TIMING BELT, INSTALLATION, Timing Belt As-
sembly.>

CO-31
 WATER PUMP
COOLING

14) Connect the radiator outlet hose and heater 2. TURBO MODEL
hose to the water pump.
1) Install the water pump onto the left-hand cylinder
head.
CAUTION:
Replace gasket with a new one.
When installing water pump, tighten bolts in
two stages in alphabetical sequence as shown
in figure.
Tightening torque:
First:
12 N.m (1.2 kgf-m, 8.7 ff-16)
Second:
15) Connect the connectors to radiator main fan (A) 12 N-m (1.2 kgf-m, 8.7 ff-lb)
and sub fan (B) motors. ,

2) Install the tensioner bracket.

Tightening torque:
25 N.m (2.5 kgf-m, 18.1 ff-16)

16) Install the under cover.

17) Lower the vehicle.
18) Connect the battery ground cable.
3) Install the left-hand belt cover No. 2.
Tightening torque:
5 N.m (0.5 kgf-m, 3.6 ff-lb)

19) Fill coolant. <Ref. to CO-25, FILLING OF EN-

GINE COOLANT, REPLACEMENT, Engine Cool-
ant.>

CO-32
 WATER PUMP
COOLING

4) Install the left-handcamshaft sprockets by using 12) Install the reservoir tank.
ST.
ST 499207400 CAMSHAFT SPROCKET
WRENCH
Tightening torque:
98 N-m (10.0 kgf-m, 72.4 ft-lb)

13) Connect the over flow hose.

14) Lift-up the vehicle.
15) Connect the radiator outlet hose (A) and heater
hose (B) to the water pump.
2M1161A 16) Connect the water by-pass hose (C) and oil
cooler hose (D).
5) Install the camshaft position sensor. <Ref. to
FU(D0HC TURBO)-31, INSTALLATION, Cam-
shaft Position Sensor.>
6) Install the belt idler No. 2 (C).
7) Install the belt idler (B).
8) Install the automatic belt tension adjuster (A)
which has a tension rod held by a pin. <Ref. to
ME(D0HC TURBO)-50, AUTOMATIC BELT TEN-
SION ADJUSTER ASSEMBLY AND BELT IDLER,
INSTALLATION, Timing Belt Assembly.>
Tightening torque:
39.4 N-m (4.0 kgf-m, 28.9 ft-16) 17) Installthe bolt which installs water by-pass pipe
onto the oil pump.
I I

-
S2M1

9) Install the timing belt. <Ref. to ME(D0HC TUR- S2M0027 1

BO)-51, TIMING BELT, INSTALLATION, Timing 18) Connect the connectors to radiator main fan
Belt Assembly.> and sub fan motors.
10) Install the V-belts. <Ref. to ME(D0HC TUR- 19) Install the radiator under cover.
BO)-44, INSTALLATION, V-belt.> 20) Install the under cover.
11) Install the radiator main fan and sub fan motor 21) Lower the vehicle.
assemblies. <Ref. to CO-47, INSTALLATION, Ra-
diator Main Fan and Fan Motor.> and <Ref. to CO-
48, INSTALLATION, Radiator Sub Fan and Fan
Motor.>

CO-33
 WATER PUMP
COOLING

22) Connect the battery ground cable. C: INSPECTION

1) Check the water pump bearing for smooth rota-
tion.
2) Check the 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)
I

23) Fill coolant. <Ref. to CO-25, FILLING OF EN-

GINE COOLANT, REPLACEMENT, Engine Cool-
ant.>

4) Check the clearance between impeller and

pump case.
Clearance between impeller and pump case:
Standard
0.5 - 0.7 mm (0.020 - 0.028 in)
Limit
1.0 mm (0.039 in)

5) After water pump installation, check pulley shaft

for engine coolant leaks. If leaks are noted, replace
the water pump assembly.

CO-34
 THERMOSTAT
COOLING

6. Thermostat 6) Remove the thermostat cover and gasket, and

pull out the thermostat.
A: REMOVAL
1) Lift-up the vehicle.
2) Remove the under cover.
3) Drain engine coolant completely. <Ref. to CO-
25, DRAINING OF ENGINE COOLANT, RE-
PLACEMENT, Engine Coolant.>

IIA / / I B: INSTALLATION
1) Install the thermostat in the water pump, and in-
stall the thermostat cover together with a gasket.
CAUTION:
When reinstalling the thermostat, use a new
gasket.
4) Disconnect the radiator outlet hose from the The thermostat must be installed with the jig-
thermostat cover. gle pin (A) facing to front side.
Non-Turbo model 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)

5 ) Disconnect the radiator outlet hose.

Turbo model

2) Fill coolant. <Ref. to CO-25, FILLING OF EN-

GINE COOLANT, REPLACEMENT, Engine Cool-
ant.>

CO-35
 THERMOSTAT

C: INSPECTION
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 wa-
ter. Raise water temperature gradually, and mea-
sure 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 temper-
ature distribution. The measurement should be to
the specification.
Starts to open:
76 - 80°C (769- 7 76°F)
Fully opens:
97°C (796°F)

(A) Thermometer
(B) Thermostat

CO-36
 RADIATOR
COOLING

7. Radiator 6) Disconnect the ATF cooler hoses (B) from the

radiator. (AT vehicles only)
A: REMOVAL
1. NON-TURBO MODEL
1) Disconnect the battery ground cable.

S2M2150A

7) Lower the vehicle.

8) Disconnect the over flow hose.

2) Lift-up the vehicle.

3) Drain engine coolant completely. <Ref. to CO-
25, DRAINING OF ENGINE COOLANT, RE-
PLACEMENT, Engine Coolant.>
4) Disconnect the connectors of radiator main fan
(A) and sub fan (B) motor.

9) Remove the reservoir tank.

10) Disconnect the radiator inlet hose from the en-

gine.

5) Disconnect the radiator outlet hose (A) from ther-

mostat cover.

CO-37
 RADIATOR
COOLING

1 1) Remove the radiator upper brackets. 2. TURBO MODEL

WARNING:
The radiator is pressurized. Wait until engine
cools down before working on the radiator.
1) Set the vehicle on the lift.
2) Disconnect the battery ground cable.

12) Detach the power steering hose from thc the

clip on the radiator.

3) Lift-up the vehicle.

4) Remove the under cover.
5 ) Drain the engine coolant completely. <Ref. to
CO-25, DRAINING OF ENGINE COOLANT, RE-
PLACEMENT, Engine Coolant.>
6) Remove the radiator under cover. (AT vehicles
only)
13) While slightly lifting radiator, slide it to left.
14) Lift the radiator up and away from the vehicle.

EN1062

CO-38
 RADIATOR
COOLING

7) Disconnect the connectors of radiator main fan 11) Remove the air intake duct.
(A) and sub fan motor (B).

12) Disconnect the over flow hose.

13) Remove the reservoir tank.

8) Disconnect the ATF cooler hoses from the radi-

ator. (AT vehicles only) 14) Remove the V-belt covers.

I EN0102 I
9) Disconnect the radiator outlet hose from the
thermostat cover.

EN0107
I

IO) Lower the vehicle.

CO-39
 RADIA T 0 R
COOL1NG
~~

15) Disconnect the radiator inlet hose (A) and cool-

ant filler tank hose (B) from the radiator.

16) Remove the radiator upper brackets.

17) While slightly lifting radiator, slide it to left.

18) Lift the radiator up and away from the vehicle.

CO-40
 RADIATOR
COOLING

B: INSTALLATION 4) Attach the power steering hose to the radiator.

1. NON-TURBO MODEL
1) Attach the radiator mounting cushions to holes
on the vehicle.

5 ) Connect the radiator inlet hose.

2) Install the radiator while fitting radiator pins to

cushions.
NOTE:
Fit pins on lower side of radiator into cushions on
body side:

6 ) Install the reservoir tank.

Tightening torque:
7.5 N-m (0.76 kgf-m, 5.5 ff-lb)

2933

3) Install the radiator brackets and tighten the bolts.

Tightening torque:
12 Nom(1.2 kgf-m, 8.7 ff-lb)

7) Lift-up the vehicle.

8) Connect the radiator outlet hose (A).
9) Connect the ATF cooler hoses (6). (AT vehicles
only)

31

S2M2150A

CO-41
 RADIATOR
COOLING

10) Connect the connectors to the radiator main fan 2. TURBO MODEL
motor (A) and sub fan motor (B). 1) Attach the radiator mounting cushions to holes
on the vehicle.

2) Install the radiator brackets and tighten bolts.

Tightening torque:
12 N.m (1.2 kgf-m, 8.7 ft-lb)

11 Install the under cover.

12) Lower the vehicle.
13) Connect the battery ground cable.

3) Connect the radiator inlet hose (A) and coolant

filler tank hose (B).

14) Fill coolant. <Ref. to CO-25, FILLING OF EN-

GINE COOLANT, REPLACEMENT, Engine Cool-
ant.>
15) Check ATF level. <Ref. to AT-9, INSPECTION,
Automatic Transmission Fluid.>

CO-42
 RADIATOR
COOLING

4) Install the reservoir tank. 9) Connect the radiator outlet hose.

Tightening torque:
7.5 N.m (0.76 kgf-m, 5.5 ft-lb)

10) Install the radiator under cover. (AT vehicle

5 ) Connect the over flow hose.

6) Lift-up the vehicle.
7) Connect the connectors to the radiator main fan
motor(A) and sub fan motor(B).
1

-u

EN1062

11) Install the under cover.

12) Lower the vehicle.
13) Install the V-belt covers.

14) Install the air intake duct.

8) Connect the ATF cooler hoses. (AT vehicles
only)

EN0102

CO-43
 RADIATOR

15) Connect the battery ground cable. C: INSPECTION

1) Remove the radiator cap, top off radiator, and at-
tach tester to the radiator in place of cap.
Non-Turbo model

16) Fill coolant. <Ref. to CO-25, FILLING OF EN-

GINE COOLANT, REPLACEMENT, Engine Cool-
ant.>
Turbo model

2) Apply a pressure of 157 kPa (1.6 kg/cm2,23 psi)

to the radiator to check if:
(1) Engine coolant leaks at/around radiator.
(2) Engine coolant leaks at/around hoses or
connections.
CAUTION:
Engine should be off.
Wipe engine coolant from check points in ad-
vance.
Be careful to prevent engine coolant from
spurting out when removing tester.
Be careful also not to deform filler neck of ra-
diator when installing or removing tester.

CO-44
 RADIATOR CAP
COOLING

8. Radiator Cap
A: INSPECTION
1) Attach the radiator cap to the tester.

G2M0223

2) Increase pressure until the tester gauge pointer

stops. Radiator cap is functioning properly if it holds
the service limit pressure for five to six seconds.
Standard pressure:
93 - 123 kPa (0.95 -1.25 k # c d , 14 - 18
Psi)
Service limit pressure:
83 kPa (0.85 k # c d , 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-45
 RADIATOR MAIN FAN AND FAN MOTOR
COOLING

9. Radiator Main Fan and Fan 7) Remove the air intake duct. (Turbo model)
Motor
A: REMOVAL
1) Disconnect the battery ground cable.

8) Disconnect the over flow hose.

2) Lift-up the vehicle.

3) Remove the under cover.
4) Remove the radiator under cover. (AT vehicle
only) .

9) Remove the over flow pipe. (Turbo model)

10) Remove the reservoir tank.

I
-
EN1063

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

11) Remove the radiator main fan motor assembly.

6) Lower the vehicle.

CO-46
 RADIATOR MAIN FAN AND FAN MOTOR
COOLING

B: INSTALLATION 2) Remove the nut which holds fan itself onto the
Install in the reverse order of removal. fan motor and shroud assembly.
NOTE:
When the main fan motor assembly cannot be in-
stalled as is, loosen the sub fan motor assembly
securing bolts to install it.

EN0120

3) Remove the bolts which install fan motor onto

the shroud.

Tightening torque:
7.5 N-m (0.76 kgf-m, 5.5 I?-lb)

1
D: ASSEMBLY
Assemble in the reverse order of disassembly.
Tightening torque:
4.4 N-m (0.45 kgf-m, 3.3 M b )
C: DISASSEMBLY

\yg
1) Remove the clip which holds motor connector
onto the shroud.

EN0121

Tightening torque:
3.4 N.m (0.35 kgf-m, 2.5 ft-lb)
S7M119.17

EN0120

CO-47
 RADIATOR SUB FAN AND FAN MOTOR
COOLING

10.Radiator Sub Fan and Fan 10) Remove the radiator sub fan shroud through
the under side of vehicle.
Motor
A: REMOVAL
1) Disconnect the battery ground cable.

B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
2) Lift-up the vehicle. 4.9 N.m (0.50 kgf-m, 3.6 ft-16)
3) Remove the under cover.
4) Remove the radiator under cover.
5) Disconnect the connector of sub fan motor.

6) Lower the vehicle.

7) Remove the air intake duct. (Turbo model)

8 ) Remove the bolts which hold sub fan shroud to

the radiator.
9) Remove the over flow pipe. (Turbo model)

CO-48
 RADIATOR SUB FAN AND FAN MOTOR
COOLING

C: DISASSEMBLY D: ASSEMBLY
1) Remove the clip which holds motor harness onto Assemble in the reverse order of disassembly.
the shroud. Tightening torque:
4.4 N.m (0.45 kgf-m, 3.3 ft-lb)

2) Remove the nut which holds fan itself onto the

fan motor and shroud assembly.
Tightening torque:
3.4 N-m (0.35 kgf-m, 2.5 ft-lb)

3) Remove the bolts which install fan motor onto EN0123

the shroud.

CO-49
 RESERVOIR TANK
COOLING

11.Reservoir Tank
A: REMOVAL
1) Disconnect the over flow hose from the radiator
filler neck position.
2) Remove the bolts which install reservoir tank
onto the radiator main fan shroud.
3) Remove the reservoir tank.

B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
7.5 N.m (0.76 kgf-m, 5.5 ff-lb)

C: INSPECTION
Make sure the engine coolant level is between full
and low.

CO-50
 COOLANT FILLER TANK
COOLING

12.Coolant Filler Tank B: INSTALLATION

1) Install in the reverse order of removal.
A: REMOVAL
Tightening torque:
WARNING: T I : 19 N.m (1.9 kgf-m, 13.7 ft-lb)
The radiator is pressurized. Wait until engine T2: 21 N-m (2.1 kgf-m, 15.2 ft-lb)
cools down before working on the radiator.
1) Drain the coolant about 3.0 (3.2 US qt, 2.6 Imp
qt). <Ref. to CO-25, DRAINING OF ENGINE
COOLANT, REPLACEMENT, Engine Coolant.>
2) Remove the air cleaner upper cover and air in-
take boot. <Ref. to IN(D0HC TURBO)-7, REMOV-
AL, Air Cleaner.>
3) Remove the air cleaner element.
4) Disconnect the engine coolant hoses from the
coolant filler tank.

5) Remove the bolts and nut which install coolant

filler tank. 2) Fill engine coolant. <Ref. to CO-25, FILLING OF
6) Disconnect the engine coolant hose which con- ENGINE COOLANT, REPLACEMENT, Engine
nects the under side of coolant filler tank. Coolant.>
7) Remove the coolant filler tank.

CO-51
 ENGINE COOLING SYSTEM TROUBLE IN GENERAL
COOLING

13.Engine Cooling System Trouble in General

A: INSPECTION
Trouble Possible cause Corrective action
Replenish engine coolant, inspect for leakage, and
a. Insufficient engine coolant
repair.
I b. Loose timing belt Repair or replace timing belt tensioner.
I c. Oil on drive belt Replace.
d. Malfunction of thermostat Replace.
1
e. Malfunction of water DumD
I .
Replace.
f. Clogged engine coolant passage Clean.
Inspect and repair ignition control system.
<Ref. to EN(SOHC)Q, Basic Diagnostic Procedure.> or
g. Improper ignition timing
<Ref. to EN(D0HC TURBO)Q, PROCEDURE, Basic
Diagnostic Procedure.>
h. Clogged or leaking radiator Clean or repair, or replace.
Over-heating i. Improper engine oil in enaine coolant Replace engine coolant.
Inspect and repair fuel injection system.<Ref. to
EN(SOHC)Q, Basic Diagnostic Procedure.> or <Ref. to
j. Aidfuel mixture ratio too lean
EN(D0HC TURBO)-2, PROCEDURE, Basic Diagnostic
Procedure.>
k. Excessive back pressure in exhaust system Clean or replace.
I 1. Insufficientclearance between piston and cylinder Adjust or replace.
m. Slipping clutch Repair or replace.
n. Dragging brake Adjust.
0.Improper transmission oil
P. Defective thermostat Replace.
I q. Malfunction of electric fan
Inspect radiator fan relay, engine coolant temperature
sensor or radiator motor and replace there.

3ver-cooling
I a. Atmospheric temperature extremely low Partly cover radiator front area.
b. Defective thermostat Replace.
a. Loosened or damaged connecting units on hoses
b. Leakage from water Dump Replace.
c. Leakage from water pipe Repair or replace.
Engine coolant
d. Leakage around cylinder head gasket Retighten cylinder head bolts or redace aasket.
eaks.
I e. Damaged or cracked cylinder head and crankcase Repair or replace.
f. Damaged or cracked thermostat case Repair or replace.
g. Leakage from radiator Repair or replace.
a. Defective drive belt Replace.

Uoise
I b. Defective radiator fan Replace.
I c. Defective water pump bearing Replace water pump.
I d. Defective water pump mechanical seal Replace water pump.

CO-52
LUBR ICAT10N
LU
Page
1. General Description .................................................................................... 2
2. Oil Pressure System ................................................................................... 7
3. Engine Oil.................................................................................................. 10
4. Oil Pump ................... ............................................................................... 12
5. Oil Pan and Strainer.................................................................................. 17
6. Oil Pressure Switch ................................................................................... 22
7. Engine Oil Cooler ...................................................................................... 25
8. Engine Oil Filter......................................................................................... 27
9. Engine Lubrication System Trouble in General......................................... 28
 GENERAL DESCRIPTION
LUBRICATION

1. General Description
A: SPECIFICATIONS
Model I Non-Turbo I Turbo I
~bricationme iod Forced lubrication
Pump type Trochoid type
Inner rotor 9
Number of teeth
Outer rotor 10
78x9mm 78xlOmm
Outer rotor diameter x thickness
(3.07 x 0.35 in) (3.07 x 0.39 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 STANDARD 0.02 - 0.07 mm (0.0008 - 0.0028 in)
pump case LIMIT 0.12 mm (0.0047 in)
3il pump Case clearance between outer rotor and I STANDARD I 0.10 - 0.175 mm (0.0039 - 0.0069 in) I
pump case I LIMIT I 0.20 mm (0.0079 in) I
- pressure 98 kPa (1.O kg/cm2, 14 psi)
700 rpm Discharge 4.2 8 (4.4 US qt, 4.6 8 (4.9 US qt,
- quantity 3.7 Imp qt)/min. 4.0 Imp qt)/min.
Capacity at
80°C (176OF) - pressure 294 kPa (3.0 kg/cm2, 43 psi)
5,000 rpm Discharge 42.0 8 (11.10 US gal, 47.0 8 (12.41 US gal,
- quantity
I I I
9.24 ImD. aalVmin.
" r
10.33 ImD aalVmin.
Ir "

490 kPa 588 kPa

Relief valve operation pressure
(5.0 kg/cm2,71 psi) (6.0 kg/cm2,85 psi)
Type I Full-flow filter type I
Filtration area 1,000 cm2 (155 sq in)
3il filter By-pass valve opening pressure 157 kPa (1.6 kg/cm2,23 psi)
Outer diameter x width 80 x 70 mm (3.15 x 2.76 in)
Oil filter to engine thread size I M 20 x 1.5 I
qelief valve (on rocker shaft) operation pressure I 69 kPa (0.7kg/cm2,10 psi) I
Type Immersed contact point type
3il pressure Working voltage - wattage 12 V - 3.4 W or less
switch Warning light activation pressure 14.7 kPa (0.15 ka/cm2. 2.1 Dsi)
1 Proof pressure I More than 981 kPa (10 kg/cm2, 142 D S ~ ) 1
4.0 8 4.5 8
3il capacity (at replacement)
(4.2 US qt, 3.5 Imp qt) (4.8 US qt, 4.0 Imp qt)

LU-2
 GENERAL DESCRIPTION
LUBRICATION

B: COMPONENT
1. NON-TURBO MODEL

B2M22351

(14) Oil filler duct (27) Gasket

(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)
(IO) Oil filter (23) Oil pan 77: 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-3
 GENERAL DESCRIPTION
LUBRICATION

2. TURBO MODEL

(1) Plug (15) Oil pump ASSY (29) O-ring

(2) Washer (16) Oil pressure switch
(3) Relief valve spring (17) Oil filler duct Tightening torque: N.m (kgf-m, ft-lb)
(4) Relief valve (18) O-ring T1: 5 (0.5, 3.6)
(5) Oil seal (19) Cylinder head cover T2: 5 (0.5, 3.6)
(6) Oil pump case (20) Baffle plate T3: 6.4 (0.65, 4.7)
(7) Inner rotor (21) O-ring T4: lO(1.0, 7.0)
(8) Outer rotor (22) Oil strainer T5: 44.1 (4.5, 32.5)
(9) On pump cover (23) Gasket T6: 69 (7.0, 4.7)
(IO) Oil filter (24) Oil level gauge guide l7: 6.4 (0.65, 50.6)
(11) Connector (25) Oil pan T8: 25 (2.5, 18.1)
(12) Water by-pass pipe (26) Oil level gauge T9: 44 (4.5, 33)
(13) Oil cooler (27) Metal gasket TlO: 54 (5.5, 40)
(14) O-ring (28) Drain plug

LU-4
 GENERAL DESCRIPTION
LUBRICATION

C: CAUTION
Wear working clothing, including a cap, protec-
tive goggles, and protective shoes during opera-
tion.
Remove contamination including dirt and corro-
sion before removal, installation or disassembly.
Keep the disassembled parts in order and pro-
tect them from dust or dirt.
Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary re-
moval, installation, disassembly, and replacement.
Be careful not to burn your hands, because each
part in the vehicle is hot after running.
Be sure to tighten fasteners including bolts and
nuts to the specified torque.
Place shop jacks or safety stands at the specified
points.
Before disconnecting electrical connectors of
sensors or units, be sure to disconnect negative
terminal from battery.

LU-5
 GENERAL DESCRIPTION
LUBR CATION

D: PREPARATION TOOL
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
499977100 CRANK PULLEY Used for stopping rotation of crankshaft pulley
WRENCH when loosening and tightening crankshaft pulley
bolt. (Non-Turbo model)

B2M387(
499977300 CRANK PULLEY Used for stopping rotation of crankshaft pulley
WRENCH when loosening and tightening crankshaft pulley
bolt. (Turbo model)

02M4157
498547000 31L FILTER Used for removing and installing oil filter.
NRENCH

499587100 3 L SEAL Used for installing oil pump oil seal.

NSTALLER

B2M3875

LU-6
 OIL PRESSURE SYSTEM
LUBRlCAT1ON

2. Oil Pressure System

A: SCHEMATIC
1. NON-TURBO MODEL

BATTERY
N0.5
3 c

COMBINATION
METER

A: @

OIL PRESSURE
SWITCH

EN1046

LU-7
 OIL PRESSURE SYSTEM
LUBRICATION

2. TURBO MODEL

BATTERY
NOS n
IGNITION
RELAY

?OMBINATION
METER

OIL PRESSURE
SWITCH

EN1047

LU-8
 OIL PRESSURE SYSTEM
L UBR I CAT10N

B: INSPECTION
Step Check Yes No
1 CHECK COMBINATION METER. Does the warning lights go on' Go to step 2. Repair or replace
1)Turnthe ignition switch to ON.(engine OFF) the combination
2)Check other warning lights. meter. <Ref. to IDI.
4, INSPECTION,
Combination
Meter System.>
2 CHECK HARNESS CONNECTOR BETWEEN Is the voltage more than 10 V? Replace the oil Go to step 3.
COMBINATION METER AND OIL PRES- pressure switch.
SURE SWITCH.
1)Turn the ignition switch to OFF.
2)Disconnect the connector from the oil pres-
sure switch.
3)Turn the ignition switch ON.
4)Measure the voltage of harness between the
combination meter connector and chassis
ground.
Connector & terminal
-
(El 1) No. 1 Chassis ground:
3 CHECK COMBINATION METER. Is the resistance less than 10 Replace the har- Repair or replace
1)Turn the ignition switch to OFF. n? 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. A7- NO. 62:

LU-9
 ENGINE OIL
LUBRICATION

3. Engine Oil B: REPLACEMENT

1) Drain the engine oil by loosening engine oil drain
A: INSPECTION Plug.
1) Park the vehicle on a level surface. Non-Turbo model
2) Remove the oil level gauge and wipe it clean.
3) Reinsert the level gauge all the way. Be sure that
the level gauge is correctly inserted and properly
orientated.
4) Remove it again and note the reading. If the en-
gine 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, en-
gine oil level may show in the range between the
“ F line and the notch mark. This is caused by ther- Turbo model
mal 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.
Oil level gauge
Engine oil filler cap
\ I

Upper level
About 1 .Of
(1.1us qt,
0.9 Imp qt)
Lower level

(A) Gasket
(B) Drain plug
B2M3883A
2) Open the engine oil filler cap for quick draining of
the engine oil.
I Oiyevel gauge
Engine oil filler cap
I

Upper level
About 1 .Of
(1.1 us qt,
0.9 Imp qt)
Lower level

B2M3883A

3) Replace the drain Dlua aasket.

LU-10
 ENGINE OIL
LUBRICATION

4) Tighten the engine oil drain plug after draining Engine oil capacity: (Turbo model)
engine oil. Upper level
4.5 Q (4.8 US qt, 4.0 Imp qt)
Tightening torque:
44 N.m (4.5 kgf-my33 it-lb)
Lower level
3.5 8 (3.7 US qty3.1 Imp qt)
Non-Turbo model
r- ~ I

SAE Viscosity No. and Applicable Temperature

('C) -30 -20 -15 0 15 30 40
( O F ) -22 -4 5 32 59 86 104

02M3885A
I I ' . ,. , I
The proper viscosity helps the vehicle to get good
Turbomodel 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. designat-
ed by SUBARU.

\t=/ my
NOTE:
If the vehicle is used in desert areas with very high
EN0010 temperatures or for other heavy duty applications,
the following viscosity oils may be used: API classi-
(A) Gasket fication: SJ or SH
(B) Drain plug SAE Viscosity No.: 30, 40, 1OW-50, 2OW-40, 20W-
50.
5) Fill the engine oil through filler pipe up to upper
6) Close the engine oil filler cap.
point on level gauge. Make sure that the vehicle is
placed level when checking oil level. Use engine oil 7) Start the engine and warm it up for a time.
of proper quality and viscosity, selected in accor- 8) After the engine stops, recheck the oil level. If
dance with the table in figure. necessary, add engine oil up to upper level on level
gauge.
Recommended oil:
A PI classification
SJ or SH with the words "Energy Conserving
1 Oiyevel gauge
Engine oil filler cap
I

or Energy conserving 11'; CCMC specification

G4 or G5, A CEA specification A 1, A2 or A3, or Upper level
New API mark displayed on the container (If it About 1.O t
(1.1 us qt,
is impossible to get SJ or SH grade, you may 0.9 Imp qt)
use SG grade.) Lower level

Engine oil capacity: (Non-Turbo model)

Upper level
4.0 0 (4.2 US qt, 3.5 Imp qt) I 02M3883A

Lower level
3.0 8 (3.2 US qty2.6 Imp qt)

LU-11
 OIL PUMP
LUBRICATION

4. Oil Pump 7) Remove the crankshaft position sensor

A: REMOVAL
1) Disconnect the battery ground cable.

8) Remove the V-belts. <Ref. to ME(S0HC)-43,

REMOVAL, V-belt.> or <Ref. to ME(D0HC TUR-
BO)-44, REMOVAL, V-belt.>
2) Lift-up the vehicle. 9) Remove the rear side V-belt tensioner.
3) Remove the under cover.
4) Remove the bolts which install water pipe of oil
cooler to oil pump. (Turbo model)

IO) Remove the crankshaft pulley by using ST.

ST 499977300 CRANKSHAFT PULLEY
/- S2M0027 1 WRENCH (Turbo model)
5) Remove the water pipe and hoses between oil ST 499977100 CRANKSHAFT PULLEY
cooler and water pump. (Turbo model) WRENCH (Non-Turbo model)

6) Remove the radiator. <Ref. to CO-37, REMOV-

AL, Radiator.>

LU-12
 OIL PUMP
LUBRICATION

11) Remove the water pump. <Ref. to CO-27, RE- B: INSTALLATION

MOVAL, Water Pump.> Install in the reverse order of removal.
12) Remove the crankshaft sprocket. Do the following:
1) Apply fluid packing to matching surfaces of oil
pump.
Fluid packing:
THREE BOND 1215 or equivalent
I

13) Remove the bolts which install oil pump onto

cylinder block.

L J W S2M0390E

(A) O-ring

2) Replace the O-ring with a new one.

3) Apply a coat of engine oil to the inside of the oil
seal.

14) Remove the oil pump by using flat bladed

screwdriver.
CAUTION:
Be careful not to scratch mating surfaces of
cylinder block and oil pump.
u w S2M01188

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.

S2M1819

LU-13
 OIL PUMP
LUBRICATION

6) Install the oil pump C: DISASSEMBLY

Tightening torque: Remove the screws which secure oil pump cover
6.4 N-m (0.65 kgf-m, 4.7 ff-lb) and then 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 the relief valve, loosen plug
when removing the oil pump from cylinder
block.

S2M0740A

S2M0735A

(A) Oil seal

(B) Pumpcase
(C) Inner rotor
(D) Outer rotor
(E) Pump cover
(F) Relief valve
(G) Relief valve spring
(H) Plug
(I) Washer

LU-14
 OIL PUMP
LUBRICATION

D: ASSEMBLY E: INSPECTION
1) Install the front oil seal by using ST. 1. TIP CLEARANCE
ST 499587100 OIL SEAL INSTALLER
Measure the tip clearance of rotors. If the clearance
CAUTION: exceeds the limit, replace rotors as a matched set.
Use a new oil seal.
Tip clearance:
Standard
0.04 - 0.14 mm (0.0076 - 0.0055 in)
Limit
0.18 mm (0.0071 in)

I
I
2) Apply a coat of engine oil to inner and outer ro-
tors.
3) Install the inner and outer rotors in their original
positions. EN1181
4) Install the oil relief valve and relief valve spring.
5 ) Install the oil pump cover. 2. CASE CLEARANCE
Tightening torque: Measure the clearance between the outer rotor and
T1: 5 N.m (0.5 kgf-m, 3.6 fi-lb) the cylinder block rotor housing. If the clearance
T2: 44 N-m (4.5 kgf-m, 32.5 fi-lb) exceeds the limit, replace the rotor.
Case clearance:
m Standard
0.10 - 0.175 mm (0.0039 - 0.0069 in)
Limit
0.20 mm (0.0079 in)

EN1182

S2M0735E

LU-15
 OIL PUMP
LUBRICATION

3. SIDE CLEARANCE
Measure the clearance between oil pump inner ro-
tor and pump cover. If the clearance exceeds the
limit, replace rotor or pump body.
Side clearance:
Standard
0.02 - 0.07 mm (0.0008 - 0.0028 in)
Limit
0.12 mm (0.0047 in)

4. OIL RELIEF VALVE

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)
lnstalled length
54.7 mm (2.154 in)
Load when installed
77.08 N (7.86 kg, 17.33 lb)
5. OIL PUMP CASE
Check the oil pump case for worn shaft hole,
clogged oil passage, worn rotor chamber, cracks,
and other faults.
6. OILSEAL
Check the oil seal lips for deformation, hardening,
wear, etc, and replace if defective.

LU-16
 OIL PAN AND STRAINER
LUBRICATION

8) Remove the pitching stopper.

5. Oil Pan and Strainer
A: REMOVAL
1) Set the vehicle on lift arms.
2) Remove the front wheels.
3) Disconnect the battery ground cable.

9) Remove the radiator upper brackets.

Non-Turbo model

4) Remove the air intake duct and air cleaner case.

(Non-Turbo model)
<Ref. to IN(S0HC)-7, REMOVAL, Air Intake Duct.>
and <Ref: to IN(S0HC)-6, REMOVAL, Air Cleaner
Case.>
5) Disconnect the connector from mass air flow
sensor. (Turbo model) 31
I

Turbo model

6) Remove the air intake boot and air cleaner upper

cover. (Turbo model)
10) Support the engine with a lifting device and wire
ropes.

7) Remove the intercooler (Turbo model) <Ref. to

IN(D0HC TURBO)-10, REMOVAL, Intercooler.>
11) Lift-up the vehicle.
CAUTION:
At this time, raise up wire ropes.

LU-17
 OIL PAN AND STRAINER
LUBRICATION

12) Remove the under cover. 17) Insert the oil pan cutter blade between cylinder
13) Drain the engine oil. block-to-oil pan clearance.
Set a container under the vehicle, and remove CAUTION:
drain plug from oil pan. Do not use a screwdriver or similar tool in place
Non-Turbo model of oil pan cutter.
Non-Turbo model

Turbo model
Turbo model

EN0041
(A) Gasket
(B) Drain plug 18) Remove the oil strainer.
14) Remove the front and center exhaust pipes.
(Non-Turbo model) <Ref. to EX(S0HC)-5, RE-
MOVAL, Front Exhaust Pipe.>
15) Remove the nuts which install front cushion
rubber onto front crossmember.

S2M0238

19) Remove the baffle plate.

16) Remove the bolts which install oil pan on cylin-

der block while raising up engine.

LU-18
 OIL PAN AND STRAINER
LUBRICATION

B: INSTALLATION 4) Tighten bolts which install the oil pan onto en-
gine block.
CAUTION:
Before installing the oil pan, clean sealant from Tightening torque:
oil pan and engine block. 5 N-m (0.5 kgf-m, 3.6 ft-lb)
1) Install the baffle plate. Non-Turbo model
Tightening torque:
6.4 N.m (0.65 kgf-m, 4.7 ft-lb)

Turbo model

2) Install the oil strainer onto baffle plate.

CAUTION:
Replace the O-ring with a new one.
Tightening torque:
70 N.m (7.0 kgf-m, 7 ft-lb)

5) Lower the engine onto front crossmember.

6) Tighten the nuts which install front cushion rub-
ber onto front crossmember.
Tightening torque:
69 N.m (7.0 kgf-m, 51 tl-lb)

3) Apply fluid packing to mating surfaces and install

the oil pan.
Fluid packing:
THREE BOND 7215 or equivalent

LU-19
 OIL PAN AND STRAINER
LUBRICATION

7) Install the front and center exhaust pipes. (Non- 12) Install the radiator upper brackets.
Turbo model) Non-Turbo model
<Ref. to EX(S0HC)-6, INSTALLATION, Front Ex-
haust Pipe.>
NOTE:
Always use new gaskets.

Turbo model

8) Install the under cover.

9) Lower the vehicle.
CAUTION:
At this tim'e, lower the lifting device and release
steel cables.
10) Remove the lifting device and steel cables.

13) Install the air intake duct and air cleaner case.
(Non-Turbo model)
<Ref. to IN(S0HC)-6, INSTALLATION,Air Cleaner
Case.> and <Ref. to IN(SOHC)-7, INSTALLATION,
Air Intake Duct.>
14) Install the intercooler. (Turbo model) <Ref. to
IN(D0HC TURBO)-11, INSTALLATION, Intercool-
er.>
15) Install the air intake boot and air cleaner upper
cover. (Turbo model)
11) Install the pitching stopper.
Tightening torque:
T I : 50 N-m (5.1 kgf-m, 37 ff-lb)
T2: 58 N.m (5.9 kgf-m, 43 ff-lb)

LU-20
 3

OIL PAN AND STRAINER

LUBRICATION

16) Connect the connector to mass air flow sensor.

(Turbo model)

I I

17) Install the front wheels.

18) Connect the battery ground cable.

19) Fill the engine oil. <Ref. to LU-10, INSPEC-

TION, Engine Oil.>
C: INSPECTION
By visual check make sure oil pan, oil strainer, oil
strainer stay and baffle plate are not damaged.

LU-21
 OIL PRESSURE SWITCH
LUBRICATION

6. Oil Pressure Switch (3) Remove the front side V-belt. <Ref. to
ME(S0HC)-43, REMOVAL, V-belt.> or <Ref. to
A: REMOVAL ME(D0HC TURBO)-44, REMOVAL, V-belt.>
1) Remove the generator from bracket. (4) Remove the bolts which install generator on
(1) Disconnect the connector and terminal from bracket .
generator .
Non-Turbo model

2) Disconnect the terminal from oil pressure switch.

B2M3105

Turbo model

3) Remove the oil pressure switch.

(2) Remove the V-belt cover

Non-Turbo model

S2M0119

-v ' It
B2M3106

Turbo model

' I --If EN0048 I

LU-22
 OIL PRESSURE SWITCH
LUB RICAT10 N

B: INSTALLATION 4) Install the generator on bracket and temporarily

1) Apply fluid packing to oil pressure switch tighten installing bolts.
threads.
Fluid packing:
THREE BOND 1215 or equivalent

5) Install the front side V-belt and adjust it.

2) Install the oil pressure switch onto engine block.
Tightening torque:
25 N.m (2.5 kgf-m, 78.1 ff-lb)
<Ref. to ME(S0HC)-43, INSTALLATION, V-belt.>
or <Ref. to ME(D0HC TURBO)-44, INSTALLA-
TION, V-belt.>
6) Install the V-belt cover.
Non-Turbo model

B2M31OE

Turbomodel
3) Connect the terminal of oil pressure switch.

' 1 - 1 1 EN0048

LU-23
 OIL PRESSURE SWITCH
LUBR CATION

7) Connect the connector and terminal to genera-

tor.
Non-Turbo model

Turbo model

C: INSPECTION
Make sure oil does not leak or seep from where the
oil pressure switch is installed.

LU-24
 ENGINE OIL COOLER
LUBRlCATlON

7. Engine Oil Cooler 7 ) Remove the connector and remove oil cooler.

A: REMOVAL
1) Lift-up the vehicle.
2) Remove the under cover.
3) Drain the engine oil.
Set a container under the vehicle, and remove
drain plug from oil pan.

I
m-”,
(A) Metal gasket
EN0010

(B) Drain plug

4) Drain the coolant.

5) Remove the water by-pass pipe between oil (A) O-ring
cooler and water pump.
(B) Oil cooler
(C) Connector

6) Remove the engine oil filter. <Ref. to LU-27, RE-

MOVAL, Engine Oil Filter.>

LU-25
 ENGINE OIL COOLER
LUBRICATION

B: INSTALLATION C: INSPECTION
1) Install in the reverse order of removal. 1) Check that coolant passages are not clogged us-
ing an air blow method.
Tightening torque:
2) Check the mating surfaces of cylinder block, 0-
T: 54 N-m (5.5 kgf-m, 39.8 ft-lb) ring groove and oil filter for damage.
CAUTION:
Always use a new O-ring.

u
I

ep,’ G2M0784

LU-26
 ENGINE OIL FILTER
LUBRICATION

8. Engine Oil Filter

A: REMOVAL
1) Remove the under cover.
2 ) Remove the oil filter with ST.
ST 498547000 OIL FILTER WRENCH
Non-Turbo model

Turbo model

B: INSTALLATION
1) Get a new oil filter and apply a thin coat of engine
oil to the seal rubber.
2) Install the oil filter turning it by hand, being care-
ful not to damage seal rubber.
3) Tighten more (approximately 213 to 314 turn) af-
ter the seal rubber contacts the oil pump case. Do
not tighten excessively, or oil may leak.
C: INSPECTION
1) After installing the oil filter, run 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-10, IN-
SPECTION, Engine Oil.>

LU-27
 ENGINE LUBRICATION SYSTEM TROUBLE IN GENERAL
LUBRICATION

9. Engine Lubrication System

Trouble in General
A: INSPECTION
Before performing diagnostics, make sure that the engine oil level is correct and no oil leakage exists.

Trouble Possible cause Corrective action

1) Oil pressure switch Cracked diaphragm or oil leakage within switch Replace.
failure Broken sDrina or seized contacts ReDlaCe.
I Cloaaed oil filter I Replace. I
I Malfunction of oil by-pass valve in oil filter I Clean or replace. I
I Malfunction of oil relief valve in oil pump I Clean or replace. I
1. Warning light remains 2) Low oil pressure Clogged oil passage Clean.
m. Excessive tip clearance and side clearance of oil
Replace.
pump rotor and aear
I Clogged oil strainer or broken pipe I Clean or replace. I
I Insufficient engine oil I Replenish. I
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 Doints ReDlaCe.
rlot go on.
3) Disconnection of wirina I Repair. I
1) Poor contact at terminals [ Repair.
3. Warning light flickers
2) Defective wiring harness I Repair.
momentarily. Check for the same
3) Low oil pressure possible causes as
listed in 1.-2).

LU-28
SPEED CONTROL SYSTEMS

SP
Page
1. General Description ................................................................................... .2
2. Accelerator Pedal ....................................................................................... .3
3. Accelerator Control Cable ........................................................................... 7
 GENERAL DESCRIPTION
SPEED CONTROL SYSTEMS

1. General Description
A: SPECIFICATION
Free play At pedal pad 1 - 4 mm (0.04- 0.16 in)
Accelerator pedal
Stroke At pedal pad 52 - 57 mm (2.05 - 2.24 in)

B: COMPONENT

(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: lS(1.8, 13.0)

C: CAUTION Place shop jacks or safety stands at the specified

Wear work clothing, including a cap, protective points.

.
goggles, and protective shoes during operation.
Remove contamination, including dirt and corro-
sion, before removal, installation or disassembly.
Before disconnecting electrical connectors of
SenSOrS Or Units, be Sure to disconnect negative
terminal from battery.
Keep the disassembled parts in order and pro-
tect them from dust and dirt.
Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary re-
moval, installation, disassembly, and replacement.
Be careful not to burn your hands, because each
part in the vehicle is hot after running.
Be sure to tighten fasteners including bolts and
nuts to the specified torque.

sP-2
 ACCELERATOR PEDAL
SPEED CONTROL SYSTEMS

2. Accelerator Pedal 6) Remove the clip inside engine compartment.

SOHCmodel
A: REMOVAL
1) Disconnect the ground terminal from battery.
2) Remove the lock nut from accelerator cable
bracket.
3) Separate the accelerator cable from bracket.
4) Remove the accelerator cable end from throttle
cam.
5 ) Disconnect the accelerator cable from throttle
body.
CAUTION:
Be careful not to kink the accelerator cable.
SOHCmodel DOHC TURBO model

DOHC TURBO model (A) Toe board

(B) Accelerator cable
(C) To accelerator pedal
(D) Brake booster
(E) Clip

7) Remove the instrument panel lower cover from

instrument panel, and connector.
8) Remove the brake and clutch pedal bracket. (MT
model) <Ref. to BR-51, REMOVAL, Brake Pedal.>
EN0919

(A) Locknut
(B) Accelerator cable bracket
(C) Accelerator cable
(D) Throttle cam

SP-3
 ACCELERATOR PEDAL
SPEED CONTROL SYSTEMS
9) Remove the accelerator pedal connecting bolt
from accelerator pedal bracket.
14) Separate the accelerator cable and bracket.
B: INSTALLATION
Install in the reverse order of removal.
CAUTION:
If cable clamp is damaged, replace it with a
new one.
Never fail to cover the outer cable end with
boot.
Be careful not to kink the accelerator cable.
Always use new clevis pins.

10) Disconnect the grommet from toe board.

NOTE:
From inside the compartment, push grommet into
hole.

11) Pull out the cable from the toe board hole.
12) Disconnect the accelerator cable bushing from
accelerator pedal lever.

13) Disconnect the accelerator cable stopper from

bracket.

sP-4
 ACCELERATORPEDAL
SPEED CONTROL SYSTEMS

C: DISASSEMBLY
1) Remove the clip, and then remove the accelera-
tor pedal from the bracket.
2) Pull out the spring pin, and then remove the ac-
celerator pedal from the accelerator pedal lever.
E: INSPECTION
Lightly move the pedal pad in lateral direction to en-
sure pedal deflection is in specified range.
CAUTION:
If excessive deflection is noted, replace the
bushing and clip with new ones.
Deflection of accelerator pedal:
Service limit
5.0 mm (0.197 in) or less

G4M033:

(A) Accelerator bracket

(B) Stopper
(C) Bushing
(D) Clip
(E) Accelerator spring
(F) Accelerator pedal spring
(G) Accelerator pedal lever
(H) Spring pin
(I) Accelerator pedal

D: ASSEMBLY
Assemble in the reverse order of disassembly.
CAUTION:
Clean and apply grease to the spacer and in-
side bore of a accelerator pedal.

SP-5
 ACCELERATOR PEDAL
SPEED CONTROL SYSTEMS

F: ADJUSTMENT
Check the pedal stroke and free play by operating
accelerator pedal by hand.
If it is not within the specified value, adjust it by turn-
ing the 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
52 -57 mm (2.05 -2.24 in)

(A) Accelerator pedal

(B) Accelerator pedal bracket

Accelerator cable lock nut tightening torque:

12 N-m (1.2 kgf-m, 9 ff-lb)

S P-6
 ACCELERATOR CONTROL CABLE
SPEED CONTROL SYSTEMS

3. Accelerator Control Cable

A: REMOVAL
1) Remove the accelerator pedal. <Ref. to SP-3,
REMOVAL, Accelerator Pedal.>
2) Separate the accelerator cable and accelerator
pedal.
B: INSTALLATION
1) Install in the reverse order of removal.
CAUTION:
If cable clamp is damaged, replace it with a
new one.
Never fail to cover the outer cable end with
boot.
Be careful not to kink the accelerator cable.
Do not apply grease to the throttle cable on
the engine side.
2) Adjust after pedal installation. <Ref. to SP-4, IN-
STALLATION, Accelerator Pedal.>
C: INSPECTION
1) Make sure the inner cable is not twisted or
frayed.
2) Make sure the outer cable is not cracked.

SP-7
 ACCELERATOR CONTROL CABLE
SPEED CONTROL SYSTEMS

SP-8
IGNITION

IG(S0HC)
Page
1. General Description .................................................................................... 2
2. Spark Plug................................................................................................... 4
3. ignition Coil and ignitor Assembly ............................................................... 7
4. Spark Plug Cord .......................................................................................... 9
 GENERAL DESCRIPTION
IGNITION

1. General Description
A: SPECIFICATIONS
Item Designation I
Model FHO137
Manufacturer DIAMOND
Ignition coil
Primary coil resistance 0.73 Q+lO%
and ignitor
assembly Secondary coil resistance 12.8 k Q f l 5 %
Insulation resistance between primary
More than 10 MQ
terminal and case
RClOYC4: CHAMPION

Spark plug
Type and manufacturer

Thread size mm I
1 BKR5E-11: NGK
BKR6E-11: NGK
14. P = 1.25
Spark gap mm (in) I 1.O - 1.I (0.039 - 0.043)

IG(SOHC)-2
 GENERAL DESCRIPTION
IGNITION

9: COMPONENT

S6M0329E

(1) Spark plug (4) Spark plug cord (#2,#4) Tightening torque: N.m (kgf-m, ft-lb)
(2) Spark plug cord (#1, #3) T1: 21 (2.1, 15)
(3) Ignition coil and ignitor ASSY T2: 6.4 (0.65, 4.7)

C: CAUTION Be careful not to burn your hands, because each

Wear working clothing, including a cap, protec-
tive goggles, and protective shoes during opera-
tion.
Remove contamination including dirt and corro-
sion before removal, installation or disassembly.
Keep the disassembled parts in order and pro-
tect them from dust or dirt.
Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary re-
moval, installation, disassembly, and replacement.
part on the vehicle is hot after running.
Be sure to tighten fasteners including bolts and
nuts to the specified torque.
Place shop jacks or safety stands at the specified
points.
Before disconnecting electrical COnneCtOrS Of
sensors or units, be sure to disconnect the negative
terminalfrom battery.

IG(S0HC)S
 SPARK PLUG
IGNITION

2. Spark Plug 4) Remove the spark plugs with the spark plug
sockets.
A: REMOVAL
CAUTION:
All spark plugs installed on an engine, must be
of the same heat range.
~

Spark plug
CHAMPION: RClOYC4

I NGK: BKR5E-11 (Alternate)

NGK: BKRGE-11 (Alternate)

1. RH SIDE B2M428E

1) Disconnect the ground terminal from battery. 2. LH SIDE

1) Disconnect the ground terminal from battery.

2) Remove the air intake duct. <Ref. to IN(S0HC)-

8, REMOVAL, Resonator Chamber.>
(1) Remove the resonator chamber. <Ref. to 2) Disconnect the washer motor connector.
IN(S0HC)-8, REMOVAL, Resonator Cham- I

ber.>
3) Remove the spark plug cords by pulling boot, not
cord itself.

3) Disconnect the rear window glass washer hose

from washer motor, then plug connection with a
suitable cap.
1137 4) Remove the two bolts which hold the washer
tank, then take the tank away from the working ar-
ea.

IG(S0HC)-4
 SPARK PLUG
IGNITION

5) Remove the spark plug cords by pulling boot, not C: INSPECTION

cord itself. Check the electrodes and inner and outer porcelain
of plugs,
. - noting the type of deposits and the degree
of electrode erosion.
i

I
I I , ,

6) Remove the spark plugs with the spark plug (E)

sockets. S6M0420F

(A) Electrode gap

(B) Carbon accumulation or wear
(C) Cracks
(D) Damage
(E) Damaged gasket

1) Normal:
Brown to grayish-tan deposits and slight electrode
wear indicate correct spark plug heat range.

B: INSTALLATION
1. RH SIDE
1) Install in the reverse order of removal.
Tightening torque (Spark plug):
27 Nom(2.7 kgf-m, 75 ff-lb)
CAUTION:
The above torque should be only applied to G6M008i
new spark plugs without oil on their threads.
In case their threads are lubricated, the torque 2) Carbon fouled:
should be reduced by approximately 1/3of the Dry fluffy carbon deposits on insulator and elec-
specified torque in order to avoid over-stress- trode are mostly caused by slow speed driving in
ing. city, weak ignition, too rich fuel mixture, dirty air
cleaner, etc.
2. LH SIDE It is advisable to replace with plugs having hotter
1) Install in the reverse order of removal. heat range.

Tightening torque (Spark plug):

27 N-m (2.7 kgf-m, 75 ff-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 1/3of the
specified torque in order to avoid over-stress-
ing.
G6M0088

IG(S0HC)d
I
SPARK PLUG
IGNITION

3) Oil fouled: E: ADJUSTMENT

Wet black deposits show excessive oil entrance Correct it if the spark plug gap is measured with a
into combustion chamber through worn rings and gap gauge, and it is necessary.
pistons or excessive clearance between valve
guides and stems. If the same condition remains Spark plug gap: L
after repair, use a hotter plug. 1.0 - 1.1 mm (0.039 - 0.043 in)

L
P---

G6M0089 S6M0412A

4) Overheating: NOTE:
White or light gray insulator with black or gray Replae with a new spark plug if this area is worn to
brown spots and bluish burnt electrodes indicate “ball” shape.
engine overheating. Moreover, the appearance re-
sults 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.

G6M0090

D: CLEANING
Clean the spark plugs in a sand blast type cleaner.
Avoid excessive blasting. Clean and remove the
carbon or oxide deposits, but do not wear away
porcelain.
If deposits are too stubborn, replace the plugs.

IG(S0HC)-6
 IGNITION COIL AND IGNITOR ASSEMBLY 3
IGNITION

3. Ignition Coil and Ignitor As- B: INSTALLATION

sembly 1) Install in the reverse order of removal.
Tightening torque:
A: REMOVAL 6.4 Nom(0.65 kgf-m, 4.7 ff-lb)
1) Disconnect the ground terminal from battery.
CAUTION:
Be sure to connect wires to their proper posi-
tions. Failure to do so will damage the unit.

2) Disconnect the spark plug cords from ignition

coil and ignitor assembly.

S6M037:

3) Disconnect the connector from ignition coil and

ignitor assembly.
4) Remove the ignition coil and ignitor assembly.

IG(SOHC)-7
 IGNITION COIL AND IGNITOR ASSEMBLY
IGNITION

C: INSPECTION
Using an 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 mlO%
Between terminal No. 2 and No. 4
0.73 &+lo%

EN104

[Secondary side]
Between (A) and (B)
12.8 k&+l5%
Between (C) and (0)
12.8 kL+15%

3) Insulation between primary terminal and case:

10 Mi2 or more.

IG(S0HC)-8
 SPARK PLUG CORD
IGNITION

4. Spark Plug Cord

A: INSPECTION
Check for:
1) Damage to cords, deformation, burning or rust
formation of terminals
2) Resistance values of cords
Resistance value:
#1 cord: 5.6- 10.6 kn
-
#2cord: 7.3 13.7 kn
#3 cord: 5.9- 11.1 ki2
#4 cord: 7.3 - 13.7 ki2

S6M0337

IG(S0HC)-9
 SPARK PLUG CORD
IGNITION

IG(S0HC)-10
STARTING/CHARG ING SYSTEMS

~
sc rage
1. General Description .................................................................................... 2
2. Starter ......................................................................................................... 6
3. Generator .................................................................................................. 13
4. Battery....................................................................................................... 18
 GENERAL DESCRIPTION
STARTING/CHARGING SYSTEMS

1. General Description
A: SPECIFICATIONS
1. NON-TURBO MODEL

Item Designation
Type Reduction type
Vehicle type MT vehicles AT vehicles
Model MOOOT83981 MOOIT86481
Manufacturer Mitsubishi Electric
-
Voltaae and outDut 12 V - 1.O kW I
- V - 1.4 kW
12
Direction of rotation Counterclockwise (when observed from pinion)
Number of pinion teeth 8 9
Voltage 11 v
No-load charac-
Current 90 A or less
teristics
Starter Rotating speed 2,800 rpm or more 2,400 rpm or more
Voltage 7.5 v 7.7 v
Current 300 A 400 A
Load character-
16.0 N.m (1.63 kg-m, 11.8 ft-lb) or
istics Torque 8.6 N.m (0.88 kg-m, 6.3 ft-lb) or more
more
I Rotating speed I 920 rpm or more I 740 rDm or more 1
Voltage 4v 3.5 v
Lock character- Current 650 A or less 940 A or less
istics 14.7 N.m (1.50 kgf-m, 10.8 ft-lb) or 28.9 N.m (2.95 kgf-m, 21.3ft-lb) or
Torque
more more
Rotating-field three-phase type, Voltage regulator built-in type, with load
Type response control system
Model A2TB6291
Manufacturer Mitsubishi Electric
Voltage and output 12 V - 90 A
Polarity on ground side Negative
Generator
Rotating direction Clockwise (when observed from Dullev side)
Armature connection 3-phase Y-type
1,500 rpm - 36 A or more
Output current 2,500 rpm - 65 A or more
5,000 rpm - 86 A or more
Regulated voltage 14.1 - 14.8 V [20°C (68"F)I

sc-2
 GENERAL DESCRIPTION
STARTING/CHARGINGSYSTEMS

I
Item Designation
Type Reduction type
Vehicle type MT vehicles AT vehicles
Model 228000 - 9270 MOOIT86481
Manufacturer DENS0 Mitsubishi Electric
Voltage and output 12 V - 1.O kW 12V-1.4kW
Direction of rotation Counterclockwise (when observed from pinion)
Number of pinion teeth 9
Voltage 11 v
No-load charac- Current
90 A or less
teristics
Rotating speed 2,860 rpm or more 2,400 rpm or more
Voltage 8V 7.7 v
Current 280 A 400 A
Load character-
16.0 N.m (1.63 kg-m, 11.8 ft-lb) or
istics Torque 9.3 N.m (0.95 kg-m, 6.9 ft-lb) or more
more
Rotating speed 860 rpm or more 740 rpm or more
Voltage 5v 3.5 v
Lock character- Current 515 A or less 940 A or less
istics 16 N.m (1.63 kgf-m, 11.8 ft-lb) or 28.9 N.m (2.95 kgf-m, 21.3 ft-lb) or
Torque
more more
Rotating-fieldthree-phase type, Voltage regulator built-in type, with load
Type response control system
Model A2TB6291
Manufacturer Mitsubishi Electric
Voltage and output 12 V - 75 A
Polarity on ground side Negative
Rotatina direction Clockwise (when observed from pulley side)
Armature connection I 3-phase Y-type
1,500 rpm - 30 A or more
Output current 2,500 rpm - 64 A or more
5.000 rDm - 76 A or more
Regulated voltage 14.1 - 14.8 V [20°C (68"F)I

sc-3
 GENERAL DESCRIPTION
START1NG/CHARGING SYSTEMS

B: COMPONENT
1. STARTER

(1) Sleeve bearing (7) Internal gear ASSY (13) Armature

(2) Front bracket (8) Shaft ASSY (14) Brush holder
(3) Leverset (9) Gear ASSY (15) Brush
(4) Magnet switch ASSY (10) Ball (16) Sleeve bearing
(5) Stopper set (11) Packing (17) Rear bracket
(6) Over running clutch (12) Yoke

sc-4
 GENERAL DESCRIPTION
STARTING/CHARGING SYSTEMS

2. GENERATOR

"1

\\
i\ 7. \
I
H6M0493(

(1) Pulley (5) Rotor (9) Brush

(2) Front cover (6) Bearing (10) Rectifier
(3) Ball bearing (7) Stator coil (1 1) Rear cover
(4) Bearing retainer (8) IC regulator with brush (12) Terminal

C: CAUTION Be careful not to burn your hands, because each

part in the vehicle is hot after running.
Wear working clothing, including a cap, protec-
Be sure to tighten fasteners including bolts and
tive goggles, and protective shoes during opera-
nuts to the specified torque.
tion.
Remove contamination including dirt and corro- Place shop jacks or safety stands at the specified
sion before removal, installation or disassembly. points.
Before disconnecting electrical Connectors Of
Keep the disassembled parts in order and pro-
sensors or units, be sure to disconnect the negative
tect them from dust or dirt.
Before removal, installation or disassembly, be terminal from battery.
sure to clarify the failure, Avoid unnecessary re-
moval, installation, disassembly, and replacement.

sc-5
 STARTER
STARTING/CHARGING SYSTEMS

2. Starter AT vehicles

A: REMOVAL
1) Disconnect the ground terminal from battery.

5 ) Disconnect the connector and terminal from

starter.

2) Remove the air cleaner case. (Non-Turbo Mod-

el)

(A) Terminal
B6M1221 (6) Connector
3) Remove the intercooler. (Turbo Model) <Ref. to 6) Remove the starter from transmission.
IN(D0HC TURBO)-10, REMOVAL, Intercooler.>
4) Remove the air cleaner case stay. (Non-Turbo
Model)
MT vehicles

SC-6
 STARTER
START1NG/CHARGING SYSTEMS

B: INSTALLATION 3) Remove both through-bolts and brush holder

Install in the reverse order of removal. screws, and detach the rear bracket and brush
holder.
Tightening torque:
50 N.m (5.1 kgf-m, 37 W b )

W
H6M0494E

(A) Brush holder

(B) Rear bracket
C: DISASSEMBLY
4) Remove the armature and yoke. Ball used as a
1. STARTER ASSEMBLY bearing will then be removed from the end of arma-
1) Loosen the nut which holds terminal M of switch ture.
assembly, and disconnect the connector. CAUTION:
2) Remove the bolts which hold switch assembly, Be sure to mark an alignment mark on the yoke
and remove the switch assembly, plunger and and front bracket before removing the yoke.
plunger spring from starter as a unit.
CAUTION:
Be careful because the pinion gap adjustment
washer may sometimes be used on the mount-
ing surface of switch assembly.

H6M0495B

(A) Front bracket

(B) Yoke
@ (C) Ball
S6M0396A (D) Armature

(A) Switch ASSY

(B) Plunger

sc-7
 STARTER
STARTING/CHARGING SYSTEMS
5 ) Remove packing A, three planetary gears, pack- 7) Remove the overrunning clutch from shaft as-
ing 6 and plate. sembly as follows:
(1) Remove the stopper from ring by lightly tap-
ping a fit tool placed on stopper.
(2) Remove the ring, stopper and clutch from
shaft.

(A)’
(A) PackingA
(B) Planetary gear I
(C) Plate I S6M0399A
(D) Packing B
(A) Stopper
6) Remove the shaft assembly and overrunning (B) Tool
clutch as a unit. (C) Ring
CAUTION: (D) Shaft
Record the direction of the lever before remov-
ing. 2. BRUSH HOLDER
Slightly open the metal fitting holding the insulating
plate to the brush holder. Remove the insulating
plate.
NOTE:
The brush and spring can be easily removed from
the brush holder at this time.

S6M0398A I
(A) Shaft ASSY
(B) Overrunning clutch
(C) Lever

(A) Brush holder

(B) Insulating plate
(C) Metal fitting

SC-8
 STARTER
START1NG/CHARGING SYSTEMS

D: ASSEMBLY 3) Depth of segment mold:

Assembly is in the reverse order of disassembly Check the depth of segment mold.
procedures. Do the following: Depth of segment mold:
1) Carefully assemble all parts in the order of as- 0.5 mm (0.020 in)
sembly and occasionally inspect nothing has been
overlooked.
2) Apply grease to the following parts during as-
sembly.
Front and rear bracket sleeve bearing
Armature shaft gear
Outer periphery of plunger
Mating surface of plunger and lever
Gear shaft splines
Mating surface of lever and clutch
Ball at the armature shaft end I S6M0401A
Internal and planetary gears
3) After assembling parts correctly, check to be (A) Depth of mold
sure the starter operates properly. (B) Segment
(C) Mold
E: INSPECTION
4) Armature short-circuit test:
1. ARMATURE
Check the armature for short-circuit by placing it on
1) Check the commutator for any sign of burns of growler tester. Hold a hacksaw blade against arma-
rough surfaces or stepped wear. If wear is of a mi- ture core while slowly rotating armature. A short-
nor nature, correct it by using sand paper. circuited armature will cause the blade to vibrate
2) Run-out test: and to be attracted to core. If the hacksaw blade is
Check the commutator run-out and replace if it ex- attracted or vibrates, the armature, which is short-
ceeds the limit. circuited, must be replaced or repaired.
Commutator run-out:
Standard
0.05 mm (0.0020 in)
Service limit
Less than 0.10 mm (0.0039 in)

3 (A) Iron sheet

(B) Growler

I S6M0400A

(A) V-block

sc-9
 STARTER
STARTING/CHARGING SYSTEMS

5 ) Armature ground test: 2) Brush movement:

Using the circuit tester, touch one probe to the Be sure the brush moves smoothly inside brush
commutator segment and the other to shaft. There holder.
should be no continuity. If there is continuity, arma- 3) Brush spring force:
ture is grounded. Measure the brush spring force with a spring scale.
Replace the armature if it is grounded. If it is less than the service limit, replace the brush
holder.
Brush spring force:
Standard
21.6 N (2.2 kg, 4.9 lb) (when new)
Service limit
5.9 N (0.6 kg, 1.3 lb)
5. SWITCH ASSEMBLY
Be sure there is continuity between terminals S and
7114 1
M, and between terminal S and ground. Use a cir-
cuit tester (set in “ohm”).
2. YOKE Also check to be sure there is no continuity be-
Make sure the pole is set in position. tween terminal M and B.
Terminal/ Specified resistance:
3. OVERRUNNING CLUTCH
S - M / less than la
Inspect the teeth of pinion for wear and damage. S - Ground / less than 1 0
Replace if it is damaged. Rotate the pinion in direc- M - B /More than 1M a
tion of rotation (counterclockwise). It should rotate
smoothly. But in opposite direction, it should be
locked. I/
CAUTION:
Do not clean the overrunning clutch with oil to
prevent grease from flowing out.
4. BRUSH AND BRUSH HOLDER
1) Brush length:
Measure the brush length and replace if it exceeds u
the service limit. S6M0403
Replace if abnormal wear or cracks are noticed. 6. SWITCH ASSEMBLY OPERATION
Brush length: 1) Connect terminal S of switch assembly to the
Standard positive terminal of battery with a lead wire, and
12.3 mm (0.484 in) starter body to ground terminal of battery. Pinion
Service limit should be forced endwise on the shaft.
7.0 mm (0.276 in)
CAUTION:
With the pinion forced endwise on shaft, starter
motor can sometimes rotate because current
flows, through pull-in coil, to motor. This is not
a problem.

H6M04968

(A) Service limit line

(B) Brush

sc-10
 STARTER
START1NG/CHARGI NG SYSTEMS

2) Disconnect the connector from terminal M, and 8. PERFORMANCE TEST

connect the positive terminal of battery and termi-
nal M using a lead wire and ground terminal to
starter body.
In this test set up, pinion should return to its original
position even when it is pulled out with a screwdriv-
er.
The starter should be submitted to performance
tests whenever it has been overhauled, to assure
its satisfactory performance when installed on the
engine.
Three performance tests, no-load test, load test,
and lock test, are presented here; however, if the
load test and lock test cannot be performed, carry
out at least the no-load test.
For these performance tests, use the circuit shown
in figure.

S6M0393A

(A) Terminal S
(B) Terminal M
S6M0395A
7. PINION GAP
1) Measure the pinion gap while the pinion is pulled (A) Variable resistance
out as shown in the figure. (B) Magnetic switch
Pinion gap: (C) Starter body
0.5 - 2.0 mm (0.020 - 0.079 in) 1) No-load test:
With switch on, adjust the variable resistance to ob-
tain 11 V, take the ammeter reading and measure
the starter speed. Compare these values with the
specifications.
No-load test (Standard):
Voltage / Current
11 V / 9 0 A max.
Rotating speed
Non-Turbo MT vehicles
2,800 rpm or more
(A) Pinion Turbo MT vehicles
(B) Gap 2,860 rpm or more
(C) Stopper AT vehicles
2,400 rpm or more
If the motor is running with the pinion forced end-
wise on the shaft, disconnect the connector from
terminal M of switch assembly and connect termi-
nal M to ground terminal (-) of battery with a lead
wire. Next, gently push the pinion back with your
fingertips and measure pinion gap.
2) If the pinion gap is outside specified range, re-
move or add number of adjustment washers used
on the mounting surface of switch assembly until
the correct pinion gap is obtained.

sc-11
 STARTER
STARTINGKHARGING SYSTEMS

2) Load test:
Apply the specified braking torque to starter. The
condition is satisfactory if the current draw and
starter speed are within specifications.
Load test (Standard):
Voltage/Load
Non-Turbo MT vehicles
7.5 W8.6 N.m (0.88 kgf-m, 6.3 ft-lb)
Turbo MT vehicles
8 V9.3 N.m (0.95 kgf-m, 6.9 ft-lb)
AT vehicles
7.7 W6.0 N-m (1.63 kg-m, 11.8 ft-lb)
Current / Speed
Non-Turbo MT vehicles
300 N920 rpm or more
Turbo MT vehicles
280 N860 rpm or more
AT vehicles
400 An40 rpm or more
3) Lock test:
With the starter stalled, or not rotating, measure the
torque developed and current draw when the volt-
age is adjusted to the specified voltage.
Lock test (Standard):
Voltage/ Current
Non-Turbo MT vehicles
4 V/650 A or less
Turbo MT vehicles
5 V/515 A or less
AT vehicles
3.5 V/940 A or less
Torque
Non-Turbo MT vehicles
14.7 N-m (1.50 kgf-m, 10.8 ft-lb) or more
Turbo MT vehicles
16 N-m (1.63 kgf-m, 11.8 ft-lb) or more
AT vehicles
28.9 N-m (2.95 kgf-m, 21.3 ft-lb) or more

sc-12
 GENERATOR
STARTING/CHARGINGSYSTEMS

3. Generator Turbo Model

A: REMOVAL
1) Disconnect the ground terminal from battery.

EN0048

4) Remove the front side V-belt.

<Ref. to ME(S0HC)-43, FRONT SIDE BELT, RE-
MOVAL, V-belt.> or <Ref. to ME(D0HC TURBO)-
2) Disconnect the connector and terminal from gen- 44, FRONT SIDE BELT, REMOVAL, V-belt.>
erator. 5) Remove the bolts which install the generator
Non-Turbo Model onto bracket.

I B2M3105 I

Turbo Model B: INSTALLATION

Install in the reverse order of removal.
CAUTION:
Check and adjust the V-belt tension. <Ref. to
ME(S0HC)-44, INSPECTION, V-belt.> and <Ref.
to ME(D0HC TURBO)-45, INSPECTION, V-belt.>

3) Remove the V-belt cover.

Non-Turbo Model

B2M3106

SC-13
 GENERATOR
STARTlNG/CHARGING SYSTEMS

C: DISASSEMBLY
1) Heat the portion (A) of rear cover to 50°C
(122°F) with heater drier.

\ - ,

H6M0498B

(A) Front bracket

(B) Pulley
(C) Nut
2) Remove the four through bolts. Then insert the (D) Rotor
tip of a flat-head screwdriver into the gap between
the stator core and front bracket. Pry then apart to 4) Unsolder connection between rectifier and stator
disassemble. coil to remove the stator coil.
CAUTION:
Finish the work rapidly (less than three sec-
onds) because the rectifier cannot withstand
heat very well.

3) Hold the rotor with a vise and remove the pulley

nut.

5) Remove the screws which secure the IC regula-

tor to rear cover, and unsolder connection between
IC regulator and rectifier to remove the IC regula-
tor.

G6M0066 I

CAUTION:
When holding the rotor with vise, insert alumi-
num plates or wood pieces on the contact sur-
faces of the vise to prevent rotor from damage.

SC-14
 GENERATOR
6) Remove the brushes by unsoldering at the pig-
tails.
U G6M0070
7 ) Remove the nut and insulating bushing at termi-
nal B, and remove the rectifier.
S6M0405P
(A) Rectifier
(B) Rear cover
(C) Nut
D: ASSEMBLY
To assemble, reverse the order of disassembly.
1) Pulling up brush:
Before assembling, press the brush down into the
brush holder with your finger and secure in that po-
sition by passing a [2 mm (0.08 in) dia. length 4 to
5 cm (1.6 to 2.0 in)] wire (A) through the hole shown
in the figure.
CAUTION:
Be sure to remove the wire after reassembly.
S6M0411P
2) Heat the bearing box in the rear bracket [50 to
60°C (122 to 140"F)l and press the rear bearing
into the rear bracket.
SC-15
START1NG/CHARGI NG SYSTEMS
CAUTION:
Grease should not be applied for the rear bear-
ing. Remove oil completely if it is found on the
bearing box.
3) After reassembly, turn the pulley by hand to
check that the rotor turns smoothly.
E: INSPECTION
1. DIODE
CAUTION:
Never use a megger tester (measuring use for
high voltage) or any other similar measure for
this test; otherwise, the diodes may be dam-
aged.
1) Checking positive diode:
Check for continuity between the diode lead and
the positive side heat sink. The positive diode is in
good condition if continuity exists only in the direc-
tion from the diode lead to the heat sink.
I
I S6M0406P
(A) Diode lead
(B) Heat sink (Positive side)
2) Checking negative diode:
Check for continuity between the negative side
heat sink and diode lead. The negative diode is in
good condition if continuity exists only in the direc-
tion from the heat sink to the diode lead.
(A) Diode lead
(B) Heat sink (Negative side)
 GENERATOR
START1NG/CHARGING SYSTEMS

2. ROTOR 5) Ball bearing (rear side):

(1) Check the rear ball bearing. Replace if it is
1) Slip ring surface:
noisy or if the rotor does not turn smoothly.
Inspect the slip rings for contamination or any
roughness of the sliding surface. Repair the slip (2) The rear bearing can be removed by using a
ring surface using a lathe or sand paper. common bearing puller.
2) Slip ring outer diameter:
Measure the slip ring outer diameter. If the slip ring
is worn replace the rotor assembly.
Slip ring outer diameter:
Standard
22.7 mm (0.894 in)
Limit
22.1 mm (0.870 in)
3) Continuity test:
Check the resistance between slip rings using a cir- I G6M0077

cuit tester. 3. STATOR

If the resistance is not within specification, replace
the rotor assembly. 1) Continuity test:
Inspect the stator coil for continuity between each
Specified resistance: end of the lead wires. If the resistance value is
Approx. 2.7 -3.2 a above 1MR between individual lead wires, the lead
wire is broken, and so replace the stator assembly.

I ,-Stator

I G6M0075 I

4) Insulation test: I G6M0078

Check the continuity between slip ring and rotor
core or shaft. If the resistance value is below l R ,
the rotor coil is grounded, and so replace the rotor
assembly.
2) Insulation test:
Inspect the stator coil for continuity between stator
coil and each end of the lead wire. If the resistance
value is below l R , the stator coil is grounded, and
so replace the stator assembly.

G6M0076
G6M0079

SC-16
 GENERATOR
STARTING/CHARGING SYSTEMS

4. BRUSH 5. BEARING (FRONT SIDE)

1) Measure the length of each brush. If wear ex- 1) Check the front ball bearing. If resistance is felt
ceeds the service limit, replace the brush. Each while rotating, or if abnormal noise is heard, re-
brush has the service limit mark (A) on it. place the ball bearing.
2) Replacing front bearing:
Brush length:
Standard (1) Remove the front bearing retainer.
18.5 mm (0.728 in) (2) Closely install a fit tool on the bearing inner
race. Press the bearing down out of front brack-
Service limit
et with a hand press or vise. A socket wrench
5.0 mm (0.197 in)
can serve as the tool.

Lu H6M0499B
2) Checking brush spring for proper pressure:
Using a spring pressure indicator, push the brush
into the brush holder until its tip protrudes 2 mm
(0.08 in). Then measure the pressure of the brush
spring. If the pressure is less than 2.648 N (270 g,
9.52 oz), replace the brush spring with a new one.
The new spring must have a pressure of 4.609 to
5.786 N (470 to 590 g, 16.58 to 20.81 02).
S6M0409A
(A) Front bracket
(B) Socket wrench
(3) Set a new bearing and closely install a fit
tool on the bearing outer race. Press the bearing
down into place with a hand press or vise. A
socket wrench can serve as the tool.
(4) Install the front bearing retainer.

I S6M0410A

(A) Bearing
(B) Socket wrench
(C) Front bracket

SC-17
I
BATTERY
STARTING/CHARGING SYSTEMS

4. Battery
A: REMOVAL
1) Disconnect the positive (+) terminal after discon-
necting the negative (-) terminal of battery.
2) Remove the flange nuts from battery rods and
take off battery holder.
150E
- fabrics, or paint-work because battery fluid is
3) Remove the battery.
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
3.4 N-m (0.35 kgf-m, 2.5 I?-lb)
NOTE:
Clean the battery cable terminals and apply
grease to retard the formation of corrosion.
Connect the positive (+) terminal of battery and
then the negative (-) terminal of the battery.
C: INSPECTION
WARNING:
Electrolyte has toxicity; be careful handling
the fluid.
Avoid contact with skin, eyes or clothing. Es-
pecially at contact with eyes, flush with water
for 15 minutes and get prompt medical atten-
tion.
Batteries produce explosive gasses. Keep
sparks, flame, cigarettes away.
Ventilate when charging or using in enclosed
space.
For safety, in case an explosion does occur,
wear eye protection or shield your eyes when
working near any battery. Never lean over a bat-
tery.
Do not let battery fluid contact eyes, skin,
corrosive acid.
To lessen the risk of sparks, remove rings,
metal watch-bands, and other metal jewelry.
Never allow metal tools to contact the positive
battery terminal and anything connected to it
while you are at the same time in contact with
any other metallic portion of the vehicle be-
cause a short circuit will be caused.
1. EXTERNAL PARTS:
Check for the existence of dirt or cracks on the bat-
tery case, top cover, vent plugs, and terminal posts.
If necessary, clean with water and wipe with a dry
cloth.
Apply a thin coat of grease on the terminal posts to
prevent corrosion.
2. ELECTROLYTE LEVEL:
Check the electrolyte level in each cell. If the level
is below MIN LEVEL, bring the level to MAX LEVEL
by pouring distilled water into the battery cell. Do
not fill beyond MAX LEVEL.

sc-18

3. SPECIFIC GRAVITY OF ELECTROLYTE:
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) us-
ing the following equation:
s, = St + 0.0007 x (t - 20)
S 2 Specific
~ gravity corrected at electrolyte
temperature of 20°C
St :Measured specific gravity
t :Measured temperature ("C)
Determine whether or not battery must be
charged, according to corrected specific
gravity.
Standard specific gravity: 1.220 - 1.290 [at
20°C (SSOF)]
I 1.28 i,
~-
1
100% 75% 50% 22%
Complete charge Charging condition (I)
Specific gravity and state of charge
2) Measuring the specific gravity of the electrolyte
in the battery will disclose the state of charge of the
battery. The relation between the specific gravity
and the state of charge is as shown in the figure.
D: MEASUREMENT
WARNING:
Do not bring an open flame close to the bat-
tery at this time.
CAUTION:
Prior to charging, corroded terminals should
be cleaned with a brush and common baking
soda solution.
Be careful since battery electrolyte overflows
while charging the battery.
Observe instructions when handling the bat-
tery charger.
Before charging the battery on vehicle, dis-
connect the battery ground terminal. Failure to
follow this rule may damage the generator's di-
odes or other electrical units.
BATTERY
START1NG/CHARGI NG SYSTEMS
1. JUDGMENT OF BATTERY IN CHARGED
CONDITION
1) Specific gravity of electrolyte is held at a specific
value in a range from 1.250 to 1.290 for more than
one hour.
2) Voltage per battery cell is held at a specific value
in a range from 2.5 to 2.8 volts for more than one
hour.
2. CHECK HYDROMETER FOR STATE OF
CHARGE
II Hydrometer
indicator
1 State of charge I Required action
Greendot 1 Above65% I Load test
Dark dot 1 Below65% 1 Charge battery
I 'Iear dot 1 1 Replace battery*
electrolyte (If cranking complaint)
I I *: Check electrical system before replacement.
3. NORMAL CHARGING
Charge the battery at current value specified by
manufacturer or at approximately 1/10 of battery's
ampere-hour rating.
4. QUICK CHARGING
!El
0%
Quick charging is a method in which the battery is
G6M01I
charged in a short period of time with a relatively
large current by using a quick charger.
Since a large current flow raises electrolyte temper-
ature, the battery is subject to damage if the large
current is used for prolonged time. For this reason,
the quick charging must be carried out within a cur-
rent range that will not increase the electrolyte tem-
perature above 40°C (104°F).
It should be also remembered that the quick charg-
ing is a temporary means to bring battery voltage
up to a fair value and, as a rule, a battery should be
charged slowly with a low current.
CAUTION:
Observe the items in 1. NORMAL CHARGING.
Never use more than 10 amperes when
charging the battery because it will shorten bat-
tery life.
sc-19
 BATTERY
STARTING/CHARGING SYSTEMS

sc-20
ENGINE (DIAGNOSTICS)

EN(S0HC)
Page
1. Basic Diagnostic Procedure ........................................................................ 2
2. Check List for Interview............................................................................... 4
3. General Description .................................................................................... 6
4. Electrical Components Location.................................................................. 9
5. Engine Control Module (ECM) I/O Signal ................................................. 22
6. Engine Condition Data .............................................................................. 25
7. Transmission Control Module (TCM) I/O Signal ....................................... 26
8. Data Link Connector ................................................................................. 29
9. OBD-II General Scan Tool ........................................................................ 30
10. Subaru Select Monitor............................................................................... 32
11. Read Diagnostic Trouble Code ................................................................. 39
12. Inspection Mode........................................................................................ 40
13. Clear Memory Mode.................................................................................. 43
14. Compulsory Valve Operation Check Mode ............................................... 44
15. Engine Malfunction Indicator Lamp (MIL) ................................................. 46
16. Diagnostics for Engine Starting Failure..................................................... 57
17. List of Diagnostic Trouble Code (DTC) ..................................................... 77
18. Diagnostic Procedure with Diagnostic Trouble Code (DTC) ..................... 84
19. General Diagnostic Table ........................................................................ 330
 BASIC DIAGNOSTIC PROCEDURE
ENGINE (DIAGNOSTICS)

1. Basic Diagnostic Procedure

A: PROCEDURE
1. ENGINE

Step Check Yes No

I CHECK ENGINE START FAILURE. loes the engine start? 30 to step 2. Inspection using
1)Ask the customer when and how the trouble “Diagnostics for
occurred using the interview check list. <Ref. to Engine Start Fail-
EN(S0HC)-4, CHECK, Check List for Inter- ure”. <Ref. to
view.> EN(S0HC)-57,
2)Start the engine. Diagnostics for
Engine Starting
Failure.>
! CHECK ILLUMINATIONOF CHECK ENGINE loes CHECK ENGINE mal- 30 to step 3. Inspection using
MALFUNCTION INDICATOR LAMP (MIL). unction indicator lamp illumi- “General Diagnos-
late? tics Table”. <Ref.
to EN(S0HC)-330,
INSPECTION,
General Diagnos-
tic Table.>
CHECK INDICATION OF DTC ON DISPLAY. Ioes the Subaru Select Moni- Record the diag- Repair the related
1)Turn the ignition switch to OFF. or or OBD-II general scan tool iostic trouble parts.
2)Connect the Subaru Select Monitor or the ndicate DTC? :ode. Repair the NOTE:
OBD-ll general scan tool to data link connec- trouble cause. If DTC is no
tor. <Ref. to shown on displa)
3)Turn the ignition switch to ON and the Sub- EN(S0HC)-77, although the MIL il.
aru Select Monitor or OBD-II general scan tool List of Diagnostic luminates, per,
switch to ON. Trouble Code form diagnostics o
4)Read the DTC on the Subaru Select Monitor (DTC).> Go to MIL (CHECK EN,
or OBD-ll general scan tool. step 4. GlNE malfunctior
indicator lamp) cir.
cuit or combinatior
meter. <Ref. tc
EN(S0HC)-46,
Engine Malfunc,
tion Indicator Lamr
(MIL).>
I PERFORM THE DIAGNOSIS. Ioes the Subaru Select Moni- Inspect using Complete the
1)Perform the clear memory mode. <Ref. to or or OBD-ll general scan tool ‘Diagnostics Pro- diagnosis.
EN(S0HC)-43, Clear Memory Mode.> ndicate DTC? cedure with Diag-
2)Perform the inspection mode. <Ref. to nostic Trouble
EN(S0HC)-40, Inspection Mode.> Code (DTC)”.
<Ref. to
EN(S0HC)-84,
Diagnostic Proce-
dure with Diagnos-
tic Trouble Code
(DTC).>

EN(S0HC)-2
 L1
BASIC DIAGNOSTIC PROCEDURE
ENGINE (DIAGNOSTICS)

2. AUTOMATIC TRANSMISSION
When the trouble code about automatic transmis-
sion is shown on display, carry out the following ba-
sic check. After that, carry out the replacement or
repair work.
1) ATF level check <Ref. to AT-9, Automatic
Transmission Fluid.>
2) Differential gear oil level check <Ref. to AT-1 1,
DifferentialGear Oil.>
3) ATF leak check <Ref. to AT-9, Automatic Trans-
mission Fluid.>
4) Differential gear oil leak check <Ref. to AT-1 1,
DifferentialGear Oil.>
5 ) Stall test <Ref. to AT-13, Stall Test.>
6) Line pressure test <Ref. to AT-16, Line Pressure
Test.>
7) Transfer clutch pressure test <Ref. to AT-18,
Transfer Clutch Pressure Test.>
8) Time lag test <Ref. to AT-15, Time Lag Test.>
9) Road test <Ref. to AT-12, Road Test.>
10) Shift characteristics <Ref. to AT-18, Transfer
Clutch Pressure Test.>

EN(S0HC)S
 CHECK LIST FOR INTERVIEW
ENGINE (DIAGNOSTICS)

2. Check List for Interview

A: CHECK
1. CHECK LIST NO. 1
Check the following items when problem has occurred.
NOTE:
Use copies of this page for interviewing customers.
Customer's name I Engine no. I
Date of sale Fuel brand
Date of repair Odometer reading km
Vin no. miles
Weather

Outdoor temperature
U Hot
U Warm
U Cool
U Cold
Place U Highway
CI Suburbs
U Inner city
U Uphill
0 Downhill
U Rough road
El Others:
Engine temperature U Cold
U Warming-up
U After warming-up
U Any temperature
U Others:
Ennine speed rpm I
Vehicle speed MPH I
Driving conditions

Headlight 0 ON/U OFF Rear defogger U ON/D OFF

Blower U ON/U OFF Radio CI O N D OFF
WC compressor U ON/U OFF CD/Cassette CI O N D OFF
Soolina fan 7 ON/U OFF Car phone CI O N D OFF
Front wiper CI ON/U OFF I CB I 0 O N D OFF
Rear wiper U ON/U OFF I

EN(SOHC)-4
 CHECK LIST FOR INTERVIEW
ENGINE IDIAGNOSTICS)

2. CHECK LIST NO. 2

Check the following items about the vehicle's state when MIL turns on.
NOTE:
Use copies of this page for interviewing customers.
a) Other warninq liahts or indicators turn on. U Yes/CI No
CI Low fuel warning light
D Charge indicator light
0 AT diagnostics indicator light
U ABS warning light
0 Engine oil pressure warning light
b) Fuel level
Lack of gasoline: U YesD No
Indicator position of fuel gauge:
c) Intentional connecting or disconnecting of harness connectors or spark plug cords: U Yes/CI No
What:
d)Intentional connecting or disconnecting of hoses: U Yes/U No
What:
e) Installing of parts other than genuine parts: U Yes/U No
What:
~~
Where: ~~

f) Occurrence of noise: U Yes/CI No

~

From where:
What kind:
g) Occurrence of smell: 0 YesQ No
From where:
What kind:
h)Intrusion of water into engine compartment or passenger compartment: U YesD No
i) Troubles occurred
D Engine does not start.
U Engine stalls during idling.
D Engine stalls while driving.
U Engine speed decreases.
U Engine speed does not decrease.
El Rough idling
Ll Poor acceleration
Ll Back fire
CI After fire
No shift
U Excessive shift shock

EN(S0HC)-5
I
GENERAL DESCRIPTION
ENGINE (DIAGNOSTICS)

3. General Description 8) Use ECM mounting stud bolts at the body head
grounding point when measuring voltage and resis-
A: CAUTION tance inside the passenger compartment.
1) Airbag system wiring harness is routed near the
engine control module (ECM), main relay and fuel
pump relay.
CAUTION:
All Airbag system wiring harness and con-
nectors are colored yellow. Do not use electri-
cal test equipment on these circuit.
Be careful not to damage the Airbag system
wiring harness when servicing the engine con-
trol module (ECM), transmission control mod-
ule (TCM), main relay and fuel pump relay.
2) Never connect the battery in reverse polarity. 9) Use engine grounding terminal or engine proper
The ECM will be destroyed instantly. as the grounding point to the body when measuring
The fuel injector and other part will be damaged voltage and resistance in the engine compartment.
in just a few minutes more.
3) Do not disconnect the battery terminals while the
engine is running.
A large counter electromotive force will be gener-
ated in the generator, and this voltage may damage
electronic parts such as ECM, etc.
4) Before disconnecting the connectors of each
sensor and the ECM, be sure to turn OFF the igni-
tion switch.
5 ) Poor contact has been identified as a primary
cause of this problem. To measure the voltage and/
or resistance of individual sensors or all electrical 10) Use TCM mounting stud bolts at the body head
control modules at the harness side connector, use grounding point when measuring voltage and resis-
a tapered pin with a diameter of less than 0.64 mm tance inside the passenger compartment.
(0.025 in). Do not insert the pin more than 5 mm
(0.20 in) into the part.
6) Before removing the ECM from the located posi-
tion, disconnect two cables on battery.
Otherwise, the ECM may be damaged.
CAUTION:
When replacing the ECM, be careful not to use
the wrong spec. ECM to avoid any damage on
fuel injection system.
7) The connectors to each sensor in the engine
1666E
compartment and the harness connectors on the
engine side and body side are all designed to be 11) Every MFI-related part is a precision part. Do
waterproof. However, it is still necessary to take not drop them.
care not to allow water to get into the connectors
when washing the vehicle, or when servicing the
vehicle on a rainy day.

EN(S0HC)-6
 GENERAL DESCRIPTION
12) Observe the following cautions when installing
a radio in MFI equipped models.
CAUTION:
The antenna must be kept as far apart as pos-
sible from the control unit.
(The ECM is located under the steering column,
inside of the instrument panel lower trim panel.)
The antenna feeder must be placed as far
apart as possible from the ECM and MFI har-
ness.
Carefully adjust the antenna for correct
matching.
When mounting a large power type radio, pay
special attention to the three items above men-
tioned.
Incorrect installation of the radio may affect
the operation of the ECM.
13) Before disconnecting the fuel hose, disconnect
the fuel pump connector and crank the engine for
more than five seconds to release pressure in the
fuel system. If engine starts during this operation,
run it until it stops.
14) Problems in the electronic-controlledautomatic
transmission may be caused by failure of the en-
gine, the electronic control system, the transmis-
sion proper, or by a combination of these. These
three causes must be distinguished clearly when
performing diagnostics.
15) Diagnostics should be conducted by rotating
with simple, easy operations and proceeding to
complicated, difficult operations. The most impor-
tant thing in diagnostics is to understand the cus-
tomer’s complaint, and distinguish between the
three causes.
16) In AT vehicles, do not continue the stall for
more than five seconds at a time (from closed throt-
tle, fully open throttle to stall engine speed).
17) On ABS vehicle, when performing driving test
in jacked-up or lifted-up position, sometimes the
warning light may be lit, but this is not a malfunction
of the system. The reason for this is the speed dif-
ference between the front and rear wheels. After di-
agnosis of engine control system, perform the ABS
memory clearance procedure of self-diagnosis sys-
tem.
B: INSPECTION
Before performing diagnostics, check the following
items which might affect engine problems:
1. BATTERY
1) Measure battery voltage and specific gravity of
electrolyte.
Standard voltage: 12 V
Specific gravity: Above 1.260
EN(SOHC)-7
ENGINE (DIAGNOSTICS)
2) Check the condition of the main and other fuses,
and harnesses and connectors. Also check for
proper grounding.
2. ENGINE GROUNDING
Make sure the engine grounding terminal is proper-
ly connected to the engine.
I
C: NOTE
1. DESCRIPTION
The on-board diagnostics (OBD) system detects
and indicates a fault in various inputs and outputs
of the complex electronic control. CHECK ENGINE
malfunction indicator lamp (MIL) in the combination
meter indicates occurrence of a fault or trouble.
Further, against such a failure or sensors as may
disable the drive, the fail-safe function is provided
to ensure the minimal driveability.
The OBD system incorporated with the vehicles
within this engine family complies with Section
1968.1, California Code of Regulations (OBD-II
regulation). The OBD system monitors the compo-
nents and the system malfunction listed in Engine
Section which affects on emissions.
When the system decides that a malfunction oc-
curs, MIL illuminates. At the same time of the MIL il-
lumination or blinking, a diagnostic trouble code
(DTC) and a freeze frame engine conditions are
stored into on-board computer.
The OBD system stores freeze frame engine
condition data (engine load, engine coolant tem-
perature, fuel trim, engine speed and vehicle
speed, etc.) into on-board computer when it detects
a malfunction first.
If the OBD system detects the various malfunc-
tions including the fault of fuel trim or misfire, the
OBD system first stores freeze frame engine condi-
tions about the fuel trim or misfire.
When the malfunction does not occur again for
three consecutive driving cycles, MIL is turned off,
but DTC remains at on-board computer.
The OBD-II system is capable of communication
with a general scan tool (OBD-ll general scan tool)
formed by IS0 9141 CARB.
 GENERAL DESCRIPTION
ENGINE (DIAGNOSTICS)
The OBD-II diagnostics procedure is different
from the usual diagnostics procedure. When trou-
bleshooting OBD-II vehicles, connect Subaru Se-
lect Monitor or the OBD-ll general scan tool to the
vehicle.
2. ENGINE AND EMISSION CONTROL SYS-
TEM
The Multipoint Fuel Injection (MFI) system is a
system that supplies the optimum air-fuel mixture
to the engine for all the various operating condi-
tions through the use of the latest electronic tech-
nology.
With this system fuel, which is pressurized at a con-
stant pressure, is injected into the intake air pas-
sage of the cylinder head. The injection quantity of
fuel is controlled by an intermittent injection system
where the electro-magnetic injection valve (fuel in-
jector) opens only for a short period of time, de-
pending on the quantity of air required for one cycle
of operation. In actual operation, the injection quan-
tity is determined by the duration of an electric
pulse applied to the fuel injector and this permits
simple, yet highly precise metering of the fuel.
Further, all the operating conditions of the engine
are converted into electric signals, and this results
in additional features of the system, such as large
D: PREPARATION TOOL
ILLUSTRATION TOOL NUMBER
24082AA150
(New adopted tool)
B2M3876
22771AA030
B2M3877
EN(SOHC)-8
improved adaptability, easier addition of compen-
sating element, etc.
The MFI system also has the following features:
Reduced emission of harmful exhaust gases.
Reduced in fuel consumption.
Increased engine output.
Superior acceleration and deceleration.
Superior startability and warm-up perfor-
mance in cold weather since compensation is
made for coolant and intake air temperature.
3. AUTOMATIC TRANSMISSION AND
ELECTRONIC-HYDRAULICCONTROL SYS-
TEM
The electronic-hydraulic control system consists of
various sensors and switches, a transmission con-
trol module (TCM) and the hydraulic controller in-
cluding solenoid valves. The system controls the
transmission proper including shift control, lock-up
control, overrunning clutch control, line pressure
control and shift timing control. It also controls the
AWD transfer clutch. In other words, the system
detects various operating conditions from various
input signals and sends output signals to shift sole-
noids 1, 2 and low clutch timing solenoid and 2-4
brake timing solenoid, line pressure duty solenoid,
lock-up duty solenoid, transfer duty solenoid and 2-
4 brake duty solenoid (a total of eight solenoids).
DESCRIPTION REMARKS
SARTRIDGE Troubleshooting for electrical
systems.
SELECT MONITOR KIT Troubleshooting for electrical
systems.
English: 22771AA030 (With-
out printer)
German: 22771AA070
(Without printer)
French: 22771AA080
(Without printer)
Spanish: 22771AA090
(Without printer)
 ELECTRICAL COMPONENTS LOCATION
ENGINE (DIAGNOSTICS)
~

4. Electrical Components Location

A: LOCATION
1. ENGINE
MODULE

(1) Engine control module (ECM) (3) Test mode connector

(2) CHECK ENGINE malfunction indi- (4) Data link connector
cator lamp (MIL)

EN1065
03M1575A

EN(S0HC)g
 ELECTRICAL COMPONENTS LOCATION
ENGINE (DIAGNOSTICS)

SENSOR

(6)
EN0719

(1) Atmospheric pressure sensor (3) Engine coolant temperature sen- (5) Knock sensor
(2) Intake air temperature and pres- sor (6) Camshaft position sensor
sure sensor (4) Throttle position sensor (7) Crankshaft position sensor

EN(S0HC)-10
ELECTRICAL COMPONENTS LOCATION
ENGINE (DIAGNOSTICS)

02M3713A

S2M12400

02M2241A / / 02M2242A

02M0213J

EN(S0HC)-11
 ELECTRICAL COMPONENTS LOCATION
ENGINE (DIAGNOSTICS)

B2M3703A

(1) Front oxygen (NF) sensor (3) Front catalytic converter

(2) Rear oxygen sensor (4) Rear catalytic converter

B2M2253A OBDOO91I

OBD0524G , I OBD0525G

EN(S0HC)-12
 ELECTRICAL COMPONENTS LOCATION
ENGINE (DIAGNOSTICS)

I .

(3) (4)
EN106i

(1) Fuel level sensor (3) Fuel tank pressure sensor

(2) Fuel temperature sensor (4) Fuel sub level sensor

S2M0270A

EN(S0HC)-13
 ELECTRICAL COMPONENTS LOCATION
ENGINE (DIAGNOSTICS)

SOLENOID VALVE, EMISSION CONTROL SYSTEM PARTS AND IGNITION SYSTEM PARTS

EN0736

(1) Air assist injector solenoid valve (3) Purge control solenoid valve
(2) Idle air control solenoid valve (4) Ignition coil & ignitor ASSY

EN(S0HC)-14
ELECTRICAL COMPONENTS LOCATION
ENGINE (DIAGNOSTICS)

'1 5A H2M3259A

H2M3258B 720A

EN(S0HC)-15
 ELECTRICAL COMPONENTS LOCATION
ENGINE (DIAGNOSTICS)

(1) Pressure control solenoid valve (3) Drain valve

(2) Canister (4) Drain filter

\ I / 1 S2M0949B

H2M2444A

EN(S0HC)-16
 ELECTRICAL COMPONENTS LOCATION
ENGINE (DIAGNOSTICS)

EN0741

(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

I
\o\ EN1069
02M2246A

EN1070

EN(S0HC)-17
 ELECTRICAL COMPONENTS LOCATION
ENGINE (DIAGNOSTICS)

EN(S0HC)-18
 ELECTRICAL COMPONENTS LOCATION
ENGINE (DIAGNOSTICS)

2. TRANSMISSION
MODULE

(1) Transmission Control Module (2) AT diagnostic indicator light (for AT

(TCM) (for AT vehicles) vehicles)

EN(S0HC)-19
 ELECTRICAL COMPONENTS LOCATION
ENGINE (DIAGNOSTICS)
SENSOR

/(5)

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(S0HC)-20
 (S3131H3A 1 W ) H311MS aNV 3AlVA alON310S

(S311SONE)Vld 3NIE)N3
N011V301 SlN3NOdW03 lV31t113313
 ENGINE CONTROL MODULE (ECM) I/O SIGNAL
ENGINE (DIAGNOSTICS)

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

A: ELECTRICAL SPECIFICATION

to to @ to @ij$

I 02M2267A

Crank-
Content

Signal (+)
I I ‘On-
nF:or

8135
Terminal
NO.

1
Ignition sw ON
(Engine OFF)
0
Signal (V)

I
Engine ON (Idling)
-7 to +7
Note

Sensor output waveform

shaft posi- Signal (-) 8135 8 0 0 -
tion sensor Shield
~~ 8135 ~~ 10 0 0 -
Camshaft Signal (+) 8135 2 0 -7 to +7 Sensor output waveform
position Signal (-) 8135 9 0 0
Sensor Shield 8135 10 0 0
Fully closed: 0.2 - 1.O
Signal 8136 17
Fully opened: 4.2 - 4.7
Throttle
Power
position 8136 15 5 5
sensor supply
GND (sen- 8136
16 0 0
sor)
Signal 8136 18 0 0 - 0.9
Rear OXY-
Shield 8136 24 0 0
gen sen-
sor GND (sen- 8136
16 0 0
sor)
Front oxy- .Signal 1 8134 22 0- 1.0 0-1.0
gen ( W
Sensor Signal2 8134 23 0- 1.0 0- 1.0
heater
Rear oxygen sensor
heater signal
-
I 8134 I 21 I 0- 1.0
I 0- 1.0 -
Engine Signal 8136 14 1.o - 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 sen- sor)
sor
Vehicle speed signal I 8135 I 24 I 0 or 5 I Oor5
“5” and “ 0 are repeatedly dis-
played when vehicle is driven.
~

EN(S0HC)-22
 ENGINE CONTROL MODULE (ECM) I/O SIGNAL
ENGINE (DIAGNOSTICS)

ON: 0.5, or less ON: 0.5, or less

N C relay control

~~ ~

EN(S0HC)-23
 ENGINE CONTROL MODULE (ECM) I/O SIGNAL
ENGINE (DIAGNOSTICS)

Content 1 1 Con-
nr:or
Terminal
No. Ignition sw ON
(Engine OFF)
Signal (V)
I Engine ON (Idling)
Note

Fuel temperature sen-

so r
~~
I B136 I 26 2.5 - 3.8 I 2.5-3.8
Ambient temperature: 25°C
(75°F)
Fuel level sensor B136 27 0.12 - 4.75 0.12 - 4.75
The valve 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 -
B136 15 5 5
sensor supply
GND (sen- B136
16 0 0
sor)
Fuel tank pressure con- ON: 1, or less ON: 1, or less
B134 1
to1 solenoid valve OFF: 10- 13 OFF: 13- 14

Drain valve I 8134 I 10

ON: 1, or less
I ON: 1, or less

AT diagnosis input sig-

nal
I B135 I 4
OFF: 10- 13
Less than 1 ++
More than 4
OFF:13-14
Less than 1 ++
More than 4
Waveform

ON: 0 ON: 0 -
Small light switch
OFF: 10- 13 OFF: 13- 14

Blower fan switch

Reardefoggerswitch
Front oxygen (NF) sen-
sor sianal 1
1 1311 1 ;;
ON: 0
OFF: 10- 13
ON: 0
OFF: 10 - 13
2.8 - 3.2
ON: 0
OFF: 13 - 14
ON: 0
OFF: 13- 14

2.8 - 3.2

Front oxygen (NF) sen-

B136 6 2.4 - 2.7 2.4 - 2.7
sor signal 2
Front oxygen (NF) sen-
B136 7 0.2 - 4.9 0.2 - 4.9
sor sianal 3
~~

Front oxygen (NF)sen-

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
~ ~ ~ / ~ ~ ~ c o m m
tion line
1 uB135 I
n i c a -
3
Less than 1 +-+
More than 4 I Less than 1 e-+
More than 4
GND (sensors) B136 16 0 0
GND (injectors) B134 7 0 0
GND (ignition system) B134 27 0 0
GND (Dower SUDD~V) B134 8 0 0
I

1 1:;: 1 1; 1
B136 21 0

1
0
8136 I 22 0 0
GND (oxygen sensor
heaterl)
GND (oxygen sensor
1 1
heater 2)

EN(S0HC)-24
 ENGINE CONDITION DATA
ENGINE (DIAGNOSTICS)
~

6. Engine Condition Data

A: ELECTRICAL SPECIFICATION
Content Specified data
1.6 - 2.9 (Yo): Idling
Engine load
6.4 - 12.8 (Yo):
2,500 rpm racing

EN(SOHC)Q5
 TRANSMISSION CONTROL MODULE (TCM) I/O SIGNAL
ENGINE (DIAGNOSTICS)

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

A: ELECTRICAL SPECIFICATION

to @I to @
I ” I
8 7 6 5 4 3 2 1
17
- 16 1514 13121110
-
24 23 22 21 2019

NOTE:
Check with ignition switch ON.
Con- Resistanceto
Termi-
Content nector Measuring conditions Voltage (V)
nal No. body (ohms)
No.
Back-up power supply B55 6 Ignition switch OFF 10- 13 -
B54 23 Ignition switch ON (with -
Ignition power supply 10-13
B54 74 enaine OFF)

“P” range
855
switch

“N” range
B55
switch More than 8
than “N” range
Selector lever in “R” ranae
~~
I
Less than 1
“R” range -
B55 17 Selector lever in any other
switch More than 8
than “R” range
I Selector lever in “ D range I Less than 1
1
Inhibitor
switch
“D” range
switch
B55
8 I
I
Selector lever in any other
than “D” ranae*
I
I
Morethan 8
I
-

I -
Selector lever in “ 3 ranQe I Less than 1
“ 3 range -
855 18 Selector lever in any other
switch More than 8
than “ 3 range
[ Selector lever in “2”range I Less than 1
“2” range
switch
854
10 II
Selector lever in any other
than “ 2 ranae“
I
I
More than8
-

I- Selector lever in “1” ranae I Less than 1

“1” range -
854 1 Selector lever in any other
switch More than 8
than “1” range
Brake pedal depressed. More than 10.5 -
Brake switch B55 24
Brake pedal released. Less than 1

EN(S0HC)-26
 TRANSMISSION CONTROL MODULE (TCM) I/O SIGNAL
ENGINE (DIAGNOSTICS)

1 1 1
Con-
Termi- Resistanceto
Content nector Measuring conditions Voltage (V)
body (ohms)
No. rial No'
ABS switch ON Less than 1 -
ABS signal 854 19
ABS switch OFF More than 6.5
Light ON Less than 1 -
AT OIL TEMP light B54 3
LiQht OFF More than 9
Throttle fully closed. Approx. 0.5
Throttle fully open. Approx. 4.3
Throttle position sensor power Ignition switch ON -
B55 1
(With engine OFF)
4.8 - 5.3
supply
ATF temperature 20°C
1.6 - 2.0 2.1 -2.9 k
(68°F)
ATF temperature sensor B55 11
ATF temperature 80°C
0.4 - 0.9 275 - 375
(176°F)
Vehicle stopped. 0
Rear vehicle speed sensor 855 3 Vehicle speed at least 20 More than (AC 450 - 650
km/h (12 MPH)
I I I Vehicle stopped.
. . I 0 I
Front vehicle speed sensor
I
I
B55 I
I
II
I
Vehicle speed at least 20
km/h ( 1 2 MPH)
Engine idling after warm-up
I

I
More than (Ac

n
I
450 - 650

v
Torque converter turbine (D range).
B55 12 450 - 650
speedsensor Engine idling after warm-up
More than 1 (AC range)
(N range).
Vehicle speed at most 10 Less than I t -
Vehicle speed output signal 855 13
km/h (6 MPH) +More than 5
Ignition switch ON (with
0
engine OFF) -
Engine speed signal 855 4
Ignition switch ON (with
0 - 13 or more
engine ON)
When cruise control is set
Less than 1
(SET lamp ON) -
Cruise set signal B54
When cruise control is not
More than 6.5
set (SET lamp OFF)
Ignition switch ON (with
Torque control 1 signal B54 13
engine ON)
More than 4.8 -
Ignition switch ON (with
Torque control 2 signal 854 21
engine ON)
More than 4.8 -
Torque control cut signal 854 2 Ignition switch ON 8 -
Intake manifold pressure sig- -
855 20 Engine idling after warm-up. 1.2 - 1.8
nal
AT load signal B55 20 Engine idling after warm-up. 1.2 - 1.8 -
Shift solenoid 1
I BS4
I - 1st gear More than 9
- 10-16
3rd gear Less than 1
2nd gear More than 9
Shift solenoid 2 R54 6 in- if7
II --' 1I - 1I 4th aear
u
I1 Less than 1 I .- .-

I
Throttle fully closed (with I I C
I .J - r2.vn
engine OFF) after warm-up.
Line pressure duty solenoid 854 9
Throttle fully open (with
Less than 1
engine OFF) after warm-up. 2.0 - 4.5
Throttle fully closed (with
More than 8.5
engine OFF) after warm-up.
Dropping resistor B54 9-15
l8 Throttle fully open (with
Less than 0.5
engine OFF) after warm-up.

EN(S0HC)-27
 TRANSMISSION CONTROL MODULE (TCM) I/O SIGNAL
ENGINE (DIAGNOSTICS)

7 Content
Con-
nector
No.
Termi-
nal No.
Measuring conditions

When lock UD occurs.

Voltage (V)

More than 8.5

Resistanceto
body (ohms)

Lock-up duty solenoid 854 16 10-17

When lock up is released. Less than 0.5
Fuse on FWD switch More than 8.5
Fuse removed from FWD
Transfer duty solenoid 854 15 switch (with throttle fully 10-17
Less than 0.5
open and with select lever in
1st gear).
Throttle fully closed (with
1.5 - 5.0
engine OFF) after warm-up.
2.0 - 4.5

-1
2-4 brake duty solenoid 654 8
Throttle fully open (with
Less than 1
enaine OFF) after warm-up.
Throttle fully closed (with
More than 8.5 9-15
engine OFF) after warm-up.
2-4 brake dropping resistor 654 17
Throttle fully open (with
Less than 0.5
engine OFF) after warm-up.
1st aear Less than 1
2-4 brake timing solenoid 654 5 10-16
3rd aear More than 9
2nd gear Less than 1
Low clutch timing solenoid 854 14 10-16
4th gear More than 9 I

Sensor ground line 855 21 0 1 Lessthan 1

System ground line 855

9
19
0 I
I
Lessthan 1

Fuse removed. More than 9

FWD switch 855 14
Fuse installed.
~~

Fuse on FWD switch Less than 1

FWD indicator light 854 12 Fuse removed from FWD
More than 9
switch
Data link signal (Subaru 7 -
855
16
Less than 1 t -
AT diagnosis signal 854 4 Ignition switch ON
+ More than 4

EN(S0HC)-28
 DATA LINK CONNECTOR
ENGINE (DIAGNOSTICS)

8. Data Link Connector

A: NOTE
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 Mon-
itor, because the circuit for the Subaru Select Monitor may be damaged.

I H2M1280

*: Circuit only for Subaru Select Monitor

EN(S0HC)-29
 OBD-II GENERAL SCAN TOOL
ENGINE (DIAGNOSTICSI

9. OBD-II General Scan Tool
A: OPERATION
1. HOW TO USE OBD-ll GENERAL SCAN
TOOL
1) Prepare a general scan tool (OBD-II general
scan tool) required by SAE J1978.
2) Connect the OBD-II general scan tool to the data
link connector located in the lower portion of the in-
strument panel (on the driver's side).
3) Using the OBD-ll general scan tool, call up diag-
nostic trouble code(s) and freeze frame data.
OBD-II general scan tool functions consist of:
(1) MODE $01: Current powertrain diagnostic
data
(2) MODE $02: Powertrain freeze frame data
(3) MODE $03: Emission-related powertrain di-
agnostic trouble codes
(4) MODE $04: Clear/Reset emission-related
diagnostic information
Read out data according to repair procedures. (For
detailed operation procedures, refer to the OBD-ll
General Scan Tool Operation Manual.)
NOTE:
For details concerning diagnostic trouble codes, re-
fer to the List of Diagnostic Trouble Code (DTC).
<Ref. to EN(S0HC)-77, List of Diagnostic Trouble
Code (DTC).>

2. MODE $01 (CURRENT POWERTRAIN DIAGNOSTIC DATA)

Refers to data denoting the current operating condition of analog input/output, digital input/output and/or the
powertrain system.
A list of the support data and PID (Parameter Identification) codes are shown in the following table.

PID Data Unit of measure

01 Number of emission-related powertrain trouble codes and MIL status ONIOFF
03 Fuel system control status -
04 Calculated enaine load value YO

05 I Enaine coolant temDerature "C

I 06 I Short term fuel trim I YO
07 Long term fuel trim YO

OB Intake manifold absolute pressure kPa

OC Engine revolution rPm
OD Vehicle speed kmlh
0
OE lanition timina advance
r 10 I Air flow rate from Dressure sensor I glsec
I 11 I Throttle valve opening angle I %
13 Check whether oxygen sensor is installed. -
Oxygen sensor output voltage and short term fuel trim associated with oxygen sensor-bank
l4 V and Yo
1
Oxygen sensor output voltage and short term fuel trim associated with oxygen sensor-bank
V and %
2
1C On-board diagnosis system -

EN(S0HC)-30
 OBD-II GENERAL SCAN TOOL
ENGINE (DIAGNOSTICS)

02 I Trouble code that caused CAR6 required freeze frame data storaue -
r 03 I Fuel svstem control status I - I
04 Calculated engine load value YO

05 Engine coolant temperature "C

06 Short term fuel trim YO

07 Long term fuel trim YO

OB Intake manifold absolute Dressure kPa

OC I Engine revolution rPm
OD I 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)
Refer to Read Diagnostic Trouble Code for information about data denoting emission-related powertrain di-
agnostic trouble codes. <Ref. to EN(S0HC)-39, Read Diagnostic Trouble Code.>
5. MODE $04 (CLEAWRESET EMISSION-RELATED DIAGNOSTIC INFORMATION)
Refers to the mode used to clear or reset emission-related diagnostic information (OBD-ll trouble diagnostic
information).
NOTE:
Refer to OBD-II general scan tool manufacturer's instruction manual to clear or reset emission-related diag-
nostic information (MODE $04).

EN(S0HC)-31
 SUBARU SELECT MONITOR
ENGINE (DIAGNOSTICS)
1O.Subaru Select Monitor
A: OPERATION
1. HOW TO USE SUBARU SELECT MONI-
TOR
1) Prepare the Subaru Select Monitor kit. <Ref. to
EN(S0HC)-8, PREPARATION TOOL, General De-
scription.>
2) Connect the diagnosis cable to Subaru Select
Monitor.
3) Insert the cartridge into Subaru Select Monitor.
<Ref. to EN(S0HC)-8, PREPARATION TOOL,
General Description.>
4) Connect the 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).
EN(S0HC)-32
(2) Connect the diagnosis cable to data link
connector.
CAUTION:
Do not connect scan tools except for Subaru
Select Monitor and OBD-ll general scan tool.
5) Turn the ignition switch to ON (engine OFF) and
Subaru Select Monitor switch to ON.
’’ S2M0288A
6) Using the Subaru Select Monitor, call up diag-
nostic trouble code(s) and various data, then
record them.
2. READ DIAGNOSTIC TROUBLE CODE
(DTC) FOR ENGINE. (NORMAL MODE)
Refer to Read Diagnostic Trouble Code for infor-
mation about how to indicate DTC. <Ref. to
EN(S0HC)-39, Read Diagnostic Trouble Code.>
3. READ DIAGNOSTIC TROUBLE CODE
(DTC) FOR ENGINE. (OBD MODE)
Refer to Read Diagnostic Trouble Code for infor-
mation about how to indicate DTC. <Ref. to
EN(S0HC)-39, Read Diagnostic Trouble Code.>
 SUBARU SELECT MONITOR
ENGINE (DIAGNOSTICSI
~

4. READ CURRENT DATA FOR ENGINE. (NORMAL MODE)

1) On the ((MainMenu,) display screen, select the {Each System Check} and press the [YES] key.
2) On the ((System Selection Menu)) display screen, select the {Engine Control System} and press the [YES]
key.
3) Press the [YES] key after displayed the information of engine type.
4) On the ((EngineDiagnosis,) display screen, select the {Current Data Display & Save} and press the [YES]
key.
5) On the ((Data Display Menu)) display screen, select the {Data Display} and press the [YES] key.
6) Using the scroll key, move the display screen up or down until the desired data is shown.
A list of the support data is shown in the following table.

Contents Display Unit of measure

Battery voltage Battery Voltage V
Vehicle speed signal Vehicle Speed km/h or MPH
Engine speed signal Engine Speed rPm
Enaine coolant temperature signal Coolant Temp. OC or OF
Ignition timing signal 1 Ignition Timing I deg
Throttle position signal Throttle Opening Angle
Throttle position signal Throttle Sensor Voltage V
Injection pulse width Fuel Injection #I Pulse ms
Idle air control sianal ISC Valve Step STEP
Enaine load data I Engine Load %
Front oxvgen (NF) sensor output signal I N F Sensor #I I -
Rear oxygen sensor output signal Rear 0 2 Sensor V
Short term fuel trim N F Correction #I YO
Knock sensor signal Knocking Correction deg
mmHg or kPa or inHg or
Atmospheric absolute pressure signal Atmosphere Pressure
psi
mmHg or kPa or inHg or
Intake manifold relative pressure signal Mani. Relative Pressure
psi
mmHg or kPa or inHg or
Intake manifold absolute pressure signal Mani. Absolute Pressure
psi
NFcorrGtion (short term fuel trim) bv rear oxvgen sensor I N F Correction #3 I %
Long term whole fuel trim N F Learning #I O/O

Front oxygen (NF) sensor heater current Front 0 2 Heater #I A

Rear oxygen sensor heater current Rear 0 2 Heater Current A
Canister purge control solenoid valve duty ratio CPC Valve Duty Ratio YO
Fuel level signal Fuel Level V
Intake air temperature sianal Intake Air Temp. "C or OF
Learned ignition timing Learned Ignition Timing deg
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 N C Switch ON or OFF
Air conditioning signal N C Compressor Signal ON or OFF
Radiator main fan relay signal Radiator Fan Relay #I 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
Power steering switch signal PIS Switch ON or OFF
Engine torque control signal #I Torque Control Signal #1 ON or OFF
Engine torque control signal #2 Torque Control Signal #2 ON or OFF
Engine torque control permission signal Torque Permission Signal ON or OFF
Rear oxygen sensor rich signal Rear 02 Rich Signal ON or OFF

EN(S0HC)-33
 SUBARU SELECT MONITOR
ENGINE (DIAGNOSTICS)

Contents Display Unit of measure

Starter switch sianal I Starter Switch Sianal ON or OFF
Idle switch signal I Idle Switch Sianal 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 Light Switch ON or OFF
Air assist iniector solenoid valve siqnal Assist Air Sol. Valve ON or OFF
AT vehicle ID signal I AT Vehicle ID Signal I ON or OFF I
NOTE:
For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL.

EN(SOHC)-34
 SUBARU SELECT MONITOR
ENGINE (DIAGNOSTICS)

5. READ CURRENT DATA FOR ENGINE. (OBD MODE)

1) On the ((MainMenu,, display screen, select the {Each System Check} and press the [YES] key.
2) On the <(SystemSelection Menu,, display screen, select the {Engine Control System} and press the [YES]
key.
3) Press the [YES] key after displayed the information of engine type.
4) On the (<EngineDiagnosis,, display screen, select the {OBD System} and press the [YES] key.
5) On the (<OBDMenu,, display screen, select the {Current Data Display & Save} and press the [YES] key.
6) On the ((DataDisplay Menu,, display screen, select the {Data Display} and press the [YES] key.
7) Using the scroll key, move the display screen up or down until the desired data is shown.
A list of the support data is shown in the following table.

Contents Display Unit of measure

Number of diagnosis code Number of Diagnosis Code -
Malfunction indicator lamp status MI (MIL) ON or OFF
Monitorina test of misfire Misfire monitorina Complete or incomplete
F M i o r i n n test of fuel system I Fuel system monitoring I Complete or incomplete
I Monitoring test of comprehensive component 1 Component monitoring I Complete or incomplete
I Test of catalyst 1 Catalyst Diagnosis I Complete or incomplete
Test of heated catalyst Heated catalyst No support
Test of evaporative emission purge control system Evaporative purge system Complete or incomplete
Test of secondary air system Secondary air system No support
Test of air conditionina system refriaerant N C system refrigerant No support
I Test of oxygen sensor I Oxygen sensor 1 Complete or incomplete
I Test of oxygen sensor heater 1 0 2 Heater Diagnosis I Complete or incomplete
Test of EGR system EGR system No support
Air fuel ratio control system for bank 1 Fuel System for Bank 1 -
Engine load data Calculated load value YO
Enaine coolant temoerature sianal Coolant Temp. "C or OF
rShort term fuel trim bv front oxygen (NF) sensor I Short term fuel trim B1 I O/O

I Long term fuel trim by front oxygen (NF) sensor 1 Long term fuel trim B1 I YO
I Intake manifold absolute pressure signal 1 Mani. Absolute Pressure
1 mmHg or kPa or inHg or
osi
Engine speed signal Engine Speed rPm
Vehicle speed sianal Vehicle Speed km/h or MPH
Ignition timing advance for #1 cylinder 1 Ignition timing adv. #I 0

Intake air temperature signal I Intake Air Temp. "C or OF

Intake air amount Mass Air Flow g/s
Throttle position signal Throttle Opening Angle O/O

N F sensor eauiment N F sensor ON or OFF

h i r fuel ratio correction by rear oxvaen sensor I Short term fuel trim #12 I YO
I On-board diagnostic system 1 OBD System I -
NOTE:
For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL.

EN(S0HC)-35
 SUBARU SELECT MONITOR
ENGINE (DIAGNOSTICS)

6. READ FREEZE FRAME DATA FOR ENGINE. (OBD MODE)

1) On the ((MainMenu)) display screen, select the {Each System Check} and press the [YES] key.
2) On the ((SystemSelection Menu)) display screen, select the {Engine Control System} and press the [YES]
key.
3) Press the [YES] key after displayed the information of engine type.
4) On the ((Engine Diagnosis))display screen, select the {OBD System} and press the [YES] key.
5) On the ((OBDMenu)) display screen, select the {Freeze Frame Data} and press the [YES] key.
A list of the support data is shown in the following table.

Contents Display Unit of measure

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
Engine load data Enaine Load %
I Engine coolant temperature signal I Coolant Temp. I "C or OF
I Short term fuel trim by front oxygen (NF) sensor I Short term fuel trim B1 I YO

I Long term fuel trim by front oxygen (NF) sensor I Long term fuel trim B1 I
I Intake manifold absolute pressure signal I Mani. Absolute Pressure
1 YO

mmHg or kPa or inHg or

DSi

I Vehicle speed signal I Vehicle Speed I km/h or MPH

NOTE:
For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL.
7. READ OXYGEN SENSOR MONITORING TEST RESULTS DATA FOR ENGINE. (OBD
MODE)
1) On the ((Main Menu)) display screen, select the {Each System Check} and press the [YES] key.
2) On the ((System Selection Menu), display screen, select the {Engine Control System} and press the [YES]
key.
3) Press the [YES] key after displayed the information of engine type.
4) On the ((EngineDiagnosis), display screen, select the {OBD System} and press the [YES] key.
5 ) On the ((OBDMenu)) display screen, select the ( 0 2 Sensor Monitor} and press the [YES] key.
6) On the ((02 Sensor Select)) display screen, select the {Bank 1-Sensorl} or {Bank 1-Sensor2) and press
the [YES] key.
Bank 1-Sensor1 indicates the front oxygen or A/F sensor, and Bank 1-Sensor2 indicates the rear oxygen
sensor.
A list of the support data is shown in the following table.

Oxygen sensor for monitoring test <02 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 I Lean to rich switch time I sec I
Maximum oxygen sensor voltage for test cycle I Maximum sensor Voltage I V I
Minimum oxygen sensor voltage for test cycle I Minimum sensor Voltage V
NOTE:
For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL.

EN(S0HC)-36
 SUBARU SELECT MONITOR
ENGINE (DIAGNOSTICS)
~~~~~ ~ ~

8. LED OPERATION MODE FOR ENGINE

1) On the ((Main Menu), display screen, select the {Each System Check} and press the [YES] key.
2) On the ((System Selection Menu)) display screen, select the {Engine Control System} and press the [YES]
key.
3) Press the [YES] key after displayed the information of engine type.
4) On the ((EngineDiagnosis),display screen, select the {Current Data Display & Save} and press the [YES]
key.
5) On the ((DataDisplay Menu))display screen, select the {Data & LED Display} and press the [YES] key.
6) Using the scroll key, move the display screen up or down until the desired data is shown.
A list of the support data is shown in the following table.

Contents 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 Dosition signal is entered. I
Air conditioning switch signal
Air conditioning relay signal
Radiator main fan relay signal
Fuel pump relay signal
Knocking signal
Radiator sub fan relay signal
Engine torque control signal #l
I
I
N C Switch
N C Relay
Radiator Fan Relay #I
Fuel Pump Relay
Knocking Signal
Radiator Fan Relay #2

Torque Control Signal #I

I
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
I
When air conditioning switch is turned ON.
When air conditioning relay is in function.
When radiator main fan relay is in function.
When fuel pump relay is in function.
When knockina sianal is entered.
Whenradiatorsub fan relav is in function.
When engine torque control signal 1 is
I

Engine torque control signal #2 Torque Control Signal #2 ON or OFF

entered.
Engine torque control permission
Torque Control Permit ON or OFF
sianal nal is entered.
~-
Front oxygen (NF) sensor rich sig- Front o2 Rich Signal
nal
I ON~~OFF
When front oxygen ( N F ) sensor mixture ratio
is rich.
When rear oxygen sensor mixture ratio is
Rear oxygen sensor rich signal Rear 0 2 Rich Signal ON or OFF
rich.
Starter switch sianal Starter Switch Sianal 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:
For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL.

EN(S0HC)-37
 SUBARU SELECT MONITOR
ENGINE (DIAGNOSTICS)

9. READ CURRENT DATA FOR AT.

1) On the ((Main Menu,) display screen, select the {Each System Check} and press the [YES] key.
2) On the ((SystemSelection Menu>> display screen, select the {Transmission Control System} and press the
[YES] key.
3) Press the [YES] key after displayed the information of transmission type.
4) On the ((TransmissionDiagnosis,, display screen, select the {Current Data Display & Save} and press the
[YES] key.
5) On the ((Data Display Menu,, display screen, select the {Data Display} and press the [YES] key.
6) Using the scroll key, move the display screen up or down until the desired data is shown.
A list of the support data is shown in the following table.

Contents Display Unit of measure

Battery voltage Battery Voltage V
Rear vehicle speed sensor signal Vehicle Speed # i km/h or MPH
Front vehicle speed sensor signal Vehicle Speed #2 km/h or MPH
Engine speed signal Engine Speed rPm
Automatic transmission fluid temperature signal ATF Temp. "Cor OF
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 dutv ratio Transfer Dutv Ratio %
Power SUPP~Vfor throttle Dosition sensor I Throttle Sensor Power I V I
Torque converter turbine speed signal AT Turbine Speed rPm
2-4 brake timing pressure control duty ratio 2-4B Duty Ratio YO

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
NeutraVParking range signal NIP Range Signal ON or OFF
Reverse range signal R Range Signal ON or OFF
Drive range signal D Range Signal ON or OFF
3rd ranae sianal 3rd Range Signal ON or OFF
2nd range signal 1 2nd Range Signal ON or OFF
1st range signal I 1st Range Signal ON or OFF
Shift control solenoid A Shift Solenoid #I 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
Toraue control outwt siunal #2 Toruue 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:
For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL.

EN(S0HC)-38
 READ DIAGNOSTIC TROUBLE CODE
ENGINE (DIAGNOSTICS)

11.Read Diagnostic Trouble 3. OBD-II GENERAL SCAN TOOL

Code Refers to data denoting emission-related power-
train diagnostic trouble codes.
A: OPERATION For details concerning diagnostic trouble codes, re-
fer to the List of Diagnostic Trouble Code (DTC).
1. SUBARU SELECT MONITOR (NORMAL <Ref. to EN(S0HC)-77, List of Diagnostic Trouble
MODE) Code (DTC).>
1) On the ((Main Menu), display screen, select the NOTE:
{Each System Check} and press the [YES] key. Refer to OBD-I1 general scan tool manufacturer's
2) On the ((System Selection Menu)) display instruction manual to access emission-related
screen, select the {Engine Control System} and powertrain diagnostic trouble codes (MODE $03).
press the [YES] key.
3) Press the [YES] key after displayed the informa-
tion of engine type.
4) On the ((Engine Diagnosis)) display screen, se-
lect the {Diagnostic Code@) Display} and press the
[YES] key.
5) On the ((Diagnostic Code(s) Display), display
screen, select the {Current Diagnostic Code@)} or
{History Diagnostic Code@)} and press the [YES]
key.
NOTE:
For detailed operation procedure, refer to the
SUBARU SELECT MONITOR OPERATION MAN-
UAL.
For detailed concerning diagnostic trouble
codes, refer to the List of Diagnostic Trouble Code
(DTC). <Ref. to EN(S0HC)-77, List of Diagnostic
Trouble Code (DTC).>
2. SUBARU SELECT MONITOR (OBD
MODE)
1) On the ((Main Menu), display screen, select the
(2.Each System Check} and press the [YES] key.
2) On the ((System Selection Menu), display
screen, select the {Engine Control System} and
press the [YES] key.
3) Press the [YES] key after displayed the informa-
tion of engine type.
4) On the ((Engine Diagnosis)) display screen, se-
lect the {OBD System} and press the [YES] key.
5) On the ((OBD Menu)) display screen, select the
{Diagnosis Code@) Display} and press the [YES]
key.
6) Make sure that a diagnostic trouble code (DTC)
is shown on the display screen.
NOTE:
For detailed operation procedure, refer to the
SUBARU SELECT MONITOR OPERATION MAN-
UAL.
For detailed concerning diagnostic trouble
codes, refer to the List of Diagnostic Trouble Code
(DTC). <Ref. to EN(S0HC)-77, List of Diagnostic
Trouble Code (DTC).>

EN(SOHC)S9
 INSPECTION MODE
ENGINE (DIAGNCSTICS)

12.lnspection Mode 2. SUBARU SELECT MONITOR

After performing diagnostics and clearing the mem-
A: OPERATION ory, check for any remaining unresolved trouble da-
1. PREPARATION FOR THE INSPECTION ta.
MODE 1) Prepare the Subaru Select Monitor kit. <Ref. to
EN(S0HC)-8, PREPARATIONTOOL, General De-
Raise the vehicle using a garage jack and place on scription.>
safety stands or drive the vehicle onto free rollers.
WARNING:
Before raising the vehicle, ensure parking
brakes are applied.
Do not use a pantograph jack in place of a
safety stand.
Secure a rope or wire to the front and rear
towing or tie-down hooks to prevent the lateral
runout of front wheels.
Do not abruptly depresshelease the clutch
pedal or accelerator pedal during works even
when engine is operating at low speeds since 2 ) Connect the diagnosis cable to Subaru Select
this may cause the vehicle to jump off free roll- Monitor.
ers. 3) Insert the cartridge into Subaru Select Monitor.
In order to prevent the vehicle from slipping <Ref. to EN(S0HC)-8, PREPARATION TOOL,
due to vibration, do not place any wooden General Description.>
blocks or similar items between the safety
stands and the vehicle.
Since the rear wheels will also rotate, do not
place anything near them. Also, make sure that
nobody goes in front of the vehicle.

4) Connect the test mode connector (A) at the low-

er portion of instrument panel (on the driver's side),
to the side of the center console box.

B2M2969A

EN(S0HC)-40
 INSPECTION MODE
5) Connect the Subaru Select Monitor to data link
connector.
(1) Connect Subaru Select Monitor to data link
connector located in the lower portion of the in-
strument panel (on the driver’s side).
1
I SUBARU SELECT MONITOR OPERATION MAN-
I wheels may light either the ABS warning light, but
(2) Connect the diagnosis cable to data link
connector.
CAUTION:
Do not connect scan tools except for Subaru
Select Monitor and OBD-II general scan tool.
6) Turn the ignition switch to ON (engine OFF) and
Subaru Select Monitor switch to ON.
I I
I ’’ S2M0288AI
7) On the <<MainMenu)) display screen, select the
{2. Each System Check} and press the [YES] key.
8) On the ((System Selection Menu)) display
screen, select the {Engine Control System} and
press the [YES] key.
9) Press the [YES] key after displayed the informa-
tion of engine type.
10) On the <<EngineDiagnosis,) display screen, se-
lect the {Dealer Check Mode Procedure} and press
the [YES] key.
11) When the “Perform Inspection (Dealer Check)
Mode?” is shown on the display screen, press the
[YES] key.
EN(S0HC)-41
ENGINE (DIAGNOSTICS)
12) Perform subsequent procedures as instructed
on the display screen.
If trouble still remains in the memory, the corre-
sponding diagnostic trouble code (DTC) appears
on the display screen.
NOTE:
For detailed operation procedure, refer to the
UAL.
For detailed concerning diagnostic trouble
codes, refer to the List of Diagnostic Trouble Code
(DTC). <Ref. to EN(S0HC)-77, List of Diagnostic
Trouble Code (DTC).>
Release the parking brake.
The speed difference between front and rear
this indicates no malfunctions. When engine con-
trol diagnosis is finished, perform the ABS memory
clearance procedure of self-diagnosis system.
3. OBD-II GENERAL SCAN TOOL
After performing the diagnostics and clearing the
memory, check for any remaining unresolved trou-
ble data:
1) Connect the test mode connector (A) at the low-
er side of the instrument panel (on the driver’s
side), to the side of the center console box.
2) Connect the OBD-I1 general scan tool to its data
link connector in the lower portion of the instrument
panel (on the driver’s side).
CAUTION:
Do not connect the scan tools except for Suba-
ru Select Monitor and OBD-ll general scan tool.
 INSPECTION MODE
ENGINE (DIAGNOSTICS)
~ ~ ~ ~ ~~ ~ ~~~

3) Start the engine.

NOTE:
Ensure the selector lever is placed in the “P” po-
sition before starting. (AT vehicles)
Depress the clutch pedal when starting the en-
gine. (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 the engine speed in the 2,500 - 3,000
rpm range for 40 seconds.
NOTE:
On models without tachometer, use the tachometer
(Secondary pickup type).
7) Place the selector lever or shift lever in the ‘ID”
position (AT vehicles) or “1st” gear (MT vehicles)
and drive the vehicle at 5 to 10 km/h (3 to 6 MPH).
NOTE:
On AWD vehicles, release the parking brake.
The speed difference between front and rear
wheels may light the ABS warning light, but this in-
dicates no malfunctions.When engine control diag-
nosis is finished, perform the ABS memory
clearance procedure of self-diagnosis system.
8) Using the OBD-ll general scan tool, check for di-
agnostic trouble code@) and record the result(s).
NOTE:
For detailed operation procedures, refer to the
OBD-II General Scan Tool Instruction Manual.
For detailed concerning diagnostic trouble
codes, refer to the List of Diagnostic Trouble Code
(DTC). <Ref. to EN(S0HC)-77, List of Diagnostic
Trouble Code (DTC).>

EN(S0HC)-42
 CLEAR MEMORY MODE
ENGINE (DIAGNOSTICS)

13.Clear Memory Mode 3. OBD-ll GENERAL SCAN TOOL

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

EN(S0HC)-43
I COMPULSORY VALVE OPERATION CHECK MODE
ENGINE (DIAGNOSTICS)
14.Compulsory Valve Operation
Check Mode
A: OPERATION
1) Prepare the Subaru Select Monitor kit. <Ref. to
EN(S0HC)-8, PREPARATION TOOL, General De-
scription.>
2) Connect the diagnosis cable to Subaru Select
Monitor.
3) Insert the cartridge into Subaru Select Monitor.
<Ref. to EN(S0HC)-8, PREPARATION TOOL,
General Description.>
4) Connect the test mode connector (A) at the low-
er portion of instrument panel (on the driver’s side),
to the side of the center console box.
EN(S0HC)-44
5) Connect the Subaru Select Monitor to data link
connector.
(1) Connect Subaru Select Monitor to data link
connector located in the lower portion of the in-
strument panel (on the driver’s side).
~ ~~ ~ ~
(2) Connect the diagnosis cable to data link
connector.
CAUTION:
Do not connect scan tools except for Subaru
Select Monitor and OBD-II general scan tool.
6) Turn the ignition switch to ON (engine OFF) and
Subaru Select Monitor switch to ON.
’’ ‘S2M0288A
7) On the ((MainMenu)) display screen, select the
(2.Each System Check} and press the [YES] key.
8) On the ((System Selection Menu)) display
screen, select the {Engine Control System} and
press the [YES] key.
9) Press the [YES] key after displayed the informa-
tion of engine type.
10) On the <<Engine Diagnosis), display screen, se-
lect the {System Operation Check Mode} and press
the [YES] key.
11) On the ((System Operation Check Mode)) dis-
play screen, select the {Actuator ON/OFF Opera-
tion} and press the [YES] key.
12) Select the desired compulsory actuator on the
((Actuator ON/OFF Operation)) display screen and
press the [YES] key.
13) Pressing the [NO] key completes the compul-
sory operation check mode. The display will then
return to the (<Actuator ON/OFF Operation,)
screen.
 COMPULSORY VALVE OPERATION CHECK MODE
ENGINE (DIAGNOSTICS)

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 Compressor Relay
Compulsory purge control solenoid valve operation check CPC Solenoid Valve
ComDulsorv air assist injector solenoid valve oOeration check AAI Solenoid Valve
~~~ ~

NOTE:
The following parts will be displayed but not functional because they are not installed on the vehicle.
Display
EGR Solenoid Valve
ASV Solenoid Valve
I PCV Solenoid Valve 1
I Vent Control Solenoid Valve I
I FlCD Solenoid I
Pressure Switching Sol. 1
-Pressure Switching Sol. 2
Fuel Tank Sensor Control Valve
For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL.

EN(S0HC)-45
 ENGINE MALFUNCTION INDICATOR LAMP (MIL)
ENGINE (DIAGNOSTICS)

15.Engine Malfunction Indicator Lamp (MIL)

A: PROCEDURE
1. Activation of check engine malfunction indicator lamp (MIL). <Ref. to EN(S0HC)-47, ACTIVATION OF CHECK ENGINE
MALFUNCTION INDICATOR LAMP (MIL). Enaine Malfunction Indicator LamD (MIL).>
1
2. Check engine malfunction indicator lamp (MIL) does not come on. <Ref. to EN(S0HC)-48, CHECK ENGINE MALFUNCTION
INDICATOR LAMP (MIL) DOES NOT COME ON., Engine Malfunction Indicator Lamp (MIL).>
1
3. Check engine malfunction indicator lamp (MIL) does not go off. <Ref. to EN(S0HC)-50, CHECK ENGINE MALFUNCTION
INDICATOR LAMP (MIL) DOES NOT GO OFF., Engine Malfunction Indicator LamD (MIL).>
1
4. Check engine malfunction indicator lamp (MIL) does not blink at a cycle of 3 Hz. <Ref. to EN(S0HC)-52, CHECK ENGINE
MALFUNCTION INDICATOR LAMP (MIL) DOES NOT BLINK AT A CYCLE OF 3 HZ., Engine Malfunction Indicator Lamp (MIL).>
1
5. Check engine malfunction indicator lamp (MIL) remains blinking at a cycle of 3 Hz. <Ref. to EN(S0HC)-54, CHECK ENGINE
MALFUNCTION INDICATOR LAMP (MIL) REMAINS BLINKING AT A CYCLE OF 3 HZ.,Engine Malfunction Indicator Lamp
(MIL).>

EN(S0HC)-46
 ENGINE MALFUNCTION INDICATOR LAMP (MIL)
ENGINE (DIAGNOSTICS)
~~

B: ACTIVATION OF CHECK ENGINE 4) When the ignition switch is turned to ON (engine

MALFUNCTION INDICATOR off) or to “START” with the test mode connector
connected, the MIL blinks at a cycle of 3 Hz.
LAMP (MIL)
1) When the 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 combina-
tion meter circuit. <Ref. to EN(S0HC)-48, CHECK Ignition
ENGINE MALFUNCTION INDICATOR LAMP switch
(MIL) DOES NOT COME ON., Engine Malfunction ON
Indicator Lamp (MIL).> OBD0055A

I EN10741

2) After starting the engine, the MIL goes out. If it

does not, either the engine or the emission control
system is malfunctioning.

a) No trouble
MIL ON
OFF
A-1
b) Trouble occurs.

ON
MIL
OFF Igniion
switch ~~~i~~
ON start OBD0053A

3) If the diagnosis system senses a misfire which

could damage the catalyzer, the MIL will blink at a
cycle of 1 Hz.

Misfire
start
OBD0054A

EN(S0HC)-47
 ENGINE MALFUNCTION INDICATOR LAMP (MIL)
ENGINE (DIAGNOSTICS)

C: CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) DOES NOT COME

ON.
DIAGNOSIS:
The CHECK ENGINE malfunction indicator lamp (MIL) circuit is open or shorted.
TROUBLE SYMPTOM:
When the ignition switch is turned ON (engine OFF), MIL does not come on.
WIRING DIAGRAM:

I= N0.5
4 0 10
13
11
- 9
BATERY
SBF-4 SBF-1
- @ 0-

Step Check
1 CHECK OUTPUT SIGNAL FROM ECM. Is the voltage less than 1 V?
1)Turn the ignition switch to ON.
2)Measure the voltage between ECM connec-
tor and chassis ground.
Connector & terminal
(8134) No. 11 (+) - Chassis ground (-):

EN(S0HC)-48
 ENGINE MALFUNCTION INDICATOR LAMP (MIL)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK POOR CONTACT. Does the MIL come on when lepair poor con- 30 to step 3.
shaking or pulling ECM con- act in ECM con-
nector and harness? ector.
CHECK ECM CONNECTOR. Is the ECM connector correctly ieplace the ECM. 3epair connection
connected? Ref. to i f ECM connector.
'U(S0HC)-47,
ingine Control
lodule.>
CHECK HARNESS BETWEEN COMBINA- I Is the resistance less than 1 i o to step 5. qepair harness
TION METER AND ECM CONNECTOR. m d connector.
1)Turn the ignition switch to OFF. VOTE:
2)Remove the combination meter. <Ref. to In this case, repaii
IDI-11, Combination Meter Assembly.> the following:
3)Disconnect the connector from ECM and Open circuit in
combination meter. iarness between
4)Measure the resistance of harness between ECM and combi-
ECM and combination meter connector. iation meter con-
Connector & terminal lector
(8134) No. 11 - (i12) No. 6: Poor contact in
:oupling connector
02)
I CHECK POOR CONTACT. Is there poor contact in combi-
lepair poor con- Go to step 6.
Check poor contact in combination meter con- nation meter connector? x t in combination
nector. neter connector.
I CHECK HARNESS BETWEEN COMBINA- Is the voltage more than 10 V?i o to step 7. Check the follow-
ing and repair if
necessary.
NOTE:
Brokendown
ignition relay.
b Blown out fuse

(No. 5).
b If replaced fuse
(No. 5 ) blows eas-
ily, check the har-
ness for short
circuit of harness
between fuse (No.
5) and ignition
relay connector.
Open or short
circuit in harness
between fuse (No.
5) and battery ter-
minal
Open circuit in
harness between
fuse (No. 5) and
ignition relay con-
nector
Poor contact in
ignition relay con-
nector
9 Poor contact in
ignition switch con,
nector
r CHECK LAMP BULB. s the lamp bulb condition OK? 3epair combina- Replace the lamp
Remove the engine malfunction indicator lamp ion meter connec- bulb.
bulb. or.

EN(S0HC)-49
 ENGINE MALFUNCTION INDICATOR LAMP (MIL)
ENGINE (DIAGNOSTICS)

D: CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) DOES NOT GO

OFF.
DIAGNOSIS:
The CHECK ENGINE malfunction indicator lamp (MIL) circuit is shorted.
TROUBLE SYMPTOM:
Although MIL comes on when the engine runs, trouble code is not shown on the Subaru select monitor
or OBD-ll general scan tool display.
WIRING DIAGRAM:

IGNmON
SWITCH BATERY
SBF-4 SBF-I

Step Check Yes No

1 CHECK HARNESS BETWEEN COMBINA- Does the MIL come on? Repair short circuit Replace the ECM.
TlON METER AND ECM CONNECTOR. in harness <Ref. to
1)Turn the ignition switch to OFF. between combina- FU(S0HC)-47,
2)Disconnect the connector from ECM. tion meter and Engine Control
3)Turn the ianition switch to ON. ECM connector. Module.>

EN(S0HC)-50
ENGINE MALFUNCTION INDICATOR LAMP (MIL)
ENGINE (DIAGNOSTICS)

EN(S0HC)-51
 ENGINE MALFUNCTION INDICATOR LAMP (MIL)
ENGINE (DIAGNOSTICS)

E: CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) DOES NOT BLINK

AT A CYCLE OF 3 HZ.
DIAGNOSIS:
The CHECK ENGINE malfunction indicator lamp (MIL) circuit is open or shorted.
Test mode connector circuit is in open.
TROUBLE SYMPTOM:
When in inspection mode, MIL does not blink at a cycle of 3 Hz.
WIRING DIAGRAM:

IGNITION RELAY
0 - N0.5
4 0 1 0 1
13
11
-9
EATERY

-E+
SBF-4 SBF-1

I
I

EN1076

EN(S0HC)-52
 ENGINE MALFUNCTION INDICATOR LAMP (MIL)
ENGINE f DIAGNOSTICS)
~

Step Check Yes No

CHECK STATUS OF CHECK ENGINE MAL- )oes the MIL come on? 30 to step 2. Repair the MIL cir-
FUNCTION INDICATOR LAMP (MIL). cuit. <Ref. to
1)Turn the ignition switch to OFF. EN(S0HC)-48,
2)Disconnect the test mode connector. CHECK ENGINE
3)Turn the ignition switch to ON. (engine OFF) MALFUNCTION
INDICATOR
LAMP (MIL)
DOES NOT
COME ON.,
Engine Malfunc-
tion Indicator
Lamp (MIL).>
CHECK HARNESS BETWEEN COMBINA- Ioes the MIL come on? 3epair ground Go to step 3.
TION METER AND ECM CONNECTOR. short circuit in har-
1)Turn the ignition switch to OFF. less between
2)Disconnect the connector from ECM. :ombination meter
3)Turn the ignition switch to ON. and ECM connec-
or.
CHECK HARNESS BETWEEN TEST MODE s the resistance less than 1 30 to step 4. Repair harness
CONNECTOR AND CHASSIS GROUND. 2? and connector.
1)Turn the ignition switch to OFF. NOTE:
2)Disconnect the connector from ECM. In this case, repaii
3)Measure the resistance of harness between the following:
test mode connector and chassis ground. Open circuit in
Connector & terminal harness between
(B76) No. 1 - Chassis ground: test mode connec-
tor and chassis
ground
CHECK POOR CONTACT. s there poor contact in ECM 3epair poor con- Go to step 5.
Check poor contact in ECM connector. :onnector? act in ECM con-
lector.
CHECK HARNESS BETWEEN ECM AND s the resistance less than 1 20 to step 6. Repair open circuit
TEST MODE CONNECTOR. 2? in harness
1)Connect the test mode connector. between ECM and
2)Measure the resistance of harness between test mode connec-
ECM and chassis ground.
Connector & terminal
(8135) No. 14 - Chassis ground:
CHECK POOR CONTACT. s there poor contact in ECM 3epair poor con-
Check poor contact in ECM connector. :onnector? :act in ECM con- <Ref. to
lector. FU(S0HC)-47,
Engine Control
Module.>

EN(S0HC)-53
 ENGINE MALFUNCTION INDICATOR LAMP (MIL)
ENGINE (DIAGNOSTICS)

F: CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) REMAINS BLINK-

ING AT A CYCLE OF 3 HZ.
DIAGNOSIS:
Test mode connector circuit is shorted.
TROUBLE SYMPTOM:
MIL blinks at a cycle of 3 Hz when the ignition switch is turned to ON.
WIRING DIAGRAM:

IGNITION RELAY
N0.5

COMBINA"
METER
A@

EN1076

EN(S0HC)-54
 ENGINE MALFUNCTION INDICATOR LAMP (MIL)
ENGINE (DIAGNOSTICS)

Step Check Yes No

1 CHECK TEST MODE CONNECTOR. Does the MIL flash on and off? Go to step 2. System is in good
1)Disconnect the test mode connector. order.
2)Turn the ignition switch to ON. NOTE:
MIL blinks at a cy
cle of 3 Hz wher
test mode connec
tor is connected.
2 CHECK HARNESS BETWEEN ECM CON- Is the resistance less than 5 Repair short circuit Replace the ECM.
NECTOR AND ENGINE GROUNDING TER- R? in harness <Ref. to
MINAL. between ECM and FU(S0HC)-47,
1)Turnthe ignition switch to OFF. test mode connec- Engine Control
2)Disconnect the connector from ECM. tor. Module.>
3)Measure the resistance of harness between
ECM connector and chassis ground.
Connector & terminal
(8135) No. 14 - Chassis ground:
I

EN(S0HC)-55
ENGINE MALFUNCTION INDICATOR LAMP (MIL)

EN(S0HC)-56
 DIAGNOSTICS FOR ENGINE STARTING FAILURE
ENGINE (DIAGNOSTICS)

16.Diagnostics for Engine Starting Failure

A: PROCEDURE
1. Inspection of starter motor circuit. <Ref. to EN(S0HC)-58, STARTER MOTOR CIRCUIT, Diagnosticsfor Engine Starting Fail-
ure.>
1
2. Inspection of ECM power supply and ground line. <Ref. to EN(S0HC)-62, CONTROL MODULE POWER SUPPLY AND
GROUND LINE, Diagnostics for Engine Starting Failure.>
1
3. Inspection of ignition control system. <Ref. to EN(S0HC)-66, IGNITION CONTROL SYSTEM, Diagnostics for Engine Start-
ina Failure.>
1
4. Inspection of fuel pump circuit. <Ref. to EN(S0HC)-70, FUEL PUMP CIRCUIT, Diagnostics for Engine Starting Failure.>
1
5. Inspection of fuel injector circuit. <Ref. to EN(S0HC)-74, FUEL INJECTOR CIRCUIT, Diagnosticsfor Engine Starting Fail-
ure.>

EN(S0HC)-57
 DIAGNOSTICS FOR ENGINE STARTING FAILURE
ENGINE (DIAGNOSTICS)

B: STARTER MOTOR CIRCUIT

CAUTION:
After repair or replacement of faulty parts, conduct CLEAR MEMORY MODEdef. to EN(S0HC)-43,
Clear Memory Mode.> and INSPECTION MODE <Ref. to EN(S0HC)-40, Inspection Mode.>.

SBF-4 SBF-1

Q AT : ATVEHICLES

@ : MTVEHICLES

I=- 4
-
-
I

1TO SECURITY SYSTEM I

STARTER
INTERLOCK
RELAY

STARTER
MOTOR

CLUTCH
SWITCH

@ ECM
-
- -
-

1 2 3 4 5 6
4 5 6
9 10 11 12

EN1077

EN(SOHC)-58
 DIAGNOSTICS FOR ENGINE STARTING FAILURE
. ENGINE (DIAGNOSTICS)

Step Check
CHECK BATTERY. Is the voltage more than 12 V?
the battery.
CHECK INPUT SIGNAL FOR STARTER MO- Is the voltage more than 10 V? 30 to step 3. Go to step 4.
TOR.
1)Turn the ignition switch to OFF.
2)Disconnect the connector from starter motor.
3)Turn the ignition switch to ST.
4)Measure the power supply voltage between
starter motor connector terminal and engine
ground.
Connector & terminal
(614) No. 1 (+) - Engine groundI)-(
NOTE:
*On AT vehicles, place the selector lever in the
“ P or “N” position.
*On MT vehicles, depress the clutch pedal.
CHECK GROUND CIRCUIT OF STARTER I Is the resistance less than 5 >heck the starter Repair open circuit
MOTOR. I notor. <Ref. to of ground cable.
1)Turn the ignition switch to OFF. X - 6 , Starter.>
2)Disconnect the terminal from starter motor.
3)Measure the resistance of ground cable
between ground cable terminal and engine
ground.
CHECK HARNESS BETWEEN BATTERY Is the voltage more than 10 V? 30 to step 6. Repair open circuit
AND IGNITION SWITCH CONNECTOR. in harness
1)Disconnectthe connector from ignition between ignition
switch. switch and bat-
2)Measure the power supply voltage between tery, and check
ignition switch connector and chassis ground. fuse SBF No. 4
Connector & terminal and SBF No.1.
(672) No. 1 (+) - Chassis ground (-): I
CHECK IGNITION SWITCH. I Is the resistance less than 5 o; to step 6. Replace the igni-
1)Disconnect the connector from ignition Q? tion switch.
switch.
2)Measure the resistance between ignition
switch terminals while turning ignition switch to
the “ST” position.
Terminals
NO. 1 -NO. 3:
CHECK TRANSMISSION TYPE. s the transmission type AT? 30 to step 7. Go to step 11.
CHECK INPUT VOLTAGE OF INHIBITOR s the voltage more than 10 V? 20 to step 8. Repair open or
SWITCH. ground short cir-
1)Turn the ignition switch to OFF. cuit in harneb
2)Disconnect the connector from inhibitor between inhibitor
switch. switch and ignition
3)Connect the connector to ignition switch. switch.
4)Measure the input voltage between inhibitor NOTE:
switch connector terminal and engine ground Check security
while turning ignition switch to ST. system (ii
Connector & terminal equipped). <Ref.
(612) No. 12 (+) - Engine ground (-): to SL-21, Security
System.>
CHECK INHIBITOR SWITCH. Is the resistance less than 1 3epair open or Replace the inhibi-
1)Place the selector lever in the “P” or “N” posi- a? jround short cir- tor switch.<Ref. to
tion. :uit in harness AT-28, Inhibitor
2)Measure the resistance between inhibitor letween inhibitor Switch.>
switch terminals. ;witch and starter
Connector & terminal notor.
(T3) NO. 11 - NO. 12:

EN(S0HC)-59
 DIAGNOSTICS FOR ENGINE STARTING FAILURE

Step Check Yes No

CHECK INPUT VOLTAGE OF STARTER IN- I Is the voltage more than 10 V? 30 to step 10. Repair open or
TERLOCK RELAY. ground short cir-
1)Turn the ignition switch to OFF. cuit in harness
2)Disconnect the connector from starter inter- between starter
lock relay. interlock relay and
3)Connect the connector to ignition switch. ignition switch.
4)Measure the input voltage between starter NOTE:
interlock relay connector and chassis ground Check security
while turning ignition switch to ST. system (ii
Connector & terminal equipped). <Ref.
(B105) No. 37 (+) - Chassis ground (-): to SL-21, Security
(B105) No. 34 (+) - Chassis ground (-): System.>
0 CHECK STARTER INTERLOCK RELAY. s the resistance less than 1 30 to step 11. Replace the
1)Connect the battery to starter interlock relay R? starter interlock
terminals No. 34 and No. 36. relay.
2)Measure the resistance between starter
interlock relay terminals.
Terminals
NO. 37- NO. 38:
1 CHECK GROUND CIRCUIT OF CLUTCH s the resistance less than 1 30 to step 12. Repair open circuit
SWITCH. n? of ground cable.
1)Disconnectthe connector from clutch switch
2)Measure the resistance between clutch
switch connector and chassis ground.
Connector & terminal
(B106) No. 1 - Chassis ground:
2 CHECK CLUTCH SWITCH. Is the resistance less than 1 30 to step 13. Replace the clutch
1)Measure the resistance between clutch R? switch. <Ref. to
switch terminal while depressing the clutch CL-30, Clutch
pedal. Switch.>
Terminals
NO. 1 - NO. 2:
3 CHECK CLUTCH SWITCH CIRCUIT. Is the resistance less than 1 3epair open or Repair open circuit
1)Connect the connector to clutch switch. n? jround short cir- in harness
2)Measure the resistance between starter :uit in harness between starter
interlock relay connector and chassis ground letween starter interlock relay and
while depressing the clutch pedal. nterlock relay and clutch switch.
Connector & terminal starter motor.
(B105) No. 36 - Chassis ground:

EN(SOHC)-60
DIAGNOSTICS FOR ENGINE STARTING FAILURE
ENGINE (DIAGNOSTICS)

EN(S0HC)-61
 DIAGNOSTICS FOR ENGINE STARTING FAILURE
ENGINE (DIAGNOSTICS)

C: CONTROL MODULE POWER SUPPLY AND GROUND LINE

CAUTION:
After repair or replacement of faulty parts, conduct CLEAR MEMORY MODEcRef. to EN(SOHCk43,
Clear Memory Mode.> and INSPECTION MODE. <Ref. to EN(SOHC)BO, Inspection Mode.>
WIRING DIAGRAM:

MAIN RELAY

EN1078

Step Check
-
1 CHECK MAIN RELAY. I Is the resistance less than 10
1)Turn the ignition switch to OFF. relay.
2)Remove the main relay.
3)Connect the battery to main relay terminals
No. 1 and No. 2.
4)Measure the resistance between main relay
terminals.
Terminals
NO. 3 - NO. 5:
NO. 4 - NO. 6:

EN(S0HC)-62
 DIAGNOSTICS FOR ENGINE STARTING FAILURE
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK GROUND CIRCUIT OF ECM. s the resistance less than 5 30 to step 3. Repair open circuit
1)Disconnectthe connector from ECM. n? n harness
2)Measure the resistance of harness between 2etween ECM
ECM and chassis ground. :onnector and
Connector & terminal mgine grounding
(8136) No. 21- Chassis ground: terminal.
-
(8136) No. 22 Chassis ground:
(8134) No. 27- Chassis ground:
(8134) No. 8 - Chassis ground:
(8134) No. 7 - Chassis ground:
(8134) No. 34 - Chassis ground:
(8134) No. 35 - Chassis ground:
-
(8135) No. 25 Chassis ground: (MT
vehicle)
1 CHECK INPUT VOLTAGE OF ECM. s the voltage more than 10 V? 30 to step 4. Repair open or
Measure the voltage between ECM connector around short cir-
and chassis ground. x i t of power sup-
Connector & terminal ~ l circuit.
y
(8136) No. 9 (+) - Chassis ground (-):
I CHECK INPUT VOLTAGE OF ECM. s the voltage more than 10 V? 30 to step 5. Repair open or
1)Turn the ignition switch to ON. around short cir-
2)Measure the voltage between ECM connec- wit of power sup-
tor and chassis ground. 2ly circuit.
Connector & terminal
(8135) No. 7 (+) - Chassis ground (-):
1 CHECK HARNESS BETWEEN ECM AND Is the resistance more than 1 30 to step 6. Repair ground
MAIN RELAY CONNECTOR. MR? short circuit in har-
1)Turn the ignition switch to OFF. ness between
2)Measure the resistance between ECM and ECM connector
chassis ground. and main relay
Connector & terminal connector, then
(8135) No. 19 - Chassis ground: replace the ECM.
i CHECK OUTPUT VOLTAGE FROM ECM. Is the voltage more than 10 V? 30 to step 7. Replace the ECM.
1)Connect the connector to ECM.
2)Turn the ignition switch to ON.
3)Measure the voltage between ECM connec-
tor and chassis ground.
Connector & terminal
(8135) No. 19 (+) - Chassis ground (-):
I
CHECK INPUT VOLTAGE OF MAIN RELAY. Is the voltage more than 10 V? 30 to step 8. Repair open circuit
Check the voltage between main relay connec- in harness
tor and chassis ground. between ECM
Connector & terminal connector and
(847) No. 2 (+) - Chassis ground (-): main relay connec.
tor.
) CHECK GROUND CIRCUIT OF MAIN RE- Is the resistance less than 5 20 to step 9. Repair open circuit
LAY. R? between main
1)Turnthe ignition switch to OFF. relay and chassis
2)Measure the resistance between main relay ground.
connector and chassis ground.
Connector & terminal
(847) No. 1 - Chassis ground:
CHECK INPUT VOLTAGE OF MAIN RELAY. Is the voltage more than 10 V? So to step 10. Repair open or
Measure the voltage between main relay con- ground short cir-
nector and chassis ground. cuit in harness of
Connector & terminal power supply cir-
(847) No. 5 (+) - Chassis ground (-): cuit.
(847) No. 6 (+) - Chassis ground (-):

EN(S0HC)-63
I
DIAGNOSTICS FOR ENGINE STARTING FAILURE
ENGINE (DIAGNOSTICS)
r
Step- Check Yes
10 CHECK INPUT VOLTAGE OF ECM. Is the voltage more than 10 V? Check ignition Repair open or
1)Connect the main relay connector. control system. ground short cir-
2)Turn the ignition switch to ON. <Ref. to cuit in harness
3)Measure the voltage between ECM connec- EN(S0HC)-66, between ECM
tor and chassis ground. IGNITION CON- connector and
Connector L? terminal TROL SYSTEM, main relay connec
-
(8136) No. 1 (+) Chassis ground (-): Diagnostics for
(8136) No. 2 (+) - Chassis ground (-): Engine Starting
Failure.>
I

EN(S0HC)-64
DIAGNOSTICS FOR ENGINE STARTING FAILURE
ENGINE (DIAGNOSTICS)

EN(S0HC)-65
 DIAGNOSTICS FOR ENGINE STARTING FAILURE
ENGINE (DIAGNOSTICS)

D: IGNITION CONTROL SYSTEM

CAUTION:
After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE<Ref. to EN(S0HC)-43,
Clear Memory Mode.> and INSPECTION MODE <Ref. to EN(SOHC)BO, Inspection Mode.>.
WIRING DIAGRAM:

n @ECM

SBF-4 SBF-I
BATERY

0 0

EN1079

Step Check Yes No

1 CHECK IGNITION SYSTEM FOR SPARKS. Does spark occur at each cyl- Check fuel pump Go to step 2.
1)Remove the plug cord cap from each spark inder? system. <Ref. to
Plug. EN(S0HC)-70,
2)lnstall the new spark plug on plug cord cap. FUEL PUMP CIR-
CAUTION: CUIT, Diagnostics
Do not remove the spark plug from engine. for Engine Start-
3)Contact the spark plug's thread portion on ing Failure.>
engine.
4)While opening the throttle valve fully, crank
the engine to check that spark occurs at each
cylinder.

EN(SOHC)-66
 DIAGNOSTICS FOR ENGINE STARTING FAILURE
ENGINE (DIAGNOSTICS)

Step Check Yes No

2 CHECK POWER SUPPLY CIRCUIT FOR IG- ;the voltage more than 10 V? Go to step 3. Repair harness
NITION COIL 81IGNITOR ASSEMBLY. and connector.
1)Turnthe ignition switch to OFF. NOTE:
2)Disconnect the connector from ignition coil & In this case, repaii
ignitor assembly. the following:
3)Turn the ignition switch to ON. Open circuit in
4)Measure the power supply voltage between harness between
ignition coil & ignitor assembly connector and ignition coil & igni-
engine ground. tor assembly, and
Connector & terminal ignition switch con.
(E12) No, 2 (+) - Engine ground (-): nector
Poor contact in
coupling connec-
tors (822)
3 CHECK HARNESS OF IGNITION COIL 81IG- i theresistance between less Go to step 4. Repair harness
NITOR ASSEMBLY GROUND CIRCUIT. ian 5 R? and connector.
1)Turn the ignition switch to OFF. NOTE:
2)Measure the resistance between ignition coil In this case, repaii
& ignitor assembly connector and engine the following:
ground. Open circuit in
Connector & terminal harness between
(€12) No. 3 - Engine ground: ignition coil & igni-
tor assembly con-
nector and engine
grounding terminal
4 CHECK IGNITION COIL 81 IGNITOR ASSEM- i the resistance between 10 Go to step 5. Replace the igni-
BLY. nd 15 kR? tion coil & ignitor
1)Remove the spark plug cords. assembly. <Ref. to
2)Measure the resistance between spark plug IG(S0HC)-7, Igni-
cord contact portions to check secondary coil. tion Coil and Igni-
Terminals tor Assembly.>
-
NO. 1 NO. 2:
5 CHECK IGNITION COIL 81IGNITOR ASSEM- j the resistance between 10 Go to step 6. Replace the igni-
BLY. nd 15 kR? tion coil & ignitor
Measure the resistance between spark plug assembly. <Ref. to
cord contact portions to check secondary coil. IG(S0HC)-7, Igni-
Terminals tion Coil and Igni-
-
NO. 3 NO.4: tor Assembly.>
6 CHECK INPUT SIGNAL FOR IGNITION COIL s the voltage more than 10 V? Go to step 7. Replace the igni-
8I IGNITOR ASSEMBLY. tion coil & ignitor
1)Connect the connector to ignition coil & igni- assembly. <Ref. to
tor assembly. IG(SOHC)-7, 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.
Connector & terminal
(E12)No. 1 (+) -Engine ground (-):
7 CHECK INPUT SIGNAL FOR IGNITION COIL s the voltage more than 10 V? Go to step 8. Replace the igni-
8I IGNITOR ASSEMBLY. tion coil & ignitor
Check if voltage varies synchronously with assembly. <Ref. ta
engine speed when cranking, while monitoring IG(SOHC)-7, Igni-
voltage between ignition coil & ignitor assem- tion Coil and Igni-
bly connector and engine ground. tor Assembly.>
Connector & terminal
(E12) No. 4 (+)- Engine ground (-):

EN(S0HC)-67
I
DIAGNOSTICS FOR ENGINE STARTING FAILURE
ENGINE (DIAGNOSTICS)

Step Check Yes No

6 CHECK HARNESS BETWEEN ECM AND IG- Is the resistance less than 1 o
; to step 9. Repair harness
NlTlON COIL & IGNITOR ASSEMBLY CON- R? and connector.
NECTOR. NOTE:
1)Turn the ignition switch to OFF. In this case, repa
2)Disconnect the connector from ECM. the following:
3)Disconnect the connector from ignition coil & Open circuit in
ignitor assembly. harness between
4)Measure the resistance of harness between ECM and ignition
ECM and ignition coil & ignitor assembly con- coil & ignitor
nector. assembly connec-
Connector & terminal tor
(8134) NO.25 - (E12) NO. 1: Poor contact in
couplingconnecto
(822)
9 CHECK HARNESS BETWEEN ECM AND IG- Is the resistance less than 1 ;o to step 10. Repair harness
NlTlON COIL & IGNITOR ASSEMBLY CON- R? and connector.
NECTOR. NOTE:
Measure the resistance of harness between In this case, repai
ECM and ignition coil & ignitor assembly con- the following:
nector. Open circuit in
Connector & terminal harness between
(8134) NO. 26 - (E12) NO. 4: ECM and ignition
coil & ignitor
assembly connec-
tor
Poor contact in
couplingconnecto
(822)
10 CHECK HARNESS BETWEEN ECM AND IG- Is the resistance more than 1 ;o to step 11. Repair ground
NlTlON COIL & IGNITOR ASSEMBLY CON- MR? short circuit in har
NECTOR. ness between
Measure the resistance of harness between ECM and ignition
ECM and engine ground. coil & ignitor
Connector & terminal: assembly connec-
(8134) No. 25 - Engine ground: tor.
11 CHECK HARNESS BETWEEN ECM AND IG- Is the resistance more than 1 ;o to step 12. Repair ground
NlTlON COIL & IGNITOR ASSEMBLY CON- MR? short circuit in har
NECTOR. ness between
Measure the resistance of harness between ECM and ignition
ECM and engine ground. coil & ignitor
Connector & terminal assembly connec-
(8134) No. 26 - Engine ground: tor.
12 CHECK POOR CONTACT. Is there poor contact in ECM 3epair poor con- Check fuel pump
Check poor contact in ECM connector. Zonnector? 3ct in ECM con- circuit. <Ref. to
lector. EN(S0HC)-70,
FUEL PUMP CIR-
CUIT, Diagnostics
for Engine Start-
inq Failure.>

EN(S0HC)-68
DIAGNOSTICS FOR ENGINE STARTING FAILURE
ENGINE (DIAGNOSTICS)

EN(S0HC)-69
 DIAGNOSTICS FOR ENGINE STARTING FAILURE
ENGINE (DIAGNOSTICS)

E: FUEL PUMP CIRCUIT

CAUTION:
After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE<Ref. to EN(S0HC)-43,
Clear Memory Mode.> and INSPECTION MODE <Ref. to EN(S0HC)-40, Inspection Mode.>.
WIRING DIAGRAM:

SBF-5

IGN"
SWITCH BATrERY
SBF-4 SBF-1
JEL PUMP
ELAY I
I I U

EN(S0HC)-70
 DIAGNOSTICS FOR ENGINE STARTING FAILURE
ilsl
ENGINE (DIAGNOSTICS)
~

Step Check Yes No

CHECK OPERATING SOUND OF FUEL loes the fuel pump produce ;heck fuel injec- 30 to step 2.
PUMP. perating sound? 3r circuit. <Ref. to
Make sure that fuel pump is in operation for iN(S0HC)-74,
two seconds when turning the ignition switch to ’UEL INJECTOR
ON. :IRCUIT, Diag-
NOTE: iostics for Engine
Fuel pump operation can also be executed us- Starting Failure.>
ing Subaru Select Monitor (Function mode:
FDO1).
For the procedure, refer to “Compulsory Valve
Operation Check Mode”. <Ref. to EN(S0HC)-
44, Compulsory Valve Operation Check
Mode.>
CHECK GROUND CIRCUIT OF FUEL PUMP. j the resistance less than 5 ;o to step 3. 3epair harness
1)Turn the ignition switch to OFF. l? md connector.
2)Remove the fuel pump access hole lid IOTE:
located on the right rear of trunk compartment n this case, repai
floor (Sedan) or luggage compartment floor he following:
(Wagon). 1 Open circuit in
3)Disconnect the connector from fuel pump. iarness between
4)Measure the resistance of harness connec- uel pump connec-
tor between fuel pump and chassis ground. or and chassis
Connector & terminal grounding termina
(R58) No. 4- Chassis ground: 1 Poor contact in
:oupling connectoi
:R67)
1 CHECK POWER SUPPLY TO FUEL PUMP. 5 the voltage more than 10 V? 3eplace the fuel 30 to step 4.
1)Turn the ignition switch to ON. lump. <Ref. to
2)Measure the voltage of power supply circuit -U(SOHC)-59,
between fuel pump connector and chassis %el Pump.>
ground.
Connector & terminal
(R58) No. 1 (+)- Chassis ground (-):
i CHECK HARNESS BETWEEN FUEL PUMP s the resistance less than 1 30 to step 5. Repair harness
AND FUEL PUMP RELAY CONNECTOR. 2? m d connector.
1)Turnthe ignition switch to OFF. VOTE:
2)Measure the resistance of harness connec- In this case, repai
tor between fuel pump and fuel pump relay. the following:
Connector & terminal Open circuit in
(R58) NO. 1 - (846) NO. 4: harness between
fuel pump connec
tor and chassis
grounding termina
Poor contact in
coupling connec-
tors
(R67 and 697)
CHECK HARNESS BETWEEN FUEL PUMP s the resistance more than 1 30 to step 6. Repair short circui
AND FUEL PUMP RELAY CONNECTOR. Lm? in harness
Measure the resistance of harness between betweenfuel pumr
fuel pump and fuel pump relay connector. and fuel pump
Connector & terminal relay connector.
/R58) No. 1 - Chassis around:

EN(SOHC)-71
 DIAGNOSTICS FOR ENGINE STARTING FAILURE
ENGINE (DIAGNOSTICS)

Step Check Yes No

, CHECK FUEL PUMP RELAY. Is the resistance less than 10 30 to step 7. Replace the fuel
1)Disconnectthe connectors from fuel pump Q? pump relay. <Ref.
relay and main relay. to FU(S0HC)-49,
2)Remove the fuel pump relay and main relay Fuel Pump Relay.>
with bracket.
3)Connect the battery to fuel pump relay con-
nector terminals No. 1 and No. 3.
4)Measure the resistance between connector
terminals of fuel pump relay.
Terminals
NO. 2 - NO. 4:
CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 20 to step 8. Repair open circuit
FUEL PUMP RELAY CONNECTOR. n? in harness
1)Disconnect the connectors from ECM. between ECM and
2)Measure the resistance of harness between fuel pump relay
ECM and fuel pump relay connector. connector.
Connector & terminal
(8134) NO. 16 - (846) NO. 3:
CHECK POOR CONTACT. Is there poor contact in ECM 3epair poor con- Check fuel injec-
Check poor contact in ECM connector. connector? act in ECM con- tor circuit. <Ref. to
lector. EN(S0HC)-74,
FUEL INJECTOR
CIRCUIT, Diag-
nostics for Engine
I
Starting Failure.>

EN(S0HC)-72
DIAGNOSTICS FOR ENGINE STARTING FAILURE
ENGINE (DIAGNOSTICS)

EN(S0HC)-73
I DIAGNOSTICS FOR ENGINE STARTING FAILURE
ENGINE (DIAGNOSTICS)

F: FUEL INJECTOR CIRCUIT

CAUTION:
Check or repair only faulty parts.
After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to EN(S0HC)-43,
Clear Memory Mode.> and INSPECTION MODE. <Ref. to EN(SOHC)40, Inspection Mode.>
WIRING DIAGRAM:

MAIN RELAY

U U U
FUEL INJECTOR FUEL INJECTOR FUEL INJECTOR FUEL INJECTOR

Step Check Yes No

1 CHECK OPERATIONOF EACH FUEL INJEC- Is the fuel injector emits “oper- Check the fuel Go to step 2.
TOR. ating” sound? pressure. <Ref. to
While cranking the engine, check that each ME(S0HC)-28,
fuel injector emits “operating” sound. Use a INSPECTION,
sound scope or attach a screwdriver to the Fuel Pressure.>
injector for this check.

EN(S0HC)-74
 DIAGNOSTICS FOR ENGINE STARTING FAILURE
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK POWER SUPPLY TO EACH FUEL j the voltage more than 10 V? io to step 3. 3epair harness
INJECTOR. and connector.
1)Turn the ignition switch to OFF. VOTE:
2)Disconnect the connector from #I cylinder n this case, repair
fuel injector. :he following:
3)Turn the ignition switch to ON. 1 Open circuit in

4)Measure the power supply voltage between iarness between

the fuel injector terminal and engine ground. nain relay and fuel
Connector & terminal njector connector
#1 (€5) No. 2 (+) - Engine ground (-): 1 Poor contact in

#2 (E 16) No. 2 (+) - Engine ground (-): nain relay connec-

#3 (€6) No. 2 (+)- Engine ground (-): :or
#4 (E17) No. 2 (+) - Engine ground (-): Poor contact in
:oupling connector
lB22)
Poor contact in
bel injector con-
lector
, CHECK HARNESS BETWEEN ECM AND ;theresistance between 5 ;o to step 4. Repair harness
FUEL INJECTOR CONNECTOR. wd 20 a? m d connector.
1)Disconnectthe connector from ECM. NOTE:
2)Measure the resistance of harness between In this case, repait
ECM and fuel injector connector. the following:
Connector & terminal Open circuit in
(8134) NO. 4 - (8136) NO. 2: iarness between
ECM and fuel
Injector connector
Poor contact in
2oupling connector

I CHECK HARNESS BETWEEN ECM AND s the resistance less than 1 iepair ground Go to step 5.
FUEL INJECTOR CONNECTOR. 2? ;hart circuit in har-
Measure the resistance of harness between less between
ECM and fuel injector connector. X M and fuel
Connector & terminal ijector connector.
(8134) No. 4 - Chassis ground:
1 CHECK HARNESS BETWEEN ECM AND s the resistance between 5 ;o to step 6. Repair harness
FUEL INJECTOR CONNECTOR. n d 20 a? and connector.
Measure the resistance of harness between NOTE:
ECM and fuel injector connector. In this case, repaii
Connector & terminal the following:
( 8 134) NO. 13 - ( 8 136) NO. 2: Open circuit in
harness between
ECM and fuel
injector connector
8 Poor contact in

couplingconnector
(822)
i CHECK HARNESS BETWEEN ECM AND s the resistance less than 1 3epair ground Go to step 7.
FUEL INJECTOR CONNECTOR. ;2? ;hort circuit in har-
Measure the resistance of harness between less between
ECM and fuel injector connector. X M and fuel
Connector & terminal njector connector.
(8134) No. 13 - Chassis ground:

EN(SOHC)-75
 DIAGNOSTICS FOR ENGINE STARTING FAILURE
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK HARNESS BETWEEN ECM AND Is the resistance between 5 Go to step 8. Repair harness
FUEL INJECTOR CONNECTOR. and 20 R? and connector.
Measure the resistance of harness between NOTE:
ECM and fuel injector connector. In this case, repaii
Connector & terminal the following:
(8134) NO. 14 - (8136) NO. 2: Open circuit in
harness between
ECM and fuel
injector connector
Poor contact in
couplingconnector
(622)
1 CHECK HARNESS BETWEEN ECM AND Go to step 9.
FUEL INJECTOR CONNECTOR. short circuit in har-
Measure the resistance of harness between ness between
ECM and fuel injector connector. ECM and fuel
Connector & terminal injector connector.
(8134) No. 14 - Chassis ground: I
I CHECK HARNESS BETWEEN ECM AND Is the resistance between 5 Go to step 10. Repair harness
FUEL INJECTOR CONNECTOR. and 20 R? and connector.
Measure the resistance of harness between NOTE:
ECM and fuel injector connector. In this case, repait
Connector & terminal the following:
(8134) NO. 15 - (8136) NO. 2: Open circuit in
harness between
ECM and fuel
injector connector
Poor contact in
couplingconnector
(822)
0 CHECK HARNESS BETWEEN ECM AND IS the resistance less than 1 Repair ground Go to step 11.
FUEL INJECTOR CONNECTOR. R? short circuit in har-
Measure the resistance of harness between ness between
ECM and fuel injector connector. ECM and fuel
Connector & terminal injector connector.
( 8 134) No. 15 - Chassis ground:
1 CHECK EACH FUEL INJECTOR. Is the resistance between 5 Go to step 12. Replace the faulty
1)Turn the ignition switch to OFF. and 20 R? fuel injector.
2)Measure the resistance between each fuel
injector terminals.
Terminals
NO. 1 -NO. 2:
2 CHECK POOR CONTACT. Is there poor contact in ECM Repair poor con- Inspection using
Check poor contact in ECM connector. connector? tact in ECM con- "General Diagnos-
tic Table". <Ref. to
EN(S0HC)-330,
INSPECTION,
General Diagnos-
tic Table.>

EN(S0HC)-76
 LIST OF DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

17.List of Diagnostic Trouble Code (DTC)

A: LIST
DTC
Item Index
No.
PO031 Front oxygen (NF) sensor heater cir- <Ref. to EN(S0HC)-84, DTC PO031 - FRONT OXYGEN (NF) SENSOR
cuit low input HEATER CIRCUIT LOW INPUT -, Diagnostic Procedure with Diagnostic
Trouble Code (DTC).>
PO032 Front oxygen (NF) sensor heater cir- <Ref. to EN(S0HC)-88, DTC PO032 - FRONT OXYGEN (NF) SENSOR
cuit high input HEATER CIRCUIT HIGH INPUT -, Diagnostic Procedure with Diagnostic
Trouble Code (DTC).>
PO037 Rear oxygen sensor heater circuit <Ref. to EN(S0HC)-90, DTC PO037 - REAR OXYGEN SENSOR HEATER
malfunction CIRCUIT MALFUNCTION-, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).s
PO038 Rear oxygen sensor heater circuit <Ref. to EN(S0HC)-94, DTC PO038 - REAR OXYGEN SENSOR HEATER
high input CIRCUIT HIGH INPUT -, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
PO065 Air assist injector solenoid valve mal- <Ref. to EN(S0HC)-96, DTC PO065 -AIR ASSIST INJECTOR SOLENOID
function VALVE MALFUNCTION -, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
PO066 Air assist injector solenoid valve cir- <Ref. to EN(S0HC)-98, DTC PO066 -AIR ASSIST INJECTOR SOLENOID
cuit low input VALVE CIRCUIT LOW INPUT -, Diagnostic Procedure with Diagnostic
Trouble Code (DTC).>
PO067 Air assist injector solenoid valve cir- <Ref. to EN(S0HC)-100, DTC PO067 -AIR ASSIST INJECTOR SOLE-
cuit high input NOID VALVE CIRCUIT HIGH INPUT -, Diagnostic Procedure with Diag-
nostic Trouble Code (DTC).>
PO106 Pressure sensor circuit range/perfor- <Ref. to EN(S0HC)-102, DTC PO106 - PRESSURE SENSOR CIRCUIT
mance problem (low input) RANGE/PERFORMANCE PROBLEM (LOW INPUT) -, Diagnostic Proce-
dure with Diagnostic Trouble Code (DTC).>
PO107 Pressure sensor circuit low input <Ref. to EN(S0HC)-104, DTC PO107 - PRESSURE SENSOR CIRCUIT
LOW INPUT -, Diagnostic Procedure with Diagnostic Trouble Code (DTC).s
PO108 Pressure sensor circuit high input <Ref. to EN(S0HC)-108, DTC PO108 - PRESSURE SENSOR CIRCUIT
HIGH INPUT -, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
PO111 Intake air temperature sensor circuit <Ref. to EN(SOHC)-112,DTC PO111 - INTAKE AIR TEMPERATURE
range/performance problem SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM -, Diagnostic
Procedure with Diagnostic Trouble Code (DTC).>
PO112 Intake air temperature sensor circuit <Ref. to EN(SOHC)-114,DTC PO112 - INTAKE AIR TEMPERATURE
low input SENSOR CIRCUIT LOW INPUT -, Diagnostic Procedure with Diagnostic
Trouble Code (DTC).>
PO113 Intake air temperature sensor circuit <Ref. to EN(SOHC)-116,DTC PO113 - INTAKE AIR TEMPERATURE
high input SENSOR CIRCUIT HIGH INPUT -, Diagnostic Procedure with Diagnostic
Trouble Code (DTC).>
PO117 Engine coolant temperature sensor <Ref. to EN(S0HC)-120, DTC PO117 - ENGINE COOLANT TEMPERA-
circuit low input TURE SENSOR CIRCUIT LOW INPUT -, Diagnostic Procedure with Diag-
nostic Trouble Code (DTC).>
PO118 Engine coolant temperature sensor <Ref. to EN(S0HC)-122, DTC PO118 - ENGINE COOLANT TEMPERA-
circuit high input TURE SENSOR CIRCUIT HIGH INPUT -, Diagnostic Procedure with Diag-
iostic Trouble Code (DTC).>
'01 21 Throttle position sensor circuit range/ <Ref. to EN(S0HC)-126, DTC PO121 -THROTTLE POSITION SENSOR
performance problem (high input) SlRCUlT RANGE/PERFORMANCE PROBLEM (HIGH INPUT) -, Diagnos-
tic Procedure with Diagnostic Trouble Code (DTC).>
'01 22 Throttle position sensor circuit low <Ref. to EN(S0HC)-128, DTC PO122 - THROTTLE POSITION SENSOR
input SlRCUlT LOW INPUT -, Diagnostic Procedure with Diagnostic Trouble
Sode ( D T C b

EN(S0HC)-77
 LIST OF DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

I NO.
"Ic, I Item Index

PO123 Throttle position sensor circuit high <Ref. to EN(S0HC)-132, DTC PO123 -THROTTLE POSITION SENSOR
input CIRCUIT HIGH INPUT -, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
PO125 Insufficient coolant temperature for <Ref. to EN(S0HC)-134, DTC PO125 - INSUFFICIENTCOOLANT TEM-
closed loop fuel control PERATURE FOR CLOSED LOOP FUEL CONTROL -, Diagnostic Proce-
dure with Diagnostic Trouble Code (DTC).>
PO128 Thermostat malfunction <Ref. to EN(S0HC)-136, DTC PO128 -THERMOSTAT MALFUNCTION -
, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
PO130 Front oxygen (NF) sensor circuit <Ref. to EN(S0HC)-138, DTC PO130 - FRONT OXYGEN (NF) SENSOR
range/performance problem (Lean) CIRCUIT RANGE/PERFORMANCE PROBLEM (LEAN) -, Diagnostic Pro-
cedure with Diagnostic Trouble Code (DTC).>
PO131 Front oxygen (NF) sensor circuit <Ref. to EN(S0HC)-142, DTC PO131 - FRONT OXYGEN (NF) SENSOR
malfunction (open circuit) CIRCUIT MALFUNCTION (OPEN CIRCUIT) -, Diagnostic Procedure with
Diagnostic Trouble Code (DTC).>
PO132 Front oxygen (NF) sensor circuit <Ref. to EN(S0HC)-144, DTC PO132 - FRONT OXYGEN (NF) SENSOR
malfunction (short circuit) CIRCUIT MALFUNCTION (SHORT CIRCUIT) -, Diagnostic Procedure with
Diagnostic Trouble Code (DTC).>
PO133 Front oxygen (NF) sensor circuit <Ref. to EN(S0HC)-146, DTC PO133 - FRONT OXYGEN (NF) SENSOR
slow response CIRCUIT SLOW RESPONSE -, Diagnostic Procedure with Diagnostic
Trouble Code (DTC).>
PO136 Rear oxygen sensor circuit malfunc- <Ref. to EN(S0HC)-148, DTC PO136 - REAR OXYGEN SENSOR CIR-
tion CUIT MALFUNCTION -, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
PO139 Rear oxygen sensor circuit slow <Ref. to EN(S0HC)-152, DTC PO139 - REAR OXYGEN SENSOR CIR-
response CUlT SLOW RESPONSE -, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
PO171 Fuel trim malfunction (NF too Lean) <Ref. to EN(S0HC)-154, DTC PO171 - FUEL TRIM MALFUNCTION (NF
TOO LEAN) -, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
PO172 Fuel trim malfunction ( N F too Rich) <Ref. to EN(S0HC)-154, DTC PO172 - FUEL TRIM MALFUNCTION (NF
TOO RICH) -, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
PO181 Fuel temperature sensor A circuit <Ref. to EN(S0HC)-156, DTC PO181 - FUEL TEMPERATURE SENSOR A
range/performance problem CIRCUIT RANGE/PERFORMANCE PROBLEM -, Diagnostic Procedure
with Diagnostic Trouble Code (DTC).>
PO182 Fuel temperature sensor A circuit low <Ref. to EN(S0HC)-158, DTC PO182 - FUELTEMPERATURE SENSOR A
input CIRCUIT LOW INPUT -, Diagnostic Procedure with Diagnostic Trouble
Code ( D T C b
PO183 Fuel temperature sensor A circuit <Ref. to EN(S0HC)-160, DTC PO183 - FUEL TEMPERATURE SENSOR A
high input CIRCUIT HIGH INPUT -, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
PO301 Cylinder 1 misfire detected <Ref. to EN(S0HC)-163, DTC PO301 -CYLINDER 1 MISFIRE DETECTED
-, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
PO302 Cylinder 2 misfire detected <Ref. to EN(S0HC)-163, DTC PO302 - CYLINDER 2 MISFIRE DETECTED
-, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
PO303 Cylinder 3 misfire detected <Ref. to EN(S0HC)-163, DTC PO303 - CYLINDER 3 MISFIRE DETECTED
-, Diagnostic Procedure with Diaanostic Trouble Code ( D T C b
PO304 Cylinder 4 misfire detected <Ref. to EN(S0HC)-164, DTC P0304- CYLINDER 4 MISFIRE DETECTED
-, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
PO327 Knock sensor circuit low input <Ref. to EN(S0HC)-170, DTC PO327 - KNOCK SENSOR CIRCUIT LOW
INPUT -, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
PO328 Knock sensor circuit high input <Ref. to EN(S0HC)-172, DTC PO328 - KNOCK SENSOR CIRCUIT HIGH
INPUT -, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
PO335 Crankshaft position sensor circuit <Ref. to EN(S0HC)-174, DTC PO335 - CRANKSHAFT POSITION SEN-
malfunction SOR CIRCUIT MALFUNCTION-, Diagnostic Procedure with Diagnostic
Trouble Code (DTC).>

EN(S0HC)-78
 LIST OF DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)
~

DTC
Item Index
No.
PO336 Crankshaft position sensor circuit <Ref. to EN(S0HC)-176, DTC PO336 - CRANKSHAFT POSITION SEN-
range/performance problem SOR CIRCUIT RANGE/PERFORMANCE PROBLEM -, Diagnostic Proce-
dure with Diagnostic Trouble Code (DTC).>
PO340 Camshaft position sensor circuit mal- <Ref. to EN(S0HC)-178, DTC PO340 - CAMSHAFT POSITION SENSOR
function CIRCUIT MALFUNCTION-, Diagnostic Procedure with Diagnostic Trouble
Code ( D T C b
PO341 Camshaft position sensor circuit <Ref. to EN(S0HC)-180, DTC PO341 - CAMSHAFT POSITION SENSOR
range/performance problem CIRCUIT RANGE/PERFORMANCE PROBLEM -, Diagnostic Procedure
with Diagnostic Trouble Code (DTC).>
PO420 Catalyst system efficiency below <Ref. to EN(S0HC)-184, DTC PO420 - CATALYST SYSTEM EFFICIENCY
threshold BELOW THRESHOLD -, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
PO442 Evaporative emission control system <Ref. to EN(S0HC)-187, DTC PO442 - EVAPORATIVE EMISSION CON-
malfunction TROL SYSTEM MALFUNCTION-, Diagnostic Procedure with Diagnostic
~~
Trouble Code ( D T C b
PO444 Evaporative errksion control system <Ref. to EN(S0HC)-192, DTC PO444 - EVAPORATIVE EMISSION CON-
purge control valve circuit low input TROL SYSTEM PURGE CONTROL VALVE CIRCUIT LOW INPUT -, Diag-
nostic Procedure with Diagnostic Trouble Code (DTC).>
PO445 Evaporative emission control system <Ref. to EN(S0HC)-196, DTC PO445 - EVAPORATIVE EMISSION CON-
purge control valve circuit high input TROL SYSTEM PURGE CONTROL VALVE CIRCUIT HIGH INPUT -,
Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
PO447 Evaporative emission control system <Ref. to EN(S0HC)-198, DTC PO447 - EVAPORATIVE EMISSION CON-
vent control low input TROL SYSTEM VENT CONTROL LOW INPUT -, Diagnostic Procedure
with Diaanostic Trouble Code ( D T C b
PO448 Evaporative emission control system <Ref. to EN(S0HC)-202, DTC PO448 - EVAPORATIVE EMISSION CON-
vent control high input TROL SYSTEM VENT CONTROL HIGH INPUT -, Diagnostic Procedure
with Diagnostic Trouble Code (DTC).>
PO451 Evaporative emission control system <Ref. to EN(S0HC)-204, DTC PO451 - EVAPORATIVE EMISSION CON-
pressure sensor range/performance TROL SYSTEM PRESSURE SENSOR RANGE/PERFORMANCE PROB-
Droblem LEM, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
PO452 Evaporative emission control system <Ref. to EN(S0HC)-206, DTC PO452 - EVAPORATIVE EMISSION CON-
pressure sensor low input TROL SYSTEM PRESSURE SENSOR LOW INPUT -, Diagnostic Proce-
dure with Diaanostic Trouble Code ( D T C b
PO453 Evaporative emission control system <Ref. to EN(SOHC)-210, DTC PO453 - EVAPORATIVE EMISSION CON-
pressure sensor high input TROL SYSTEM PRESSURE SENSOR HIGH INPUT -, Diagnostic Proce-
dure with Diagnostic Trouble Code (DTC).>
PO456 Evaporative emission control system <Ref. to EN(SOHC)-213, DTC PO456 - EVAPORATIVE EMISSION CON-
malfunction TROL SYSTEM MALFUNCTION-, Diagnostic Procedure with Diagnostic
Trouble Code (DTC).>
PO461 Fuel level sensor circuit range/perfor- <Ref. to EN(S0HC)-218, DTC PO461 - FUEL LEVEL SENSOR CIRCUIT
mance problem RANGE/PERFORMANCE PROBLEM -, Diagnostic Procedure with Diag-
nostic Trouble Code ( D T C b
PO462 Fuel level sensor circuit low input <Ref. toEN(S0HC)-220, DTC PO462 - FUEL LEVEL SENSOR CIRCUIT
LOW INPUT -, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
PO463 Fuel level sensor circuit high input <Ref. to EN(S0HC)-224, DTC PO463 - FUEL LEVEL SENSOR CIRCUIT
HIGH INPUT -, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
PO464 FUGlevel sensor intermittent input <Ref. to EN(S0HC)-228, DTC PO464 - FUEL LEVEL SENSOR INTERMIT-
TENT INPUT-, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
PO480 Cooling fan relay 1 circuit low input <Ref. to EN(SOHC)-231,DTC PO480 - COOLING FAN RELAY 1 CIRCUIT
LOW INPUT -, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
PO483 Cooling fan function problem <Ref. to EN(SOHC)-235, DTC PO483 - COOLING FAN FUNCTION PROB-
LEM -, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
PO500 Vehicle speed sensor malfunction <Ref. to EN(S0HC)-238, DTC PO500 - VEHICLE SPEED SENSOR MAL-
FUNCTION-, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>

EN(S0HC)-79
 LIST OF DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

DTC
Item Index
No.
PO506 Idle control system RPM lower than <Ref. to EN(S0HC)-240, DTC PO506 - IDLE CONTROL SYSTEM RPM
expected LOWER THAN EXPECTED -, Diagnostic Procedure with Diagnostic Trou-
ble Code (DTC).>
PO507 Idle control system RPM higher than <Ref. to EN(S0HC)-242, DTC PO507 - IDLE CONTROL SYSTEM RPM
expected HIGHER THAN EXPECTED -, Diagnostic Procedure with Diagnostic Trou-
ble Code (DTC).>
PO512 Starter switch circuit high input <Ref. to EN(S0HC)-245, DTC PO512 - STARTER SWITCH CIRCUIT
HIGH INPUT -, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
PO604 Internal control module memory <Ref. to EN(S0HC)-248, DTC PO604 - INTERNAL CONTROL MODULE
check sum error MEMORY CHECK SUM ERROR -, Diagnostic Procedure with Diagnostic
Trouble Code (DTC).>
PO703 Brake switch input malfunction <Ref. to EN(S0HC)-250, DTC PO703 - BRAKE SWITCH INPUT MAL-
FUNCTION -, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
PO705 Transmission range sensor circuit <Ref. to AT-115, CHECK INHIBITOR SWITCH., Diagnostic Procedure for
malfunction No-DiagnosticTrouble Code (DTC).>
PO710 Transmissionfluid temperature sen- <Ref. to AT-48, DTC 27 ATF TEMPERATURE SENSOR, Diagnostic Proce-
sor circuit malfunction dure with Diagnostic Trouble Code (DTC).>
PO715 Torque converter turbine speed sen- <Ref. to AT-62, DTC 36 TORQUE CONVERTER TURBINE SPEED SEN-
sor circuit malfunction SOR, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
PO720 Output speed sensor (Front vehicle <Ref. to AT-57, DTC 33 FRONT VEHICLE SPEED SENSOR, Diagnostic Pro-
speed sensor) circuit malfunction cedure with Diagnostic Trouble Code (DTC).>
PO725 Engine speed input circuit malfunc- <Ref. to AT-44, DTC 11 ENGINE SPEED SIGNAL, Diagnostic Procedure
tion with Diagnostic Trouble Code (DTC).>
PO731 Gear 1 incorrect ratio <Ref. to EN(S0HC)-252, DTC PO731 - GEAR 1 INCORRECT RATIO -,
Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
PO732 Gear 2 incorrect ratio <Ref. to EN(S0HC)-252, DTC PO732 - GEAR 2 INCORRECT RATIO -,
Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
PO733 Gear 3 incorrect ratio <Ref. to EN(S0HC)-252, DTC PO733 - GEAR 3 INCORRECT RATIO -,
Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
PO734 Gear 4 incorrect ratio <Ref. to EN(S0HC)-253, DTC PO734 - GEAR 4 INCORRECT RATIO -,
Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
PO741 Torque converter clutch system mal- <Ref. to EN(S0HC)-254, DTC PO741 -TORQUE CONVERTER CLUTCH
function SYSTEM MALFUNCTION -, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
PO743 Torque converter clutch system <Ref. to AT-94, DTC 77 LOCK-UP DUTY SOLENOID, Diagnostic Procedure
(Lock-up duty solenoid) electrical with Diagnostic Trouble Code (DTC).>
PO748 Pressure control solenoid (Line pres- <Ref. to AT-86, DTC 75 LINE PRESSURE DUTY SOLENOID, Diagnostic
sure duty solenoid) electrical Procedure with Diagnostic Trouble Code (DTC).>
PO753 Shift solenoid A (Shift solenoid 1) <Ref. to AT-70, DTC 71 SHIFT SOLENOID 1, Diagnostic Procedure with
electrical Diagnostic Trouble Code (DTC).>
PO758 Shift solenoid B (Shift solenoid 2) <Ref. to AT-74, DTC 72 SHIFT SOLENOID 2, Diagnostic Procedure with
electrical Diagnostic Trouble Code (DTC).>
PO778 2-4 brake pressure control solenoid <Ref. to AT-90, DTC 76 2-4 BRAKE DUTY SOLENOID, Diagnostic Proce-
valve circuit malfunction dure with Diagnostic Trouble Code (DTC).>
PO785 2-4 brake timing control solenoid <Ref. to AT-82, DTC 74 2-4 BRAKE TIMING SOLENOID, Diagnostic Proce-
valve circuit malfunction dure with Diagnostic Trouble Code (DTC).>
'1 110 Atmospheric pressure sensor low <Ref. to EN(S0HC)-256, DTC P1110 - ATMOSPHERIC PRESSURE SEN-
input SOR CIRCUIT LOW INPUT -, Diagnostic Procedure with Diagnostic Trou-
ble Code (DTC).>
'1111 Atmospheric pressure sensor high <Ref. to EN(S0HC)-260, DTC P l l l l -ATMOSPHERIC PRESSURE SEN-
input SOR CIRCUIT HIGH INPUT -, Diagnostic Procedure with Diagnostic Trou-
ble Code (DTC).>
'1 112 Atmospheric pressure sensor range/ <Ref. to EN(S0HC)-264, DTC P1112 - ATMOSPHERIC PRESSURE SEN-
performance problem SOR CIRCUIT RANGE/PERFORMANCE PROBLEM -, Diagnostic Proce-
dure with Diagnostic Trouble Code (DTC).>

EN(S0HC)-80
 LIST OF DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

DTC
Item Index
No.
P I 137 Front oxygen (NF) sensor circuit <Ref. to EN(S0HC)-266, DTC P1137 - FRONT OXYGEN (NF) SENSOR
range/perfomance problem CIRCUIT RANGE/PERFORMANCE PROBLEM -, Diagnostic Procedure
with Diagnostic Trouble Code (DTC).>
PI142 Throttle position sensor circuit range/ <Ref. to EN(S0HC)-270, DTC P I 142 -THROTTLE POSITION SENSOR
performance problem (low input) CIRCUIT RANGE/PERFORMANCE PROBLEM (LOW INPUT) -, Diagnos-
tic Procedure with Diagnostic Trouble Code (DTC).>
P I 146 Pressure sensor circuit range/perfor- <Ref. to EN(S0HC)-272, DTC P1146 - PRESSURE SENSOR CIRCUIT
mance problem (high input) RANGE/PERFORMANCE PROBLEM (HIGH INPUT) -, Diagnostic Proce-
dure with Diagnostic Trouble Code (DTC).>
PI400 Fuel tank pressure control solenoid <Ref. to EN(S0HC)-274, DTC P1400 - FUEL TANK PRESSURE CON-
valve circuit low input TROL SOLENOID VALVE CIRCUIT LOW INPUT -, Diagnostic Procedure
with Diagnostic Trouble Code (DTC).>
P I 420 Fuel tank pressure control solenoid <Ref. to EN(S0HC)-278, P I 420 - FUEL TANK PRESSURE CONTROL
valve circuit high input SOLENOID VALVE CIRCUIT HIGH INPUT -, Diagnostic Procedure with
Diagnostic Trouble Code (DTC).>
P I 442 Fuellevelsensor circuit range/perfor- <Ref. to EN(S0HC)-280, DTC P1442 - FUEL LEVEL SENSOR CIRCUIT
mance problem 2 RANGE/PERFORMANCE PROBLEM 2 -, Diagnostic Procedure with Diag-
nostic Trouble Code (DTC).>
P I 443 Evaporative emission control system <Ref. to EN(S0HC)-282, DTC PI443 - EVAPORATIVE EMISSION CON-
vent control function problem TROL SYSTEM VENT CONTROL FUNCTION PROBLEM -, Diagnostic
Procedure with Diagnostic Trouble Code (DTC).>
P I 480 Cooling fan relay 1 circuit high input <Ref. to EN(S0HC)-285, DTC P1480 - COOLING FAN RELAY 1 CIRCUIT
HIGH INPUT -, Diagnostic Procedure with Diagnostic Trouble Code
IDTC).>
P I 507 Idle control system malfunction (fail- <Ref. to EN(S0HC)-288, DTC P I 507 - IDLE CONTROL SYSTEM MAL-
safe) FUNCTION (FAIL-SAFE) -, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
PI510 Idle air control solenoid valve signal 1 <Ref. to EN(S0HC)-290, DTC P1510 - IDLE AIR CONTROL SOLENOID
circuit low input VALVE SIGNAL 1 CIRCUIT LOW INPUT -, Diagnostic Procedure with
Diagnostic Trouble Code (DTC).>
PI511 Idle air control solenoid valve signal 1 <Ref. to EN(S0HC)-290, DTC P I 511 - IDLE AIR CONTROL SOLENOID
circuit high input VALVE SIGNAL 1 CIRCUIT HIGH INPUT -, Diagnostic Procedure with
Diaanostic Trouble Code (DTC).>
PI512 Idle air control solenoid valve signal 2 <Ref. to EN(S0HC)-290, DTC PI512 - IDLE AIR CONTROL SOLENOID
circuit low input VALVE SIGNAL 2 CIRCUIT LOW INPUT -, Diagnostic Procedure with
Diagnostic Trouble Code (DTC).>
P I 513 Idle air control solenoid valve signal 2 <Ref. to EN(S0HC)-290, DTC PI513 - IDLE AIR CONTROL SOLENOID
circuit high input VALVE SIGNAL 2 CIRCUIT HIGH INPUT -, Diagnostic Procedure with
Diagnostic Trouble Code (DTC).>
PI514 Idle air control solenoid valve signal 3 <Ref. to EN(S0HC)-290, DTC PI514 - IDLE AIR CONTROL SOLENOID
circuit low input VALVE SIGNAL 3 CIRCUIT LOW INPUT -, Diagnostic Procedure with
Diaanostic Trouble Code IDTO.>
P I 515 Idle air control solenoid valve signal 3 <Ref. to EN(S0HC)-290, DTC PI515 - IDLE AIR CONTROL SOLENOID
circuit high input VALVE SIGNAL 3 CIRCUIT HIGH INPUT -, Diagnostic Procedure with
Diagnostic Trouble Code (DTC).>
PI516 Idle air control solenoid valve signal 4 <Ref. to EN(S0HC)-292, DTC P1516 - IDLE AIR CONTROL SOLENOID
circuit low input VALVE SIGNAL 4 CIRCUIT LOW INPUT -, Diagnostic Procedure with
DiagnosticaTrouble Code (DTC).>
PI517 Idle air control solenoid valve signal 4 <Ref. to EN(S0HC)-296, DTC PI517 - IDLE AIR CONTROL SOLENOID
circuit high input VALVE SIGNAL 4 CIRCUIT HIGH INPUT -, Diagnostic Procedure with
Diaanostic Trouble Code ( D T C b
PI518 Starter switch circuit low input <Ref.to EN(SOHC)-299, DTC P1518 - STARTER SWITCH CIRCUIT LOW
INPUT -, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P I 540 Vehicle speed sensor malfunction 2 <Ref. to EN(S0HC)-302, DTC P I 540 - VEHICLE SPEED SENSOR MAL-
FUNCTION 2 -, Diagnostic Procedure with Diagnostic Trouble Code
IDTC).>

EN(S0HC)-81
 LIST OF DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

DTC
Item Index
No.
P i 560 Back-up voltage circuit malfunction <Ref. to EN(S0HC)-304, DTC Pi560 - BACK-UP VOLTAGE CIRCUIT
MALFUNCTION -, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
PI590 Neutral position switch circuit high <Ref. to EN(S0HC)-306, DTC P i 590 - NEUTRAL POSITION SWITCH
input CIRCUIT HIGH INPUT (AT MODEL) -, Diagnostic Procedure with Diagnos-
tic Trouble Code (DTC).>
Pi591 Neutral position switch circuit low <Ref. to EN(SOHC)-310, DTC Pi591 - NEUTRAL POSITION SWITCH
input CIRCUIT LOW INPUT (AT MODEL) -, Diagnostic Procedure with Diagnos-
tic Trouble Code (DTC).>

+---
<Ref. to EN(SOHC)-312, DTC Pi592 - NEUTRAL POSITION SWITCH
model) CIRCUIT LOW INPUT (MT MODEL) -, Diagnostic Procedure with Diagnos-
tic Trouble Code (DTC).>
P i 594 Automatic transmission diagnosis <Ref. to EN(SOHC)-314, DTC Pi594 - AUTOMATIC TRANSMISSION
input signal circuit malfunction DIAGNOSIS INPUT SIGNAL CIRCUIT MALFUNCTION -, Diagnostic Pro-
cedure with Diagnostic Trouble Code (DTC).>
Pi595 Automatic transmission diagnosis <Ref. to EN(SOHC)-316,DTC Pi595 -AUTOMATIC TRANSMISSION
input signal circuit low input DIAGNOSIS INPUT SIGNAL CIRCUIT LOW INPUT -, Diagnostic Proce-
dure with Diagnostic Trouble Code (DTC).>
P I 596 Automatic transmission diagnosis <Ref. to EN(SOHC)-318, DTC P i 596 - AUTOMATIC TRANSM1,SSION
input signal circuit high input DIAGNOSIS INPUT SIGNAL CIRCUIT HIGH INPUT -, Diagnostic Proce-
dure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(S0HC)-320, DTC P i 698 - ENGINE TORQUE CONTROL CUT
cuit low input SIGNAL CIRCUIT LOW INPUT -, Diagnostic Procedure with Diagnostic
Trouble Code (DTC).>
<Ref. to EN(S0HC)-322, DTC P i 699 - ENGINE TORQUE CONTROL CUT
cuit high input SIGNAL CIRCUIT HIGH INPUT -, Diagnostic Procedure with Diagnostic
Trouble Code (DTC).>
Pi700 Throttle position sensor circuit mal- <Ref. to AT-52, DTC 31 THROTTLE POSITION SENSOR, Diagnostic Proce-
function for automatic transmission dure with Diagnostic Trouble Code (DTC).>
PI701 Cruise control set signal circuit mal- <Ref. to EN(S0HC)-324, DTC P i 701 - CRUISE CONTROL SET SIGNAL
function for automatic transmission CIRCUIT MALFUNCTION FOR AUTOMATIC TRANSMISSION-, Diagnos-
tic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to AT-78, DTC 73 LOW CLUTCH TIMING SOLENOID, Diagnostic Pro-
valve circuit malfunction cedure with Diagnostic Trouble Code (DTC).>
Pi711 Engine torque control signal 1 circuit <Ref. to EN(S0HC)-326, DTC P i 711 - ENGINE TORQUE CONTROL SIG-
malfunction NAL 1 CIRCUIT MALFUNCTION-, Diagnostic Procedure with Diagnostic
Trouble Code (DTC).>
<Ref. to EN(S0HC)-328, DTC P i 712 - ENGINE TORQUE CONTROL SIG-
malfunction NAL 2 CIRCUIT MALFUNCTION -, Diagnostic Procedure with Diagnostic
Trouble Code (DTC).>

EN(S0HC)-82
LIST OF DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

EN(S0HC)-83
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

18.Diagnostic Procedure with Diagnostic Trouble Code (DTC)

A: DTC PO031 - FRONT OXYGEN (NF) SENSOR HEATER CIRCUIT LOW IN-
PUT -
DTC DETECTING CONDITION:
Immediately at fault recognition
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode<Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(S0HC)-40, OPERATION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

1
Y
A@

c@
ECM

A:@

EN1082

Step Check Yes I No

1 CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Moni- Go to step 2. Go to step 5.
tor or OBD-ll general scan tool
indicate DTC PO031 and
PO037 at the same time?

EN(S0HC)-84
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENG I NE (DIAG NOSTlCS)

Step Check Yes ~ NO

! CHECK POWER SUPPLY TO FRONT OXY- the voltage more than 10 V? ;o to step 3. Repair power sup.
GEN (NF) SENSOR. ply line.
1)Turn the ignition switch to OFF. NOTE:
2)Disconnect the connector from front oxygen In this case, repai
(NF) sensor. the following:
3)Turn the ignition switch to ON. Open circuit in
4)Measure the voltage between front oxygen harness between
(NF) sensor connector and engine ground. main relay and
Connector & terminal front oxygen (NF)
(E24) No. 2 (+) - Engine groundI)-( sensor connector
Poor contact in
front oxygen (NF)
sensor connector
Poor contact in
main relay connec
tor
1 CHECK GROUND CIRCUIT OF ECM. the resistance less than 5 i o to step 4. Repair harness
Measure the resistance of harness between ? and connector.
ECM connector and chassis ground. NOTE:
Connector & terminal In this case, repa
(8134) No. 35 - Chassis ground: the following:
(8134) No. 34 - Chassis ground: Open circuit in
harness between
ECM and engine
ground terminal
Poor contact in
ECM connector
Poor contact in
couplingconnect0
(B2.3
1 CHECK CURRENT DATA. the value more than 0.2 A? 3epair poor con- Go to step 5.
1)Start the engine. act in connector.
2)Read the data of front oxygen (NF)sensor IOTE:
heater current using Subaru Select Monitor or n this case, repail
OED-ll general scan tool. he following:
NOTE: 1 Poor contact in
OSubaru Select Monitor ront oxygen (NF)
For detailed operation procedure, refer to the sensor connector
“READ CURRENT DATA FOR ENGINE”. <Ref. Poor contact in
to EN(S0HC)-32, Subaru Select Monitor.> ICM connector
*OED-II scan tool
For detailed operation procedures, refer to the
OED-ll General Scan Tool Instruction Manual.
I CHECK OUTPUT SIGNAL FROM ECM. the voltage less than 1.O V? ;o to step 7. Go to step 6.
1)Start and idle the engine.
2)Measure the voltage between ECM connec-
tor and chassis ground.
Connector 81terminal
(8134) No. 22 (+) - Chassis ground (-):
i CHECK OUTPUT SIGNAL FROM ECM. ies the voltage change less lepair poor con- Go to step 7.
Measure the voltage between ECM connector m 1.O V by shaking harness act in ECM con-
and chassis ground. id connector of ECM while lector.
Connector & terminal mitoring the value with volt-
(8134) No. 22 (+) - Chassis ground (-): le meter?
I
CHECK OUTPUT SIGNAL FROM ECM. the voltage less than 1.O V? ;o to step 9. Go to step 8.
Measure the voltage between ECM connector
and chassis ground.
Connector & terminal
(8134) No. 23 (+) - Chassis ground (-):

EN(S0HC)-85
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

I CHECK OUTPUT SIGNAL FROM ECM. Does the voltage change less Repair poor con- Go to step 9.
Measure the voltage between ECM connector than 1.O V by shaking harness tact in ECM con-
and chassis ground. and connector of ECM while nector.
Connector & terminal monitoring the value with volt-
(8134) No. 23 (+) - Chassis ground (-): age meter?
I CHECK FRONT OXYGEN (NF)SENSOR. Is the resistance less than 10 Repair harness Replace the front
1)Turn the ignition switch to OFF. n? and connector. oxygen (NF) sen-
NOTE: sor. <Ref. to
In this case, repair FU(S0HC)-50,
the following: Fuel.>
Open or ground
short circuit in har-
ness betweenfront
oxygen (NF) sen-
sor and ECM con-
nector
Poor contact in
front oxygen (NF)
sensor connector
Poor contact in
ECM connector I

EN(S0HC)-86
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

EN(S0HC)-87
I
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

B: DTC PO032 - FRONT OXYGEN (NF) SENSOR HEATER CIRCUIT HIGH IN-
PUT -
DTC DETECTING CONDITION:
Immediately at fault recognition
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory ModecRef. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(S0HC)-40, Inspection Mode.>.
WIRING DIAGRAM:

BAlTERY
SBF-5

EN1082

Step Check Yes No

1 CHECK OUTPUT SIGNAL FROM ECM. Is the voltage more than 8 V? Go to step 3. Go to step 2.
1)Turnthe ignition switch to ON.
2)Measure the voltage between ECM connec-
tor and chassis ground.
Connector & terminal
(B134) No. 23 (+) - Chassis ground (-):

EN(S0HC)-88
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGI NE (DIAGNOSTlCS)
~~

Step Check Yes No

CHECK OUTPUT SIGNAL FROM ECM. Is the voltage more than 8 V? 20 to step 3. io to step 4.
Measure the voltage between ECM connector
and chassis ground.
Connector & terminal
(8134) No. 22 (+) - Chassis ground (-):
CHECK FRONT OXYGEN ( N F ) SENSOR Is the value more than 2.3 A? 3eplace the ECM. :ND
HEATER CURRENT. :Ref. to
1)Turn the ignition switch to OFF. ‘U(SOHC)-47,
2)Repair the battery short circuit in harness ingine Control
between ECM and front oxygen (NF) sensor vlodule.>
connector.
3)Turn the ignition switch to ON.
4)Read the data of front oxygen (NF)sensor
heater current using Subaru Select Monitor or
the OBD-II general scan tool.
NOTE:
*Subaru Select Monitor
For detailed operation procedure, refer to the
“READ CURRENT DATA FOR ENGINE. <Ref.
to EN(S0HC)-32, Subaru Select Monitor.>
*OBD-II general scan tool
For detailed operation procedure, refer to the
OBD-ll General Scan Tool Instruction Manual.
CHECK OUTPUT SIGNAL FROM ECM. 3epair battery
Does the voltage change more ;o to step 5.
Measure the voltage between ECM connector ;hort circuit in har-
than 8 V by shaking harness
and chassis ground. less between
and connector of ECM while
Connector & terminal ICM and front
monitoring the value with volt-
(8134) No. 23 (+) - Chassis groundI)-( age meter? ixygen (NF) sen-
$01connector.

I CHECK OUTPUT SIGNAL FROM ECM. Does the voltage change more 3epair battery ZND
Measure the voltage between ECM connector than 8 V by shaking harness short circuit in har-
and chassis ground. and connector of ECM while less between
Connector & terminal monitoring the value with volt- ECM and front
(8134) No. 22 (+) - Chassis ground (-): age meter? Ixygen (NF) sen-
;or connector.

EN(S0HC)-89
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

C: DTC PO037 - REAR OXYGEN SENSOR HEATER CIRCUIT MALFUNCTION

-
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode<Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(S0HC)-40, OPERATION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

MAIN RELAY BAlTERY

A:@

EN1083

EN(S0HC)-90
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK GROUND CIRCUIT OF ECM. ;the resistance less than 5 30 to step 3. 30 to step 2.
1)Turn the ignition switch to OFF. 2?
2)Disconnect the connector from ECM.
3)Measure the resistance of harness between
ECM connector and chassis ground.
Connector & terminal
(8134) No. 35 - Chassis ground:
I
CHECK GROUND CIRCUIT OF ECM. s the resistance less than 5 30 to step 3. Repair harness
1)Repair the harness and connector. L? snd connector.
NOTE: VOTE:
In this case, repair the following: In this case, repair
*Open circuit in harness between ECM and the following:
engine ground terminal b Open circuit in
*Poor contact in ECM connector harness between
*Poor contact in coupling connector (B22) ECM and engine
1)Measure resistance of harness between around terminal
ECM connector and chassis ground. b Poor contact in
Connector & terminal ECM connector
(8134) No. 34 - Chassis ground: Poor contact in
couplingconnector
(B22)
I CHECK CURRENT DATA. s the value more than 0.2 A? 3epair the con- Go to step 4.
1)Start the engine. lector.
2)Read the data of rear oxygen sensor heater UOTE:
current using Subaru Select Monitor or OBD-II n this case, repair
general scan tool. ,he following:
1 Poor contact in
NOTE:
*Subaru Select Monitor .ear oxygen sen-
For detailed operation procedure, refer to the ;or connector
“READ CURRENT DATA FOR ENGINE. <Ref. 1 Poor contact in
to EN(S0HC)-32, Subaru Select Monitor.> ’ear oxygen sen-
*OBD-II scan tool :or connecting
For detailed operation procedures, refer to the iarness connector
OBD-ll General Scan Tool Instruction Manual. 1 Poor contact in
ECM connector
I CHECK OUTPUT SIGNAL FROM ECM. s the voltage less than 1.O V? 30 to step 7. Go to step 5.
1)Start and idle the engine.
2)Measure the voltage between ECM connec-
tor and chassis ground.
Connector & terminal
(8134) No. 21 (+)- Chassis ground (-):
b CHECK OUTPUT SIGNAL FROM ECM. >oesthe voltage change less 3epair poor con- Go to step 6.
Measure the voltage between ECM connector han 1.O V by shaking harness :act in ECM con-
and chassis ground. ind connector of ECM while lector.
Connector & terminal nonitoring the value with volt-
(8134) No. 21 (+)- Chassis ground (-): ige meter?
i CHECK OUTPUT SIGNAL FROM ECM. s the voltage less than 1.O V? 3eplace the ECM. Repair battery
1)Disconnectthe connector from rear oxygen <Ref. to short circuit in har-
sensor. FU(S0HC)-47, ness between
2)Measure the voltage between ECM connec- Engine Control ECM and rear oxy
tor and chassis ground. Module.> gen sensor con-
Connector & terminal nector. After
(B 134) No. 21 (+) - Chassis ground (-): repair, replace the
ECM. <Ref. to
FU(S0HC)-47,
Engine Control
Module.>

EN(S0HC)-91
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK POWER SUPPLY TO REAR OXY- s the voltage more than 10 V? 30 to step 8. Repair power sup-
GEN SENSOR. ply line.
1)Turn the ignition switch to OFF. NOTE:
2)Disconnect the connector from rear oxygen In this case, repai
sensor. the following:
3)Turn the ignition switch to ON. Open circuit in
4)Measure the voltage between rear oxygen harness between
sensor connector and engine ground or chas- main relay and
sis ground. rear oxygen sen-
Connector & terminal sor connector
(E25) No. 2 (+) - Chassis ground (-): Poor contact in
rear oxygen sen-
sor connector
Poor contact in
couplingconnectoi
(El 1
I CHECK REAR OXYGEN SENSOR. s the resistance less than 30 3epair harness Replace the rear
1)Turn the ignition switch to OFF. 2? md connector. oxygen sensor.
2)Measure the resistance between rear oxy- UOTE: <Ref. to
gen sensor connector terminals. n this case, repair FU(SOHC)-45,
Terminals he following: Rear Oxygen Sen
NO. 1 - NO. 2: 1 Open circuit in SOT.>
iarness between

EN(S0HC)-92
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

EN(S0HC)-93
 a
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

D: DTC PO038 - REAR OXYGEN SENSOR HEATER CIRCUIT HIGH INPUT -

DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode<Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(S0HC)-40, OPERATION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

EN1083

Step Check Yes No

1 CHECK INPUT SIGNAL FOR ECM. Is the voltage more than 8 V? Go to step 2. Go to step 3.
Measure the voltage between ECM connector
and chassis ground.
Connector & terminal
(81341 No. 21 /+I - Chassis around (4:

EN(S0HC)-94
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE IDIAGNOSTICS)

Step Check Yes

CHECK CURRENT DATA. Is the value more than 7 A? 3eplace the ECM.
1)Turn the ignition switch to OFF. :Ref. to
2)Repair the battery short circuit in harness ‘U(S0HC)-47,
between ECM and rear oxygen sensor connec- Engine Control
tor. vlodule.>
3)Turn the ignition switch to ON.
4)Read the data of rear oxygen sensor heater
current using Subaru Select Monitor or the
OBD-II general scan tool.
NOTE:
*Subaru Select Monitor
For detailed operation procedure, refer to the
“READ CURRENT DATA FOR ENGINE. <Ref.
to EN(S0HC)-32, Subaru Select Monitor.>
*OBD-ll general scan tool
For detailed operation procedure, refer to the
OBD-ll General Scan Tool Instruction Manual.
I CHECK POOR CONTACT. Is there poor contact in ECM 3epair poor con- !ND
Check poor contact in ECM connector. connector? act in ECM con-
lector.

EN(S0HC)-95
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

E: DTC PO065 -AIR ASSIST INJECTOR SOLENOID VALVE MALFUNCTION -

DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(S0HC)-40, OPERATION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

MAIN RELAY

AIR ASSIST
INJECTOR
SOLENOID

EN(S0HC)-96
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)
~

Step Check Yes No

I CHECK ANY OTHER DTC ON DISPLAY. Is there any other DTC on dis- nspect the rele- Go to step 2.
play? rant DTC using
List of Diagnostic
iouble Code
DTC)”. <Ref. to
!N(SOHC)-77,
.ist of Diagnostic
iouble Code
DTC).>
2 CHECK AIR ASSIST INJECTOR SOLENOID Does the air assist injector 20 to step 3. Replace the air
VALVE OPERATION. solenoid valve operating assist injector
1)Turn the ignition switch to OFF. sound? solenoid valve.
2)Connect the test mode connector at the <Ref. to
lower portion of instrument panel (on the FU(S0HC)-37, Air
driver’s side), to the side of the center console Assist Injector
box. Solenoid Valve.>
3)Turn the ignition switch to ON.
4)Operate the air assist injector solenoid valve
NOTE:
Air assist injector solenoid valve operation car
also be executed using Subaru Select Monitor
For the procedure, refer to the “Compulsorq
Valve Operation Check Mode”. <Ref. tc
EN(S0HC)-77, List of Diagnostic Trouble Code
(DTC).>
3 CHECK AIR BY-PASS HOSES. Is the air by-pass hose dam- 3epair or replace Go to step 4.
Use your mouth to blow through the air by- aged? he air by-pass
pass hose to make sure that there is a smooth loses.
air flow (no clogging).
1 CHECK FUEL INJECTOR. Is the fuel injector clogged? 3eplace the fuel Replace the air
1)Turn the ignition switch to OFF. njector. <Ref. to assist injector
2)Remove the fuel injector. <Ref. to ‘U(SOHC)-41, solenoid valve.
FU(S0HC)-38, REMOVAL, Fuel Injector.> NSTALLATION, <Ref. to
3)Check for clogged fuel injectors. %el Injector.> FU(S0HC)-37, Air
Assist Injector
Solenoid Valve.>

EN(S0HC)-97
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

F: DTC PO066 - AIR ASSIST INJECTOR SOLENOID VALVE CIRCUIT LOW IN-
PUT -
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory ModeeRef. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(S0HC)-40, OPERATION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

MAIN RELAY

AIR ASSIST
INJECTOR
SOLENOID

EN1084

EN(S0HC)-98
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE IDlAGNOSTICSl

Step Check Yes No

CHECK OUTPUT SIGNAL FROM ECM. s the voltage more than 10 V? Iepair poor con- Go to step 2.
1)Turn the ignition switch to ON. act in ECM con-
2)Measure the voltage between ECM and lector.
chassis ground.
Connector 81terminal
(8134) No, 24 (+)- Chassis ground (-):
CHECK POWER SUPPLY TO AIR ASSIST IN s the voltage more than 10 V? i o to step 3. Repair harness
JECTOR SOLENOID VALVE. and connector.
1)Turn the ignition switch to OFF. NOTE:
2)Disconnect the connector from air assist In this case, repai
injector solenoid valve. the following:
3)Turn the ignition switch to ON. Open circuit in
4)Measure the voltage between air assist harness between
injector solenoid valve and engine ground. air assist injector
Connector 81terminal solenoid valve anc
-
(E42) No. 2 (+) Engine ground (-): main relay connec
tor
Poor contact in
coupling connecto
(B22)
CHECK HARNESS BETWEEN ECM AND AIR s the resistance less than 1 20 to step 4. Repair harness
‘ASSIST INJECTOR SOLENOID VALVE CON n? and connector.
NECTOR. NOTE:
1)Turn the ignition switch to OFF. In this case, repai
2)Disconnect the connector from ECM. the following:
3)Measure the resistance of harness between Open circuit in
ECM and air assist injector solenoid valve con harness between
nector. ECM and air assis
Connector & terminal injector solenoid
-
(8134) NO. 24 (E42) NO. 1: valve connector
Poor contact in
couplingconnecto
(822)
CHECK HARNESS BETWEEN ECM AND AIF Is the resistance less than 10 3epair ground Go to step 5.
ASSIST INJECTOR SOLENOID VALVE CON n? short circuit in har-
NECTOR. less between
Measure the resistance of harness between ICM and air assist
ECM and chassis ground. njector solenoid
Connector 8I terminal ialve connector.
(8134) No. 24 - Chassis ground:
CHECK POOR CONTACT. Is there poor contact in ECM 3epair poor con- Replace the air
Check poor contact in ECM and air assist and air assist injector solenoid act in ECM and assist injector
injector solenoid valve connectors. valve connectors? 3ir assist injector solenoid valve.
;olenoid valve <Ref. to
:onnectors. FU(S0HC)-37, Ai
Assist Injector
Solenoid Valve.>

EN(SOHC)-99
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

G: DTC PO067 - AIR ASSIST INJECTOR SOLENOID VALVE CIRCUIT HIGH IN-
PUT -
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory ModeeRef. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(SOHC)40, OPERATION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

MAIN RELAY

BATTERY
SBF-5
@ 0-

I
I I

EN1084

EN(S0HC)-100
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE IDIAGNOSTICS)

Step Check Yes No

I CHECK OUTPUT SIGNAL FROM ECM. s the voltage more than 10 V? Go to step 2. Go to step 3.
1)Turnthe ignition switch to ON.
2)Measure the voltage between ECM and
chassis ground.
Connector & terminal
(8134) No. 24 (+) - Chassis ground (-):
! CHECK OUTPUT SIGNAL FROM ECM. s the voltage more than 10 V? Repair battery Replace the air
1)Turn the ignition switch to OFF. short circuit in har- assist injector
2)Disconnect the connector from air assist ness between solenoid valve
injector solenoid valve. ECM and air assist <Ref. to
3)Turn the ignition switch to ON. injector solenoid FU(S0HC)-37, Air
4)Measure the voltage between ECM and valve connector. Assist Injector
chassis ground. After repair, Solenoid Valve.>
Connector & terminal replace the ECM. and ECM <Ref. to
(8134) No. 24 (+) - Chassis ground (-): <Ref. to FU(S0HC)-47,
FU(S0HC)-47, Engine Control
Engine Control Module.>
Module.>
3 CHECK OUTPUT SIGNAL FROM ECM. Ioes the voltage change more Repair battery Contact with SOA
Measure the voltage between ECM and chas- han 10 V by shaking harness short circuit in har- (distributor) ser-
sis ground. md connector of ECM while ness between vice.
Connector & terminal nonitoring the value with volt- ECM and air assist NOTE:
(8134) No. 24 (+) - Chassis groundI)-( 3ge meter? injector solenoid lnsepction by DTh
valve connector. is required, be
After repair, cause probablc
replace the ECM. cause is deteriora
<Ref. to tion of multipli
FU(S0HC)-47, parts.
Engine Control
Module.>

EN(S0HC)-101
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

H: DTC PO106 - PRESSURE SENSOR CIRCUIT RANGWPERFORMANCE

PROBLEM (LOW INPUT) -
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode<Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(SOHCp40, OPERATION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

INTAKE AIR
TEMPERATURE

PRESSURE
SENSOR

EN1085

EN(S0HC)-102
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLEENGINE
CODE (DTC)
(DIAGNOSTICS)

Step Check Yes No

CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Moni- Inspect DTC 30 to step 2.
tor or OBD-II general scan tool PO107, PO108 or
NOTE: P1112 Using “List
In this case, it is not necessary to inspect DTC indicate DTC P0107, PO108 or
of Diagnostic Trou-
PO106. P I 112?
ble Code (DTC)”.
<Ref. to
EN(S0HC)-77,
List of Diagnostic
Trouble Code
(DTC).>
CHECK AIR INTAKE SYSTEM. Are there holes, loose bolts or Repair air intake Go to step 3.
disconnection of hose on air system.
intake system?
Is the value within the specifi- ]Go to step 4. Replace the intake
CHECK PRESSURE SENSOR.
Ications? air temperature
1)Start the engine and warm-up engine until
sensor and pres-
coolant temperature is greater than 60°C
sure sensor. <Ref.
(140°F).
to FU(S0HC)-34,
2)Place the shift lever in the selector lever in
Intake Air Temper-
“N” or “ P position.
ature and Pres-
3)Turn the A/C switch to OFF.
sure Sensor.>
4)Turn all accessory switches to OFF.
5)Read the data of intake manifold pressure
sensor signal using Subaru Select Monitor or
OBD-ll general scan tool.
NOTE:
*Subaru Select Monitor
For detailed operation procedure, refer to the
“READ CURRENT DATA FOR ENGINE. <Ref.
to EN(S0HC)-32, Subaru Select Monitor.>
*OBD-II general scan tool
For detailed operation procedure, refer to the
OBD-ll General Scan Tool Instruction Manual.
Specification:
*Intake manifold absolute pressure
Ignition ON
-
73.3 106.6 kPa (550 - 800 mmHg,
21.65 - 31.50 inHg)
Idling
20.0 - 46.7 kPa (150 - 350 mmHg, 5.91
- 13.78 inHg)
Is the throttle positioning ratio 30 to step 5. Adjust or replace
CHECK THROITLE POSITION.
equal to or less than 5% when the throttle posi-
Read the data of throttle position signal using
throttle is fully closed? tion sensor. <Ref.
Subaru Select Monitor or OBD-ll general scan
to FU(SOHC)-31,
tool.
Throttle Position
NOTE: Sensor.>
*Subaru Select Monitor
For detailed operation procedure, refer to the
“READ CURRENT DATA FOR ENGINE”. <Ref.
to EN(S0HC)-32, Subaru Select Monitor.>

¶
*OBD-ll general scan tool
For detailed operation procedure, refer to the
OBD-ll General Scan Tool Instruction Manual.
CHECK THROTTLE POSITION. Is the throttle positioning ratio
equal to or more than 85%
when throttle is fully open?
4-
ReDlace the intake
air temperature
and pressure sen-
Replace the throt-
tle position sen-
sor. <Ref. to
sor. <Ref. to FU(S0HC)-31,
FU(S0HC)-34, Throttle Position
Intake Air Temper- Sensor.>
ature and Pres-
sure Sensor.>

EN(SOHC)-103
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

I: DTC PO107 - PRESSURE SENSOR CIRCUIT LOW INPUT -

DTC DETECTING CONDITION:
Immediately at fault recognition
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory ModeeRef. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(S0HC)-40, OPERATION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

1
iKE AIR
ERATURE
9ND
iSSURE

-NSOR

l,

a
I A
I
I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I
k

EN1085

EN(S0HC)-104
 9
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK CURRENT DATA. s the value less than 13.3 kPa io to step 3. i o to step 2.
1)Start the engine. 100 mmHg, 3.94 inHg)?
2)Read the data of intake manifold absolute
pressure signal using Subaru Select Monitor or
OBD-ll general scan tool.
NOTE:
*Subaru Select Monitor
For detailed operation procedure, refer to the
“READ CURRENT DATA FOR ENGINE. <Ref.
to EN(S0HC)-32, Subaru Select Monitor.>
*OBD-II general scan tool
For detailed operation procedures, refer to the
OBD-ll General Scan Tool Instruction Manual.
CHECK POOR CONTACT. s there poor contact in ECM or Iepair poor con- Iven if MIL lights
Check poor contact in ECM and pressure sen. iressure sensor connector? act in ECM or ip, the circuit has
sor connector. wessure sensor eturned to a nor-
:onnector. nal condition at
his time.
CHECK INPUT SIGNAL FOR ECM. s the voltage more than 4.5 V I 30 to step 5. 30 to step 4.
Measure the voltage between ECM connector
and chassis ground.
.Connector & terminal
(8136) No. 15 (+) - Chassis ground (-):
CHECK INPUT SIGNAL FOR ECM. )oes the vottage change more iepair poor con- iontact with SOA
Measure the voltage between ECM connector han 4.5 V by shaking harness act in ECM con- distributor) ser-
and chassis ground. ind connector of ECM while ector. ‘ice.
Connector & terminal nonitoring the value with volt- JOTE:
(8136) No. 15 (+) -Chassis ground (-): ige meter? nspection by DTF
j required, be
:ause probabl
:ause is deteriorz
ion of multipl
)arts.
CHECK INPUT SIGNAL FOR ECM. s the voltage less than 0.2 V? i o to step 7. $0to step 6.
Measure the voltage between ECM and chas-
sis ground.
Connector & terminal
(8136) No. 5 (+)- Chassis ground (-):
CHECK INPUT SIGNAL FOR ECM. (USING Ioes the value change more lepair poor con- 20 to step 7.
SUBARU SELECT MONITOR.) han 13.3 kPa (100 mmHg, act in ECM con-
Read the data of atmospheric absolute pres- 3.94 inHg) by shaking harness )ector.
sure signal using Subaru Select Monitor. 2nd connector of ECM while
NOTE: nonitoring the value with Sub-
*Subaru Select Monitor iru Select Monitor?
For detailed operation procedure, refer to the
“READ CURRENT DATA FOR ENGINE. <Ref
to EN(S0HC)-32, Subaru Select Monitor.>
CHECK HARNESS BETWEEN ECM AND IN s the voltage more than 4.5 VI 30 to step 8. 3epair open circu
TAKE AIR TEMPERATURE AND PRESSURE n harness
SENSOR CONNECTOR. ietween ECM and
1)Turn the ignition switch to OFF. ntake air tempera.
2)Disconnect the connector from intake air ure and pressure
temperature and pressure sensor. :ensor connector.
3)Turn the ignition switch to ON.
4)Measure the voltage between intake air tem-
perature sensor and pressure sensor connec-
tor and engine ground.
Connector & terminal
(€20) No. 3 (+) - Engine ground (-):

EN(SOHC)-105
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

5 CHECK HARNESS BETWEEN ECM AND IN- Is the resistance less than 1 20 to step 9. Repair open circuit
TAKE AIR TEMPERATURE AND PRESSURE Q? in harness
SENSOR CONNECTOR. between ECM and
1)Turn the ignition switch to OFF. intake air tempera-
2)Disconnect the connector from ECM. ture and pressure
3)Measure the resistance of harness between sensor connector.
ECM and intake air temperature and pressure
sensor connector.
Connector & terminal
(8136) NO. 16 - (E20) NO. 1:
B CHECK HARNESS BETWEEN ECM AND IN- Is the resistance more than 30 to step 10. Repair ground
TAKE AIR TEMPERATURE AND PRESSURE 500 kQ? short circuit in har-
SENSORCONNECTOR. ness between
Measure the 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.
(E20) No. 4 - Engine ground:
IO CHECK POOR CONTACT. Is there poor contact in intake qepair poor con- Replace the intake
Check poor contact in intake manifold pressure manifold pressure sensor con- act in intake air air temperature
sensor connector. nector? emperature and and pressure sen-
wessure sensor sor. <Ref. to
:onnector. FU(S0HC)-34,
Intake Air Temper-
ature and Pres-
sure Sensor.>

EN(S0HC)-106
I
I DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
1 ENGINE (DIAGNOSTICS)

EN(S0HC)-107
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

J: DTC PO108 - PRESSURE SENSOR CIRCUIT HIGH INPUT -

DTC DETECTING CONDITION:
I Immediately at fault recognition
t CAUTION:

i After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(S0HC)-40, OPERATION, Inspec-
tion Mode.>.
WIRING DIAGRAM:
I
i

LKEAIR
t IRATURE
i \ND
, SSURE

-
NSOR

,I

- a
- !@ 1

f I
I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I

EN1085

EN(S0HC)-108
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

I Step Check Yes No

CHECK CURRENT DATA. s the value more than 119.5 i o to step 10. ;o to step 2.
1)Start the engine. :Pa (896.5 mmHg, 35.29
2)Read the data of intake manifold absolute nHg)?
pressure signal using Subaru Select Monitor or
OBD-ll general scan tool.
NOTE:
*Subaru Select Monitor
For detailed operation procedure, refer to the
"READ CURRENT DATA FOR ENGINE. <Ref.
to EN(S0HC)-32, Subaru Select Monitor.>
*OBD-ll general scan tool
For detailed operation procedures, refer to the
OBD-ll General Scan Tool Instruction Manual.
CHECK INPUT SIGNAL FOR ECM. s the voltage more than 4.5 V' i o to step 4. io to step 3.
Measure the voltage between ECM connector
and chassis ground.
Connector & terminal
(6136) No. 15 (+) - Chassis ground (-):
CHECK INPUT SIGNAL FOR ECM. loes the voltage change more lepair poor con- :ontact with SOA
Measure the voltage between ECM connector han 4.5 V by shaking harness act in ECM con- distributor) ser-
and chassis ground. md connector of ECM while lector. ice.
- Connector & terminal
(6136) No. 15 (+) - Chassis ground (-):
nonitoring the value with volt-
ige meter?
JOTE:
nspection by DTh
s required, be
:ause probablt
:ause is deteriora
ion of multiplc
)arts.
CHECK INPUT SIGNAL FOR ECM. s the voltage less than 0.2 V? io to step 6. o
; to step 5.
Measure the voltage between ECM connector
and chassis ground.
Connector & terminal
(6136) No. 5 (+) - Chassis ground (-):
CHECK INPUT SIGNAL FOR ECM. (USING Ioes the value change more Iepair poor con- o
; to step 6.
SUBARU SELECT MONITOR.) han 13.3 kPa (100 mmHg, act in ECM con-
Read the data of atmospheric absolute pres- 3.94 inHg) by shaking harries lector.
sure signal using Subaru Select Monitor. ind connector of ECM while
NOTE: nonitoring the value with Sub-
*Subaru Select Monitor iru Select Monitor?
For detailed operation procedure, refer to the
"READ CURRENT DATA FOR ENGINE". <Ref.
to EN(S0HC)-32, Subaru Select Monitor.>
CHECK HARNESS BETWEEN ECM AND IN. s the voltage more than 4.5 V' ;o to step 7. 3epair open circui
TAKE AIR TEMPERATURE AND PRESSURE n harness
SENSOR CONNECTOR. letween ECM anc
1)Turnthe ignition switch to OFF. ntake air tempera
2)Disconnect the connector from intake air ure and pressure
temperature and pressure sensor. iensor connector.
3)Turn the ignition switch to ON.
4)Measure the voltage between intake air tem,
perature and pressure sensor connector and
engine ground.
Connector & terminal
(E20) No. 3 (+) - Engine ground (-):

EN(S0HC)-109
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK HARNESS BETWEEN ECM AND IN. s the resistance less than 1 Go to step 8. Repair open circuit
TAKE AIR TEMPERATURE AND PRESSURE 2? in harness
SENSOR CONNECTOR. between ECM and
1)Turn the ignition switch to OFF. intake air tempera-
2)Disconnect the connector from ECM. ture and pressure
3)Measure the resistance of harness between sensor connector.
ECM and intake air temperature and pressure
sensor connector.
Connector & terminal
(8136) NO. 5 - (€20) NO. 4:
CHECK HARNESS BETWEEN ECM AND IN- s the resistance less than 1 Go to step 9. Repair open circuit
TAKE AIR TEMPERATURE AND PRESSURE n? in harness
SENSOR CONNECTOR. between ECM and
Measure the resistance of harness between intake air tempera-
ECM and intake air temperature and pressure ture and pressure
sensor connector. sensor connector.
Connector & terminal
(B 136) NO. 16 - (€20)NO. 1:
CHECK POOR CONTACT. s there poor contact in intake Repair poor con- Replace the intake
Check poor contact in intake air temperature nanifold pressure sensor con- tact in intake air air temperature
and pressure sensor connector. lector? temperature and and pressure sen-
pressure sensor sor. <Ref. to
connector. FU(S0HC)-34,
Intake Air Temper-
ature and Pres-
sure Sensor.>
CHECK HARNESS BETWEEN ECM AND IN* s the value more than 119.5 Repair battery Replace the intake
TAKE AIR TEMPERATURE AND PRESSURE (Pa (896.5 mmHg, 35.29 short circuit in har- air temperature
SENSOR CONNECTOR. nHg)? ness between and pressure sen-
1)Turnthe ignition switch to OFF and Subaru ECM and intake sor. <Ref. to
Select Monitor or the OBD-II general scan tool air temperature FU(S0HC)-34,
switch to OFF. and pressure sen- Intake Air Temper-
2)Disconnect the connector from intake air sor connector. ature and Pres-
temperature and pressure sensor. sure Sensor.>
3)Turn the ignition switch to ON and Subaru
Select Monitor or the OBD-I1 general scan tool
switch to ON.
4)Read the data of intake manifold absolute
pressure signal using Subaru Select Monitor 01
OBD-ll general scan tool.
NOTE:
*Subaru Select Monitor
For detailed operation procedure, refer to the
“READ CURRENT DATA FOR ENGINE. <Ref.
to EN(S0HC)-32, Subaru Select Monitor.>
*OBD-ll general scan tool
For detailed operation procedures, refer to the
OBD-ll General Scan Tool Instruction Manual.

EN(S0HC)-110
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

EN(S0HC)-111
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

K: DTC PO111 - INTAKE AIR TEMPERATURE SENSOR CIRCUIT RANGE/PER-

FORMANCE PROBLEM -
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
TROUBLE SYMPTOM:
Erroneous idling
Poor driving performance
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(S0HC)-40, OPERATION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

INTAKE AIR
TEMPERATURE
AND
PRESSURE
SENSOR

EN1085

EN(S0HC)-112
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

I CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Moni- Inspect DTC 30 to step 2.
tor or OBD-ll general scan tool PO112, PO113,
indicate DTC PO112, PO113, P0117, P0118or
PO117, PO118 or P0125? PO125 using “List
of Diagnostic Trou-
ble Code (DTC)”.
<Ref. to
EN(S0HC)-77,
List of Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it i:
not necessary tc
inspect DTC
P0111.
! CHECK ENGINE COOLANT TEMPERA- Is the engine coolant tempera- Replace the intake Inspect DTC
TURE. ture between 75°C (167°F) and air temperature PO125 using “List
1)Start the engine and warm it up completely. 95°C (203”F)? and pressure sen- of Diagnostic Trou.
2)Measure the engine coolant temperature sor. <Ref. to ble Code (DTC)”.
using Subaru Select Monitor or OBD-ll general FU(S0HC)-34, <Ref. to
scan tool. Intake Air Temper- EN(S0HC)-77,
NOTE: ature and Pres- List of Diagnostic
*Subaru Select Monitor sure Sensor.> Trouble Code
For detailed operation procedure, refer to the (DTC).>
“READ CURRENT DATA FOR ENGINE. <Ref.
to EN(S0HC)-32, Subaru Select Monitor.>
*OBD-II general scan tool
For detailed operation procedures, refer to the
OBD-ll General Scan Tool Instruction Manual.

EN(S0HC)-113
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

L: DTC PO112 - INTAKE AIR TEMPERATURE SENSOR CIRCUIT LOW INPUT

-
DTC DETECTING CONDITION:
Immediately at fault recognition
TROUBLE SYMPTOM:
Erroneous idling
Poor driving performance
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(SOHC)BO, OPERATION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

IKE AIR
ERATURI
4ND
SSURE
NSOR

iI@@ I

:. I
I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I

EN1085

EN(SOHC)-114
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK CURRENT DATA. Is the value greater than 120°C io to step 2. Repair poor con-
1)Start the engine. (248”F)? tact.
2)Read the data of intake air temperature sen- NOTE:
sor signal using Subaru Select Monitor or the In this case, repaii
OBD-ll general scan tool. the following:
NOTE: Poor contact in
*Subaru Select Monitor intake air tempera-
For detailed operation procedure, refer to the ture and pressure
“READ CURRENT DATA FOR ENGINE. <Ref. sensor
to EN(S0HC)-32, Subaru Select Monitor.> * Poor contact in
*OBD-ll general scan tool ECM
For detailed operation procedure, refer to the Poor contact in
OBD-ll General Scan Tool Instruction Manual. couplingconnector
(821)
Poor contact in
joint connector
(B83), (8122)
! CHECK HARNESS BETWEEN INTAKE AIR Is the value less than -40°C (- 3eplace the intake Repair ground
TEMPERATURE AND PRESSURE SENSOR 40”F)? iir temperature short circuit in har-
AND ECM CONNECTOR. ind pressure sen- ness between
1)Turn the ignition switch to OFF. ior. <Ref. to intake air tempera
2)Disconnect the connector from intake air ‘U(SOHC)-34, ture sensor and
temperature and pressure sensor. ntake Air Temper- ECM connector.
3)Turn the ignition switch to ON. iture and Pres-
4)Read the data of intake air temperature sen- jure Sensor.>
sor signal using Subaru Select Monitor or the
OBD-II general scan tool.
NOTE:
*Subaru Select Monitor
For detailed operation procedure, refer to the
“READ CURRENT DATA FOR ENGINE”. <Ref.
to EN(S0HC)-32, Subaru Select Monitor.>
*OBD-ll general scan tool
For detailed operation procedure, refer to the
OBD-ll General Scan Tool Instruction Manual.

EN(S0HC)-115
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE IDIAGNOSTICS)

M: DTC PO113 - INTAKE AIR TEMPERATURE SENSOR CIRCUIT HIGH INPUT

-
DTC DETECTING CONDITION:
Immediately at fault recognition
TROUBLE SYMPTOM:
Erroneous idling
Poor driving performance
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(SOHC)dO, OPERATION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

INTAKE AIR
TEMPERATURE
AND
PRESSURE
SENSOR

1
I I
I I
I I
I I
I I
I I
I I
I I
I I

r-
I I
I I
I I
I I
I
I

-
- ?
I
EN1085

EN(S0HC)-116
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK CURRENT DATA. ithe value less than -40°C (- io to step 2. iepair poor con-
1)Start the engine. D’F)? 3ct.
2)Read the data of intake air temperature sen- IOTE:
sor signal using Subaru Select Monitor or the ithis case, repaii
OBD-II general scan tool. i e following:
NOTE: Poor contact in
*Subaru Select Monitor itake air tempera-
For detailed operation procedure, refer to the Jre and pressure
“READ CURRENT DATA FOR ENGINE”. <Ref. ensor
to EN(S0HC)-32, Subaru Select Monitor.> Poor contact in
*OBD-ll general scan tool CM
For detailed operation procedure, refer to the Poor contact in
OBD-ll General Scan Tool Instruction Manual. ouplingconnectoi
B21)
Poor contact in
lint connector
B83), (8122)
CHECK HARNESS BETWEEN INTAKE AIR ;the voltage more than 10 V? lepair battery io to step 3.
TEMPERATURE AND PRESSURE SENSOR hort circuit in har-
AND ECM CONNECTOR. less between
1)Turn the ignition switch to OFF. itake air tempera-
2)Disconnect the connector from intake air Jre and pressure
temperature and pressure sensor. ensor and ECM
3)Measure the voltage between intake air tem- onnector.
perature and pressure sensor connector and
engine ground.
Connector & terminal
(€20) No. 2 (+) - Engine ground (-):
CHECK HARNESS BETWEEN INTAKE AIR ;the voltage more than 10 V? tepair battery ;o to step 4.
TEMPERATURE AND PRESSURE SENSOR ,hart circuit in har.
AND ECM CONNECTOR. less between
1)Turnthe ignition switch to ON. itake air tempera.
2)Measure the voltage between intake air tem- ure and pressure
perature and pressure sensor connector and ;ensor and ECM
engine ground. :onnector.
Connector & terminal
(E20) No. 2 (+) - Engine ground (-):
CHECK HARNESS BETWEEN INTAKE AIR s the voltage more than 3 V? ;o to step 5. 3epair harness
TEMPERATURE AND PRESSURE SENSOR 2nd connector.
AND ECM CONNECTOR. \JOTE:
Measure the voltage between intake air tem- n this case, repai
perature and pressure sensor connector and he following:
engine ground. 1 Open circuit in
Connector & terminal iarness between
(E20) No. 2 (+) - Engine ground (-): ntake air tempera
ure and pressure
;ensor and ECM
:onnector
1 Poor contact in
ntake air tempera
.ure and pressure
sensor
I Poor contact in

ECM
1 Poor contact in

:oupling connect0
[B21)
1 Poor contact in

oint connector
(883) and (8122)

EN(S0HC)-117
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK HARNESS BETWEEN INTAKE AIR s the resistance less than 5 Replace the intake Repair harness
TEMPERATURE AND PRESSURE SENSOR 3? air temperature and connector.
AND ECM CONNECTOR. and pressure sen- NOTE:
1)Turnthe ignition switch to OFF. sor. <Ref. to In this case, repair
2)Measure the resistance of harness between
intake air temperature and pressure sensor
connector and engine ground.
FU(S0HC)-34,
Intake Air Temper-
ature and pres-
.
the following:
Opes circuit in
harness between
Connector i? terminal sure Sensor.> intake air tempera-
(€20) No. 1 -Engine ground:

EN(SOHC)-I 1a
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

EN(S0HC)-119
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

N: DTC PO117 - ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT LOW

INPUT -
DTC DETECTING CONDITION:
Immediately at fault recognition
TROUBLE SYMPTOM:
Hard to start
Erroneous idling
Poor driving performance
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(SOHC)-40, OPERATION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

ENGINE
COOLANT
EMPERATUR
SENSOR

EN1086

EN(S0HC)-120
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICSI
~

Step Check Yes No

CHECK CURRENT DATA. j the value greater than 150°C 20 to step 2. Repair poor con-
1)Start the engine. 302”F)? tact.
2)Read the data of engine coolant temperature NOTE:
sensor signal using Subaru Select Monitor or In this case, repaii
OBD-ll general scan tool. the following:
n Poor contact in
NOTE:
*Subaru Select Monitor engine coolant
For detailed operation procedure, refer to the temperature sen-
“READ CURRENT DATA FOR ENGINE. <Ref. sor
to EN(S0HC)-32, Subaru Select Monitor.> n Poor contact in
*OBD-ll general scan tool ECM
For detailed operation procedures, refer to the * Poor contact in
OBD-I1 General Scan Tool Instruction Manual. couplingconnector
(B21)
Poor contact in
joint connector
(B122)
! CHECK HARNESS BETWEEN ENGINE s the value less than -40°C (- 3eplace the Repair ground
COOLANT TEMPERATURE SENSOR AND IO’F)? ingine coolant short circuit in har-
ECM CONNECTOR. emperature sen- ness between
1)Turn the ignition switch to OFF. ior. <Ref. to engine coolant
2)Disconnect the connector from engine cool- W(SOHC)-27, temperature sen-
ant temperature sensor. Engine Coolant sor and ECM con-
3)Turn the ignition switch to ON. remperature Sen- nector.
4)Read the data of engine coolant temperature ;or.>
sensor signal using Subaru Select Monitor or
OBD-I1 general scan tool.
NOTE:
*Subaru Select Monitor
For detailed operation procedure, refer to the
“READ CURRENT DATA FOR ENGINE. <Ref.
to EN(S0HC)-32, Subaru Select Monitor.>
*OBD-ll general scan tool
For detailed operation procedures, refer to the
OBD-II General Scan Tool Instruction Manual.

EN(S0HC)-121
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

0:DTC PO118 - ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT HIGH

INPUT -
DTC DETECTING CONDITION:
Immediately at fault recognition
TROUBLE SYMPTOM:
Hard to start
Erroneous idling
Poor driving performance
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(SOHC)40, OPERATION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

ENGINE
COOLANT
EMPERATUR
SENSOR

10

li

EN108€

EN(S0HC)-122
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK CURRENT DATA. s the value less than -40°C (- 30 to step 2. Repair poor con-
1)Start the engine. IOOF)? tact.
2)Read the data of engine coolant temperature NOTE:
sensor signal using Subaru Select Monitor or In this case, repai
OBD-ll general scan tool. the following:
NOTE: Poor contact in
*Subaru Select Monitor engine coolant
For detailed operation procedure, refer to the temperature sen-
“READ CURRENT DATA FOR ENGINE. <Ref. sor
to EN(S0HC)-32, Subaru Select Monitor.> Poor contact in
*OBD-ll general scan tool ECM
For detailed operation procedures, refer to the Poor contact in
OBD-ll General Scan Tool Instruction Manual. couplingconnectoi
(B21)
Poor contact in
joint connector
(B122)
CHECK HARNESS BETWEEN ENGINE s the voltage more than IO V? 3epair battery Go to step 3.
COOLANT TEMPERATURE SENSOR AND short circuit in har-
ECM CONNECTOR. less between
1)Turn the ignition switch to OFF. ICM and engine
2)Disconnect the connector from engine cool- :oolant tempera-

r
ant temperature sensor. ure sensor con-
3)Measure the voltage between engine coolant lector.
temperature sensor connector and engine
ground.
Connector & terminal
(€8) No. 1 (+) - Engine ground (-):
CHECK HARNESS BETWEEN ENGINE s the voltage more than 10 V? 3epair battery Go to step 4.
COOLANT TEMPERATURE SENSOR AND ;hort circuit in har-
ECM CONNECTOR. less between
1)Turnthe ignition switch to ON. ICM and engine
2)Measure the voltage between engine coolant :oolant tempera-
temperature sensor connector and engine ure sensor con-
ground. lector.
Connector & terminal
(€8) No. 1 (+) - Engine ground (-): I
CHECK HARNESS BETWEEN ENGINE s the voltage more than 4 V? 30 to step 5. Repair harness
COOLANT TEMPERATURE SENSOR AND and connector.
ECM CONNECTOR. NOTE:
Measure the voltage between engine coolant In this case, repai
temperature sensor connector and engine the following:
ground. Open circuit in
Connector & terminal harness between
(€8) No. 1 (+) - Engine ground (-): ECM and engine
coolant tempera-
ture sensor con-
nector
Poor contact in
engine coolant
temperature sen-
sor connector
Poor contact in
ECM connector
Poor contact in
couplingconnectoi
(B21)
Poor contact in
joint connector
(B122)

EN(S0HC)-123
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)
~

Step Check Yes No

I CHECK HARNESS BETWEEN ENGINE Is the resistance less than 5 3eplace the Repair harness
COOLANT TEMPERATURE SENSOR AND n? mgine coolant and connector.
ECM CONNECTOR. emperature sen- NOTE:
1)Turnthe ignition switch to OFF. ;or. <Ref. to In this case, repaii
2)Measure the resistance of harness between 'U( S0HC)-27, the following:
engine coolant temperature sensor connector Engine Coolant Open circuit in
and engine ground. Bmperature Sen- harness between
Connector & terminal ;or.> ECM and engine
(€8) No. 2 - Engine ground: coolant tempera-
ture sensor con-
nector
* Poor contact in
engine coolant
temperature sen-
sor connector
Poor contact in
ECM connector
Poor contact in
couplingconnector
(B21)
Poor contact in
joint connector
(B122)

EN(S0HC)-124
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

EN(S0HC)-125
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE IDlAGNOSTlCSl
~

P: DTC PO121 - THROTTLE POSITION SENSOR CIRCUIT RANGE/PERFOR-

MANCE PROBLEM (HIGH INPUT) -
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
Poor driving performance
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(SOHC)40, OPERATION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

THROTTLE
POSITION

li

EN1087

EN(S0HC)-126
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

1 CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Moni- Inspect DTC Replace the throt-
tor or OBD-II general scan tool PO122 or PO123 tle position sen-
indicate DTC PO122 or PO123? using “List of Diag- sor. <Ref. to
nostic Trouble FU(S0HC)-31,
Code (DTC)”. Throttle Position
<Ref. to Sensor.>
EN(S0HC)-77,
List of Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
PO121.

EN(S0HC)-127
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Q: DTC PO122 - THROTTLE POSITION SENSOR CIRCUIT LOW INPUT -

DTC DETECTING CONDITION:
Immediately at fault recognition
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
Poor driving performance
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(S0HC)-40, OPERATION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

THROlTLE
POSITION
SENSOR

EN1087

EN(S0HC)-128
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK CURRENT DATA. s the value less than 0.1 V? IGo to step 2. Even if MIL lights
1)Start the engine. up, the circuit has
2)Read the data of throttle position sensor sig- returned to a nor-
nal using Subaru Select Monitor or OBD-11 mal condition at
general scan tool. this time. A tempo-
NOTE: rary poor contact
*Subaru Select Monitor of the connector
For detailed operation procedure, refer to the may be the cause.
“READ CURRENT DATA FOR ENGINE. <Ref. NOTE:
to EN(S0HC)-32, Subaru Select Monitor.> In this case, repair
*OBD-ll general scan tool the following:
For detailed operation procedures, refer to the Poor contact in
OBD-I1 General Scan Tool Instruction Manual. throttle position
sensor connector
Poor contact in
ECM connector
Poor contact in
couplingconnector
(B21)
I
CHECK INPUT SIGNAL FOR ECM. s the voltage more than 4.5 V? Go to step 4. Go to step 3.
Measure the voltage between ECM connector
end chassis ground while throttle valve is fully
closed.
Connector & terminal
(6136) No. 15 (+) -Chassis ground (-):
1 CHECK INPUT SIGNAL FOR ECM. loes the voltage change more Repair poor con- Contact with SOA
Measure the voltage between ECM connector han 4.5 V by shaking harness tact in ECM con- (distributor) ser-
and chassis ground. and connector of ECM while nector. vice.
Connector & terminal nonitoring the value with volt- NOTE:
(6136) No. 15 (+) -Chassis ground (-): age meter? Inspection by DTM
is required, be.
cause probable
cause is deteriora.
tion of multiple
parts.
I CHECK INPUT SIGNAL FOR ECM. s the voltage less than 0.1 V?
Measure the voltage between ECM connector
and chassis ground.
Connector & terminal
(8136) No. 17 (+) -Chassis ground (-):
1 CHECK INPUT SIGNAL FOR ECM. (USING 9oes the voltage change more
SUBARU SELECT MONITOR.) :han 0.1 V by shaking harness tact in ECM con-
Measure the voltage between ECM connector and connector of ECM while nector.
and chassis ground. nonitoring the value with Sub-
aru Select Monitor?

EN(S0HC)-129
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK HARNESS BETWEEN ECM AND s the voltage more than 4.5 VS i o to step 7. Repair harness
THROTTLE POSITION SENSOR CONNEC- and connector.
TOR. NOTE:
1)Turnthe ignition switch to OFF. In this case, repair
2)Disconnectthe connectors from throttle posi- the following:
tion sensor. Open circuit in
3)Turn the ignition switch to ON. harness between
4)Measure the voltage between throttle posi- throttle position
tion sensor connector and engine ground. sensor and ECM
Connector & terminal connector
(€13) No. 4 (+) -Engine ground (-): Poor contact in
throttle position
sensor connector
Poor contact in
ECM connector
Poor contact in
couplingconnector
(8211
Poor contact in
joint connector
(8122)
.CHECK HARNESS BETWEEN ECM AND s the resistance less than 1 $0to step 8. Repair harness
THROlTLE POSITION SENSOR CONNEC- 3? and connector.
TOR. NOTE:
1)Turn the ignition switch to OFF. In this case, repaii
2)Measure the resistance of harness between the following:
ECM connector and throttle position sensor Open circuit in
connector. harness between
Connector & terminal throttle position
(8136) NO. 17 - (€13) NO. 3: sensor and ECM
connector
Poor contact in
ECM connector
Poor contact in
throttle position
sensor connector
Poor contact in
couplingconnector
I
(B21)
CHECK HARNESS BETWEEN ECM AND
THROlTLE POSITION SENSOR CONNEC- R? short circuit in har-
TOR. ness between
Measure the resistance of harness between throttle position
throttle position sensor connector and engine sensor and ECM
ground. connector.

7
Connector & terminal
-
(E13) No. 3 Engine ground:
CHECK POOR CONTACT. s there poor contact in throttle Repair poor con- Replace the throt-
Check poor contact in throttle position sensor losition sensor connector? tact in throttle posi- tle position sen-
connector. tion sensor sor. <Ref. to
connector. FU(S0HC)-31,
Throttle Position
Sensor.>

EN(S0HC)-130
EN(S0HC)-131
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

R: DTC PO123 - THROTTLE POSITION SENSOR CIRCUIT HIGH INPUT -

DTC DETECTING CONDITION:
Immediately at fault recognition
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
Poor driving performance
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(S0HC)-40, OPERATION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

-THROTTLE
POSITION
SENSOR

-1F 11

EN1087

EN(S0HC)-132
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK CURRENT DATA. s the value more than 4.9 V? i o to step 2. Even if MIL lights
1)Start the engine. up, the circuit has
2)Read the data of throttle position sensor sig- returned to a nor-
nal using Subaru Select Monitor or OBD-ll mal condition at
general scan tool. this time. A tempo-
NOTE: rary poor contact
OSubaru Select Monitor of the connector
For detailed operation procedure, refer to the may be the cause.
“READ CURRENT DATA FOR ENGINE”. <Ref. NOTE:
to EN(S0HC)-32, Subaru Select Monitor.> In this case, repaii
*OBD-ll general scan tool the following:
For detailed operation procedures, refer to the Poor contact in
OBD-II General Scan Tool Instruction Manual. throttle position
sensor connector
8 Poor contact in

ECM connector
8 Poor contact in

coupling connector
(6211
CHECK HARNESS BETWEEN THROTTLE s the resistance less than 5 20 to step 3. Repair harness
POSITION SENSOR AND ECM CONNEC- n? and connector.
TOR. NOTE:
1)Turn the ignition switch to OFF. In this case, repaii
2)Disconnect the connector from throttle posi- the following:
tion sensor. Open circuit in
3)Measure the resistance of harness between harness between
throttle position sensor connector and engine throttle position
ground. sensor and ECM
Connector & terminal connector
(E 13) No. 2 - Engine ground: Poor contact in
couplingconnectoi
(821)
Poor contact in
joint connector
(6122)
CHECK HARNESS BETWEEN THROlTLE Is the voltage more than 4.9 V‘ 3epair battery Replace the throt-
POSITION SENSOR AND ECM CONNEC- ;hort circuit in har tle position sen-
TOR. less between sor. <Ref. to
1)Turn the ignition switch to ON. hrottle position FU(S0HC)-31,
2)Measure the voltage between throttle posi- sensor and ECM Throttle Position
tion sensor connector and engine ground. :onnector. After Sensor.>
Connector & terminal .epair, replace the
(E13) No. 3 (+) - Engine ground (-): X M . <Ref. to
‘U(SOHC)-47,
Engine Control
Module.>

EN(S0HC)-133
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE /DIAGNOSTICS)

S: DTC PO125 - INSUFFICIENT COOLANT TEMPERATURE FOR CLOSED

LOOP FUEL CONTROL -
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
TROUBLE SYMPTOM:
Engine would not return to idling.
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(SOHC)40, OPERATION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

/cfEMPERATUR
E;/

U ECM

EN1086

EN(S0HC)-134
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)
~~

Step Check Yes No

CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Moni- nspect DTC ;o to step 2.
tor or OBD-II general scan tool ’01 17 or PO118
indicate DTC PO117 or PO118? sing “List of Diag-
iostic Trouble
;ode (DTC)”.
:Ref. to
IN(S0HC)-77,
A t of Diagnostic
rrouble Code
DTC).>
VOTE:
n this case, it i$
lot necessary tc
nspect DTC
p0125.
! CHECK THERMOSTAT. Does the thermostat remain Replace the ther- Replace the
opened? mostat. <Ref. to engine coolant
GO-35, Thermo- temperature sen-
stat.> sor. <Ref. to
FU(S0HC)-27,
Engine Coolant
Temperature Sen-
sor.>

EN(S0HC)-I 35
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

T: DTC PO128 - THERMOSTAT MALFUNCTION -

DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
TROUBLE SYMPTOM:
Thermostat remains open.
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(S0HC)-40, OPERATION, Inspec-
tion Mode.>.

Step Check I Yes No

CHECK VEHICLE CONDITION. Has engine operated at idle or
has vehicle been driven with
part of engine submerged
under water?
CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Moni-
tor or OBD-lI general scan tool
indicate DTC PO125, P0301,
P0302, PO303 and PO304 at
same time?
CHECK ENGINE COOLANT. Are cootant level and mixture Go to step 4.
ratio of cooling water to anti-
freeze solution correct?
CHECK RADIATOR FAN. Does the radiator fan continu- Repair radiator fan Replace the ther-
1)Start the engine. ously rotate for more than 3
2)Check radiator fan operation. minutes during idling?
In this case, it is Go to step 2.
not necessary to
inspect DTC
~ PO128.
Go to step 3. Inspect DTC
I PO1 25, P0301,
P0302, PO303 and
PO304 using “List
of Diagnostic Trou-
ble Code (DTC)”.
I <Ref. to
EN(S0HC)-77,
List of Diagnostic
Trouble Code
(DTC).>
Replace the
engine coolant.
I
<Ref. to CO-25,
REPLACEMENT,
Engine Coolant.>
hircuit. <Ref. to mostat. <Ref. to
CO-46, Radiator CO-35, Thermo-
Main Fan and Fan stat.>
,Motor.>and <Ref.
to CO-48, Radiator
Sub Fan and Fan
Motor.>

EN(S0HC)-136
 a
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

EN(S0HC)-137
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

U: DTC PO130 - FRONT OXYGEN (NF) SENSOR CIRCUIT RANGE/PERFOR-

MANCE PROBLEM (LEAN) -
DTC DETECTING CONDITION:
Immediately at fault recognition
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(S0HC)-40, OPERATION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

MAIN RELAY BAlTERY

R
FRONT OXYGEN

EN1082

EN(S0HC)-I38
 4
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLEENGINE
CODE (DTC)
(DIAGNOSTICS)
~

Check Yes No
Step
Does the Subaru Select Moni- Inspect DTC 30 to step 2.
CHECK ANY OTHER DTC ON DISPLAY.
:or or OBD-ll general scan tool PO131, PO132,
ndicate DTC PO131, PO132, PO031 or PO032
PO031 or P0032? using “List of Diag-
nostic Trouble
Code (DTC)”.
<Ref. to
EN(SOHC)-77,
List of Diagnostic
Trouble Code
(DTC).>
Go to step 3. io to step 4.
CHECK FRONT OXYGEN (NF) SENSOR DA Is the value equal to or more
TA. than 0.85 and equal to less
1)Start the engine. than 1.I 5 in idling?
2)While observing the Subaru Select Monitor
or OBD-ll general scan tool screen, warm-up
the engine until coolant temperature is above
70°C (160°F).
If the engine is already warmed-up, operate ai
idle speed for at least 1 minute.
3)Read the data of front oxygen (NF)sensor
signal using Subaru Select Monitor or OBD-II
general scan tool.
NOTE:
OSubaru Select Monitor
For detailed operation procedure, refer to the
“READ CURRENT DATA FOR ENGINE. <Rei
to EN(S0HC)-32, Subaru Select Monitor.>
*OBD-ll general scan tool
For detailed operation procedures, refer to tht
OBD-ll General Scan Tool Instruction Manual
30 to step 6. Go to step 4.
CHECK FRONT OXYGEN (NF) SENSOR DA- ;the value more than 1.I fori
TA. loment?
Race the engine at speeds from idling to 5,000
rpm for a total of 5 cycles.
NOTE:
To increase engine speed to 5,000 rpm, slowly
depress accelerator pedal, taking approximate-
ly 5 seconds, and quickly release accelerator
pedal to decrease engine speed.
s the resistance less than 5 Go to step 5. Repair open circui
1 CHECK HARNESS BETWEEN ECM AND
2? between ECM ant
FRONT OXYGEN (NF) SENSOR.
front oxygen (NF)
1)Turn the ignition switch to OFF.
sensor.
2)Disconnect the connector from ECM and
front oxygen (NF)sensor connector.
3)Measure the resistance between ECM and
front oxygen (NF) sensor.
Connector & terminals
-
(8136) NO. 6 (€24) NO. 3:
(8136) NO. 7 - (E24) NO. 4:
-
(8136) NO. 19 (€24) NO. 1:
-
(8136) NO. 20 (€24) NO. 6:

EN(SOHC)-139
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

I CHECK HARNESS BETWEEN ECM AND Is the resistance more than 1 20 to step 6. Repair ground
FRONT OXYGEN (NF)SENSOR. MR? short circuit
Measure the resistance between ECM and between ECM and
chassis ground. front oxygen (NF)
Connector & terminals sensor.
(8136) No. 6 - Chassis ground:
(8136) No. 7 - Chassis ground:
(8136) No. 19 - Chassis ground:
(8136) No. 20 - Chassis ground:
i CHECK EXHAUST SYSTEM. Is there a fault in exhaust sys- 3epair or replace Replace the front
Check exhaust system parts. tem? aulty parts. oxygen (NF) sen-
NOTE: sor. <Ref. to
Check the following items. FU(S0HC)-43,
*Loose installation of portions Front Oxygen (A/
*Damage (crack, hole etc.) of parts F) Sensor.>
*Looseness of front oxygen (NF) sensor
*Looseness and ill fitting of parts between front
oxygen (NF) sensor and rear oxygen sensor

EN(S0HC)-140
 ¶

DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)

ENGINE (DIAGNOSTICS)

EN(S0HC)-141
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

V: DTC PO131 - FRONT OXYGEN ( N F ) SENSOR CIRCUIT MALFUNCTION

(OPEN CIRCUIT) -
DTC DETECTING CONDITION:
Immediately at fault recognition
CAUTION:
After repair or replacement of faulty parts, conduct J e a r Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(SOHC)BO, OPERATION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

SBF-5
~0 e-

Y EN1082

EN(S0HC)-142
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK HARNESS BETWEEN ECM AND s the resistance less than 1 \Go to step 2. Repair harness
FRONT OXYGEN (NF) SENSOR CONNEC- 2? and connector.
TOR. NOTE:
1)Turn the ignition switch to OFF. In this case, repaii
2)Disconnect the connectors from ECM and the following:
front oxygen (NF)sensor connector. b Open circuit in

3)Measure the resistance of harness between harness between

ECM and front oxygen (NF)sensor connector. ECM and front
Connector & terminal oxygen (NF)sen-
-
(8136) NO. 6 (€24) NO. 3: sor connector
-
(6136) NO. 7 (E24) NO. 4: 8 Poor contact in
(8136) NO. 19 -(€24) NO. 1: front oxygen (NF)
(8136) NO. 20 - (€24) NO. 6: sensor connector
8 Poor contact in
ECM connector
! CHECK POOR CONTACT. s there poor contact in front fiepair poor con- Replace the front
Check poor contact in front oxygen (NF)sen- ixygen (NF) sensor connec- tact in front oxygen oxygen ( N F ) sen-
sor connector. :or? (NF)sensor con- sor. <Ref. to
nector. FU(S0HC)-43,
Front Oxygen (A/
F) Sensor.>

EN(S0HC)-143
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE IDIAGNOSTICS)

W: DTC PO132 - FRONT OXYGEN (NF) SENSOR CIRCUIT MALFUNCTION

(SHORT CIRCUIT) -
DTC DETECTING CONDITION:
Immediately at fault recognition
CAUTION:
After repair or replacement of faulty parts, c o n c x t Clear Memory Mode <Ref. to Etc SOHC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(SOHC)40,OPEl \TION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

MAIN RELAY BATTERY

0 e-

EN1082

EN(S0HC)-144
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK HARNESS BETWEEN ECM AND s the resistance more than 10 Replace the front Repair ground
FRONT OXYGEN (NF) SENSOR CONNEC- II? oxygen (NF) sen- short circuit in har-
TOR. sor. <Ref. to ness between
1)Turn the ignition switch to OFF. FU(S0HC)-43, ECM and front
2)Disconnect the connector from ECM. Front Oxygen (A/ oxygen (NF) sen-
3)Measure the resistance of harness between F) Sensor.> sor connector.
ECM connector and chassis ground.
Connector & terminal
(8136) No. 6 - Chassis ground:
( 8 136) No. 7 - Chassis ground:
(8136) No. 19 - Chassis ground:
( 8 136) No. 20 - Chassis ground:

EN(S0HC)-145
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)
~

X: DTC PO133 - FRONT OXYGEN (NF)SENSOR CIRCUIT SLOW RESPONSE

-
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(S0HC)-40, OPERATION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

MAIN RELAY BATTERY

A:@

EN1082

EN(S0HC)-146
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK ANY OTHER DTC ON DISPLAY. )oes the Subaru Select Moni- Inspect DTC 20 to step 2.
or or OBD-ll general scan tool PO131, P0132,
ndicate DTC PO131, PO132, PO031 or PO032
’0031 or P0032? using “List of Diag.
nostic Trouble
Code (DTC)”.
<Ref. to
EN(S0HC)-77,
List of Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it i:
not necessary tc
inspect DTC
PO133.
CHECK EXHAUST SYSTEM. s there a fault in exhaust sys- Repair exhaust 3eplace the front
NOTE: em? system. )xygen (NF) sen-
Check the following items. ;or. <Ref. to
*Loose installation of front portion of exhaust ‘U(SOHC)-43,
pipe onto cylinder heads ‘ront Oxygen (A/
$Looseconnection between front exhaust pipe 7 Sensor.>
and front catalytic converter
*Damage of exhaust pipe resulting in a hole

EN(S0HC)-147
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Y: DTC PO136 - REAR OXYGEN SENSOR CIRCUIT MALFUNCTION -

DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(S0HC)-40, OPERATION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

F REAROXYGEN

i
s

r-
1-
I
I
I

Lc’:

7-
f-
I
I
I
I
I
I

:-r
7
A(
C:@
c(

A:@

$x EN1083

Step Check
1 CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Moni-
tor or OBD-II general scan tool
indicate DTC PO131 or PO132?

EN(S0HC)-148
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK FAILURE CAUSE OF PO131 or s the failure cause of PO131 01 :heck fuel system. $0 to step 3.
P0132. ’01 32 in the fuel system? IOTE:
Inspect DTC PO131 or PO132 using “List of i this case, it is
Diagnostic Trouble Code (DTC)”. <Ref. to lot necessary to
EN(S0HC)-77, List of Diagnostic Trouble Code ispect DTC
(DTC).> ’01 36.
CHECKREAROXYGENSENSORDATA. Ioes the value fluctuate? i o to step 7. ;o to step 4.
1)Warm-upthe 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 the data of rear oxygen sensor signal
using Subaru Select Monitor or OBD-II general
scan tool.
NOTE:
*Subaru Select Monitor
For detailed operation procedure, refer to the
“READ CURRENT DATA SHOWN ON DIS-
PLAY FOR ENGINE”. <Ref. to EN(S0HC)-32,
Subaru Select Monitor.>
*OBD-ll general scan tool
For detailed operation procedures, refer to the
OBD-ll General Scan Tool Instruction Manual.
CHECKREAROXYGENSENSORDATA. s the value fixed between 0.2 i o to step 5. Heplace the rear
Read the data of rear oxygen sensor signal ind 0.4 V? oxygen sensor.
using Subaru Select Monitor or OBD-II Gen- <Ref. to
eral Scan Tool. FU(S0HC)-43,
Front Oxygen (A/
F) Sensor.>
CHECK HARNESS BETWEEN ECM AND s the resistance more than 3 iepair open circuit Go to step 6.
REAR OXYGEN SENSOR CONNECTOR. 2? iharness
1)Turnthe ignition switch to OFF. ietween ECM and
2)Disconnect the connectors from ECM and ear oxygen sen-
rear oxygen sensor. ,or Connector.
3)Measure the resistance of harness between
ECM and rear oxygen sensor connector.
Connector & terminal
(6136) NO. 16 - (€25) NO. 3:
CHECK HARNESS BETWEEN REAR OXY- s the voltage more than 0.2 V’
GEN SENSOR AND ECM CONNECTOR.
1)Turnthe ignition switch to OFF. :Ref. to NOTE:
2)Disconnect the connector from rear oxygen
sensor.
3)Turn the ignition switch to ON. upen circun in
4)Measure the voltage between rear oxygen harness between
sensor harness connector and engine ground rear oxygen sen-
or chassis ground. sor and ECM con-
Connector & terminal nector
(E25) No. 4 (+) - Engine ground (-): Poor contact in
rear oxygen sen-
sor connector
Poor contact in
ECM connector

EN(S0HC)-I 49
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

7 CHECK EXHAUST SYSTEM. Is there a fault in exhaust sys- Repair or replace Replace the rear
Check exhaust system parts. tem? faulty parts. oxygen sensor.
NOTE: <Ref. to
Check the following items. FU(S0HC)-43,
*Loose installation of portions Front Oxygen (A/
*Damage (crack, hole etc.) of parts F) Sensor.>
*Looseness and ill fitting of parts between front
oxygen (NF) sensor and rear oxygen sensor

EN(SOHC)-150
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTlCS)

EN(S0HC)-151
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Z: DTC PO139 - REAR OXYGEN SENSOR CIRCUIT SLOW RESPONSE -

DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(SOHC)40, OPERATION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

SBF-5
-0 e-

x" EN1083

EN(SOHC)-152
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAG NOSTlCS)

Step Check Yes No

1 CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Moni- Inspect DTC Replace the rear
tor or OBD-ll general scan tool PO136 using “List oxygen sensor.
indicate DTC PO136? of Diagnostic Trou- <Ref. to
ble Code (DTC)”. FU(S0HC)-43,
<Ref. to Front Oxygen (A/
EN(S0HC)-77, F) Sensor.>
List of Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary tc
inspect DTC
PO139.

EN(S0HC)-153
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

AA:DTC PO171 - FUEL TRIM MALFUNCTION ( N F TOO LEAN) -

Refer to DTC PO172 for diagnostic procedure. <Ref. to EN(S0HC)-154, DTC PO172 - FUEL TRIM MAL-
FUNCTION ( N F TOO RICH) -, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
AB:DTC PO172 - FUEL TRIM MALFUNCTION ( N F TOO RICH) -
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
Poor driving performance
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(S0HC)-40, OPERATION, Inspec-
tion Mode.>.

Step Check Yes No

CHECK EXHAUST SYSTEM. ire there holes or loose bolts 3epair exhaust Go to step 2.
)n exhaust system? jystem.
CHECK AIR INTAKE SYSTEM. ire there holes, loose bolts or 3epair air intake Go to step 3.
lisconnection of hose on air system.
ntake system?
CHECK FUEL PRESSURE. s fuel pressure between 284 30 to step 4. Repair the follow-
Warning: ind 314 kPa (2.9 - 3.2 kgl ing items.
*Place “NO FIRE” signs near the working :m2, 41 - 46 psi)? Fuel pressure too
area. high
*Be careful not to spill fuel on the floor. Clogged fuel
1)Release fuel pressure. return line or
(1) Disconnect the connector from fuel bent hose
pump relay. Fuel pressure too
(2) Start the engine and run it until it stalls. low
(3) After the engine stalls, crank it for five Improper fuel
more seconds. pump discharge
(4) Turn the ignition switch to OFF. Clogged fuel
2)Connect the connector to fuel pump relay. supply line
3)Disconnect the fuel delivery hose from fuel
filter, and connect fuel pressure gauge.
4)lnstall the fuel filler cap.
5)Start the engine and idle while gear position
is neutral.
6)Measure the fuel pressure while disconnect-
ing pressure regulator vacuum hose from
intake manifold.
Warning:
Before removing the fuel pressure gauge,
release fuel pressure.
NOTE:
If fuel pressure does not increase, squeeze fuel
return hose 2 to 3 times, then measure fuel
Dressure aaain.

EN(S0HC)-154
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)
~

Step Check Yes No

CHECK FUEL PRESSURE. s fuel pressure between 206 i o to step 5. 3epair the follow-
After connecting the pressure regulator vac- ind 235 kPa (2.1 - 2.4 kgl ng items.
uum hose, measure fuel pressure. :m2, 30 - 34 psi)? ‘uel pressure too
Warning: )igh
Before removing the fuel pressure gauge, Faulty pres-
release fuel pressure. sure regulator
Clogged fuel
NOTE:
.If fuel pressure does not increase, squeeze return line or
fuel return hose 2 to 3 times, then measure bent hose
fuel pressure again. ‘uel pressure too
.If out of specificationas measured at this step, DW

check or replace pressure regulator and pres- Faulty pres-

sure regulator vacuum hose. sure regulator
Improper fuel
pump discharge
Clogged fuel
supply line
CHECK ENGINE COOLANT TEMPERATURE s temperature between 70°C ;o to step 6. 3eplace the
SENSOR. 158°F) and 100°C (212”F)? mgine coolant
1)Start the engine and warm-up completely. emperature sen-
2)Read the data of engine coolant temperature ior. <Ref. to
sensor signal using Subaru Select Monitor or W(SOHC)-27,
OBD-ll general scan tool. ingine Coolant
NOTE: remperature Sen-
OSubaru Select Monitor ior.>
For detailed operation procedure, refer to the
“READ CURRENT DATA FOR ENGINE. <Ref.
to EN(S0HC)-32, Subaru Select Monitor.>
.OBD-ll general scan tool
For detailed operation procedures, refer to the
OBD-ll General Scan Tool Instruction Manual.
CHECK INTAKE MANIFOLD PRESSURE s the voltage within the specifi, :ontact with S( 3eplace the intake
SENSOR SIGNAL. :ations? distributor) ser iir temperature
1)Start the engine and warm-up engine until ice. ind pressure sen-
coolant temperature is greater than 60°C JOTE: ior. <Ref. to
(140°F). nspection by C W(SOHC)-34,
2)Place the selector lever in “N” or “ P position 3 required, ntake Air Temper-
3)Turn the A/C switch to OFF. :ause probc iture and Pres-
4)Turn all accessory switches to OFF. :ause is deteric iure Sensor.>
5)Read the data of intake manifold pressure ion of mult
sensor signal using Subaru Select Monitor or )arts.
OBD-II general scan tool.
NOTE:
.Subaru Select Monitor
For detailed operation procedure, refer to the
“READ CURRENT DATA FOR ENGINE”. <Ref.
to EN(S0HC)-32, Subaru Select Monitor.>
.OBD-II general scan tool
For detailed operation procedures, refer to the
OBD-ll General Scan Tool Instruction Manual.
Specification:
Idling
- 24.0 -41.3 kPa (180 -310 mmHg, 7.09
- 12.20 inHg)
Ignition ON
73.3 - 106.6 kPa (550 - 800 mmHg,
21.65 - 31.50 inHd

EN(S0HC)-155
 a

DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)

ENG INE (DIAGNOSTICS)

AC:DTC PO181 - FUEL TEMPERATURE SENSOR A CIRCUIT RANGE/PERFOR-

MANCE PROBLEM -
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(S0HC)-40, OPERATION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

EN108E

EN(S0HC)-156
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

1 CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Moni- Inspect DTC Replace the fuel
tor or OBD-II general scan tool PO182 or PO183 temperature sen-
indicate DTC PO182 or PO183? using “List of Diag- sor. <Ref. to
nostic Trouble EC(S0HC)-8, Fuel
Code (DTC)”. Temperature Sen-
<Ref. to sor.>
EN(S0HC)-77,
List of Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
PO181.

EN(S0HC)-157
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

AD:DTC PO182 - FUEL TEMPERATURE SENSOR A CIRCUIT LOW INPUT -

DTC DETECTING CONDITION:
Immediately at fault recognition
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(SOHC)40, OPERATION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

FUELTANK
I

11
'I
FUEL TEMPERATURE
SENSOR I
I

EN1088

EN(S0HC)-158
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check
1 CHECK CURRENT DATA. ;the value greater than 150°C
1)Start the engine. 302”F)? up, the circuit has
2)Read the data of fuel temperature sensor returned to a nor-
signal using Subaru Select Monitor or OBD-ll mal condition at
general scan tool. this time.
NOTE:
*Subaru Select Monitor
For detailed operation procedure, refer to the
“READ CURRENT DATA FOR ENGINE”. <Ref.
to EN(S0HC)-32, Subaru Select Monitor.>
*OED-ll general scan tool
For detailed operation procedures, refer to the
OED-ll General Scan Tool Instruction Manual.
2 CHECK CURRENT DATA. s the value less than -40°C (-
1)Turn the ignition switch to OFF: .O”F)?
2)Remove the access hole lid. ;or. <Ref. to ness between fuel
3)Disconnect the connector from fuel pump.
4)Turn the ignition switch to ON.
5)Read the data of fuel temperature sensor ;or.>
signal using Subaru Select Monitor or the
OBD-ll general scan tool.
NOTE:
Gubaru Select Monitor
For detailed operation procedure, refer to the
“READ CURRENT DATA FOR ENGINE”. <Ref.
to EN(S0HC)-32, Subaru Select Monitor.>
*OBD-ll general scan tool
For detailed operation procedures, refer to the
OED-ll General Scan Tool Instruction Manual.

EN(SOHC)-159
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

AE:DTC PO183 - FUEL TEMPERATURE SENSOR A CIRCUIT HIGH INPUT -

DTC DETECTING CONDITION:
Immediately at fault recognition
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(SOHC)BO, OPERATION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

FUELTANK

FUEL TEMPERATURE

L @ ECM

EN1088

EN(S0HC)-160
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK CURRENT DATA. ;the value less than -40°C (- ;o to step 2. 3epair poor con-
1)Start the engine. O'F)? act.
2)Read the data of fuel temperature sensor \IOTE:
signal using Subaru Select Monitor or OBD-ll n this case, repaii
general scan tool. he following:
NOTE: 1 Poor contact in
*Subaru Select Monitor uel pump connec-
For detailed operation procedure, refer to the or
"READ CURRENT DATA FOR ENGINE. <Ref. 1 Poor contact in
to EN(S0HC)-32, Subaru Select Monitor.> X M connector
*OBD-ll general scan tool 1 Poor contact in
For detailed operation procedures, refer to the :oupling connec-
OBD-ll General Scan Tool Instruction Manual. :ors (822, B98 and
357)
Poor contact in
oint connector
:B122)
CHECK HARNESS BETWEEN FUEL TEM- j the voltage more than 10 V? Repair battery 30 to step 3.
PERATURE SENSOR AND ECM CONNEC- short circuit in har-
TOR. ness between
1)Turn the ignition switch to OFF. ECM and fuel
2)Remove the access hole lid. pump connector.
3)Disconnect the connector from fuel pump.
4)Measure the voltage between fuel pump
connector and chassis ground.
Connector & terminal
(R58)No. 6 (+) - Chassis ground (-):
CHECK HARNESS BETWEEN FUEL TEM- 5 the voltage more than 10 V? Repair battery Go to step 4.
PERATURE SENSOR AND ECM CONNEC- short circuit in har-
TOR. ness between
1)Turnthe ignition switch to ON. ECM and fuel
2)Measure the voltage between fuel pump pump connector.
connector and chassis ground.
Connector & terminal
(R58) No. 6 (+) - Chassis ground (-):
CHECK HARNESS BETWEEN FUEL TEM- s the voltage more than 4 V? Go to step 5. Repair harness
PERATURE SENSOR AND ECM CONNEC- and connector.
TOR. NOTE:
Measure the voltage between fuel pump con- In this case, repai
nector and chassis ground. the following:
Connector & terminal Open circuit in
(R58)No. 6 (+) - Chassis ground (-): harness between
ECM and fuel
pump connector
Poor contact in
fuel pump connec
tor
Poor contact in
ECM connector
Poor contact in
coupling connec-
tors (898 and R5i

EN(S0HC)-161
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK HARNESS BETWEEN FUEL TEM- the resistance less than 5 3eplace the fuel Repair harness
PERATURE SENSOR AND ECM CONNEC- ? emperature sen- and connector.
TOR. ;or. <Ref. to NOTE:
1)Turnthe ignition switch to OFF. X(SOHC)-8, Fuel In this case, repair
2)Measure the resistance of harness between remperature Sen- the following:
fuel pump connector and chassis ground. SO 1.> Open circuit in
Connector & terminal
i harness between
(R58) No. 5 - Chassis ground: ECM and fuel
pump connector
Poor contact in
fuel pump connec-
tor
Poor contact in
ECM connector
Poor contact in
coupling connec-
tors (898 and R57)
Poor contact in
joint connector
(8122)

EN(S0HC)-162
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

AF:DTC PO301 - CYLINDER 1 MISFIRE DETECTED -

NOTE:
For the diagnostic procedure, refer to DTC P0304. <Ref. to EN(S0HC)-164, DTC PO304 - CYLINDER 4
I
MISFIRE DETECTED -, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>

AG:DTC PO302 - CYLINDER 2 MISFIRE DETECTED -

NOTE:
For the diagnostic procedure, refer to DTC P0304. <Ref. to EN(S0HC)-164, DTC PO304 - CYLINDER 4
MISFIRE DETECTED -, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>

AH:DTC PO303 - CYLINDER 3 MISFIRE DETECTED -

NOTE:
For the diagnostic procedure, refer to DTC P0304. <Ref. to EN(S0HC)-164, DTC PO304 - CYLINDER 4
MISFIRE DETECTED -, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>

EN(S0HC)-163
 II

DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)

ENG INE (DIAGNOSTICS)

AI: DTC PO304 - CYLINDER 4 MISFIRE DETECTED -

DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
Immediately at fault recognition (A misfire which could damage catalyst occurs.)
TROUBLE SYMPTOM:
Engine stalls.
Erroneous idling
Rough driving
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(S0HC)-40, OPERATION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

eY
c
A:@ C:@ECM

*
r
I
r O
I
)
I
1z1
I
3-

I-
-
!
FUELINJECTOR FUEL INJECTOR FUEL INJECTOR FUEL INJECTOR
No.1 No.2 No.3 No.4

C:@ A@

EN1

EN(S0HC)-164
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)
~

Step Check Yes No

CHECK ANY OTHER DTC ON DISPLAY. )oes the Subaru Select Moni- nspect DTC i o to step 2.
3r or OBD-II general scan tool ’01 06, PO107,
idicate DTC P0106, P0107, )0108, PO117,
’01 08, PO117, PO118 or )0118 or PO125
’01 25? ising “List of Diag-
iostic Trouble
:ode (DTC)”.
:Ref. to
!N(SOHC)-77,
.ist of Diagnostic
[rouble Code
DTC).>
JOTE:
n this case, it iz
lot necessary tc
nspect DTC
)0301, PO302
)0303 and P0304.
! CHECK OUTPUT SIGNAL FROM ECM. s the voltage more than 10 V? 30 to step 7. i o to step 3.
1)Turn the ignition switch to ON.
2)Measure the voltage between ECM connec-
tpr and chassis ground on faulty cylinders.
Connector & terminal
#1 (8134) No. 4 (+) - Chassis
ground (-):
#2 (B 134) No. 13 (+) - Chassis
ground (-):
#3 (8134) No. 14 (+) - Chassis
ground (-):
#4 (8134) No. 15 (+) - Chassis
groundI)-(
CHECK HARNESS BETWEEN FUEL INJEC- s the resistance less than 10 3epair ground i o to step 4.
TOR AND ECM CONNECTOR. 2? short circuit in har-
1)Turn the ignition switch to OFF: less between fuel
2)Disconnect the connector from fuel injector njector and ECM
on faulty cylinders. :onnector.
3)Measure the voltage between ECM connec-
tor and engine ground on faulty cylinders.
Connector & terminal
#1 (€5) No. 1 - Engine ground:
#2 (€16) No. 1- Engine ground:
#3 (€6) No. 1 - Engine ground:
-
#4 (€1 7) No. 1 Engine ground:
I CHECK HARNESS BETWEEN FUEL INJEC- s the resistance less than 1 30 to step 5. 3epair harness
TOR AND ECM CONNECTOR. 3? ind connector.
Measure the resistance of harness connector JOTE:
between ECM connector and fuel injector on n this case, repai
faulty cylinders. he following:
Connector & terminal Open circuit in
#1(8134) NO. 4 - (ES) NO. 1: iarness between
#2 (8134) NO. 13 - (€16) NO. 1: ICM and fuel
#3 (B 134) NO. 14 - (E6) NO. 1: njector connector
. #4 (8134) NO. 15 - (E17) NO. 1: Poor contact in
:oupling connecto,
822)
> CHECK FUEL INJECTOR. s the resistance between 5 30 to step 6. 3eplace the faulty
Measure the resistance between fuel injector md 20 a? uel injector. <Ref.
terminals on faulty cylinder. o FU(S0HC)-38,
Terminals %el Injector.>
NO. 1 -NO. 2:

EN(SOHC)-165
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE IDIAGNOSTICS)

Step Check Yes No

CHECK POWER SUPPLY LINE. s the voltage more than 10 V? Repair poor con- Repair harness
1)Turn the ignition switch to ON. tact in all connec- and connector.
2)Measure the voltage between fuel injector tors in fuel injector NOTE:
and engine ground on faulty cylinders. circuit. In this case, repaii
Connector & terminal the following:
#1 (€5) No. 2 (+) - Engine ground (-): Open circuit in
#2 (€16) No. 2 (+) - Engine ground (-): harness between
#3 (E6) No. 2 (+) - Engine ground (-): main relay and fuel
#4 (El 7) No. 2 (+) - Engine ground (-): injector connector
on faulty cylinders
Poor contact in
coupling connectoi
Poor contact in
main relay connec.
tor
Poor contact in
fuel injector con-
nector on faulty
cylinders
CHECK HARNESS BETWEEN FUEL INJEC- s the voltage more than 10 V? Pepair battery Go to step 8.
TOR AND ECM CONNECTOR. short circuit in har-
1)Turn the ignition switch to OFF. nessbetween
2)Disconnect the connector from fuel injector ECM and fuel
on faulty cylinder. injector. After
3)Turn the ignition switch to ON. repair, replace the
4)Measure the voltage between ECM connec- ECM. <Ref. to
tor and chassis ground on faulty cylinders. FU(S0HC)-47,
Connector & terminal Engine Control
#1 (8134) No. 4 (+) - Chassis Module.>
ground (-):
#2 (8134) No. 13 (+) - Chassis
ground (-):
#3 (8134) No. 14 (+) - Chassis
ground (-):
#4 (8134) No. 15 (+) - Chassis
ground (-):
CHECK FUEL INJECTOR. s the resistance less than 1 Replace the faulty Go to step 9.
1)Turn the ignition switch to OFF. a? fuel injector <Ref.
2)Measure the resistance between fuel injector to FU(S0HC)-38,
terminals on faulty cylinder. Fuel Injector.> and
Terminals ECM <Ref. to
NO. 1 -NO. 2: FU(S0HC)-47,
Engine Control
Module.>
CHECK INSTALLATION OF CAMSHAFT PO- s the camshaft position sensor Tighten camshaft Go to step 10.
SITION SENSOWCRANKSHAFT POSITION )r crankshaft position sensor position sensor or
SENSOR. oosely installed? crankshaft posi-
tion sensor.
CHECK CRANKSHAFT SPROCKET. s the crankshaft sprocket Replace the crank- Go to step 11.
Remove the timing belt cover. usted or does it have broken shaft sprocket.
eeth? <Ref. to
ME(S0HC)-54,
Crankshaft
Sprocket.>
CHECK INSTALLATION CONDITION OF s the timing belt dislocated Repair installation Go to step 12.
TIMING BELT. rom its proper position? condition of timing
Turn the crankshaft using ST, and align align- belt. <Ref. to
ment mark on crankshaft sprocket with align- ME(S0HC)-47,
ment mark on cylinder block. Timing Belt
ST 499987500 CRANKSHAFT SOCKET Assembly.>

EN(S0HC)-166
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

2 CHECK FUEL LEVEL. ;the fuel meter indication IO to step 13. leplenish fuel so
igher than the "Lower" level? iel meter indica-
on is higher than
i e "Lower" level.
,iter replenishing
iel, Go to step 13.
3 CHECK STATUS OF CHECK ENGINE MAL- j the MIL coming on or blink- io to step 15. io to step 14.
FUNCTION INDICATOR LAMP (MIL). lg?
1)Clear the memory using Subaru Select Mon-
itor.
<Ref. to EN(S0HC)-43, Clear Memory Mode.>
2)Start the engine, and drive the vehicle more
than 10 minutes.
4 CHECK CAUSE OF MISFIRE DIAGNOSED. Vas the cause of misfire diag- inish diagnostics lepair poor con-
losed when the engine is run- peration, if the 3ct.
ling? ngine has no IOTE:
bnormality. ithis case, repaii
IOTE: i e following:
:x. Remove tht Poor contact in
park plug cord jnitor connector
tc. Poor contact in
pition coil con-
lector
Poor contact in
Jel injector con-
lector on faulty
:ylinders
Poor contact in
:CM connector
Poor contact in
:ouplingconnect0
5 CHECK AIR INTAKE SYSTEM. s there a fault in air intake sys- tepair air intake i o to step 16.
em? ystem.
IOTE:
:heck the follow
l g items:
Are there air
2aks or air suctior
aused by loose oi
lislocated nuts
n d bolts?
Are there crack:
ir any disconnec-
ion of hoses?
6 CHECK MISFIRE SYMPTOM. Ioes the Subaru Select Moni- $0to step 21. ;o to step 17.
1)Turnthe ignition switch to ON. or or OBD-ll general scan tool
2)Read the diagnostic trouble code (DTC). ndicate only one DTC?
*Subaru Select Monitor
<Ref. to EN(S0HC)-32, Subaru Select Moni-
tor.>
*OBD-ll general scan tool
For detailed operation procedures, refer to the
OBD-ll General Scan Tool Operation Manual.
NOTE:
Perform diagnosis according to the items listel
below.
7 CHECK DIAGNOSTIC TROUBLE CODE loes the Subaru Select Moni- 20 to step 22. 30 to step 18.
(DTC) ON DISPLAY. :or or OBD-ll general scan tool
ndicate DTC PO301 and
'0302?

EN(S0HC)-167
 E

DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)

ENGINE (DIAGNOSTICS)

Step Check Yes No

8 CHECK DIAGNOSTICTROUBLE CODE Ioes the Subaru Select Moni- Go to step 23. So to step 19.
(DTC) ON DISPLAY. or or OBD-11 general scan tool
ndicate DTC PO303 and
’0304?
9 CHECK DIAGNOSTICTROUBLE CODE Ioes the Subaru Select Moni- Go to step 24. So to step 20.
(DTC) ON DISPLAY. or or OBD-I1general scan tool
ndicate DTC PO301 and
’0303?
!O CHECK DIAGNOSTICTROUBLE CODE Ioes the Subaru Select Moni- Go to step 25. So to step 26.
(DTC) ON DISPLAY. or or OBD-I1general scan tool
ndicate DTC PO302 and
’0304?
!1 ONLY ONE CYLINDER s there a fault in that cylinder? Repair or replace Go to DTC PO170.
faulty parts. <Ref. to
NOTE: EN(SOHC)-154,
Check the follow- DTC PO171 -
ing items. FUEL TRIM MAL-
Spark plug FUNCTION (NF
Spark plug cord roo LEAN) -,
Fuel injector Diagnostic Proce-
Compression jure with Diagnos
ratio tic Trouble Code
[DTC).>
!2 GROUP OF #1 AND #2 CYLINDERS 4re there faults in #I and #2 Repair or replace So to DTC PO170.
:ylinders? faulty parts. <Ref. to
NOTE: EN(S0HC)-154,
Check the fol- DTC PO171 -
lowing items. FUEL TRIM MAL-
Spark plugs FUNCTION (NF
Fuel injectors roo LEAN) -,
Ignition coil Diagnostic Proce-
Compres- dure with Diagnos
sion ratio tic Trouble Code
If no abnormal is [ DTC).>
discovered, check
for “IGNITION
CONTROL SYS-
TEM” of #I and #2
cylinders side.
<Ref. to
EN(S0HC)-66,
IGNITION CON-
TROL SYSTEM,
Diagnostics for
Engine Starting
Failure.>

EN(S0HC)-168
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

!3 GROUP OF #3 AND #4 CYLINDERS ire there faults in #3 and #4 Repair or replace Go to DTC PO170.
:ylinders? faulty parts. <Ref. to
NOTE: EN(SOHC)-154,
Check the fol- DTC PO171 -
lowing items. FUEL TRIM MAL-
Spark plugs FUNCTION (NF
Fuel injectors TOO LEAN) -,
Ignition coil Diagnostic Proce-
Ifno abnormal is dure with Diagnos.
discovered, check tic Trouble Code
for “16. D: IGNI- (DTCI.2
TlON CONTROL
SYSTEM” of #3
and #4 cylinders
side. <Ref. to
EN(S0HC)-66,
IGNITION CON-
TROL SYSTEM,
Diagnostics for
Engine Starting
Failure.>
!4 GROUP OF #I AND #3 CYLINDERS Ire there faults in #1 and #3 Repair or replace Go to DTC P0170.
:yl inders? faulty parts. <Ref. to
NOTE: EN(SOHC)-l54,
Check the follow- DTC PO171 -
ing items. FUEL TRIM MAL-
Spark plugs FUNCTION ( N F
Fuel injectors TOO LEAN) -,
Skipping timing Diagnostic Proce-
belt teeth dure with Diagnos,
tic Trouble Code
(DTC).>
25 GROUP OF #2 AND #4 CYLINDERS ire there faults in #2 and #4 Repair or replace Go to DTC P0170.
:ylinders? faulty parts. <Ref. to
NOTE: EN(S0HC)-154,
Check the follow- DTC PO171 -
ing items. FUEL TRIM MAL-
Spark plugs FUNCTION (NF
Fuel injectors TOO LEAN) -,
Compression Diagnostic Proce-
ratio dure with Diagnos
Skipping timing tic Trouble Code
belt teeth (DTC).>
!6 CYLINDER AT RANDOM s the engine idle rough? Go to DTC PO170. Repair or replace
<Ref. to faulty parts.
EN(S0HC)-154, NOTE:
DTC PO171 - Check the follow
FUEL TRIM MAL- ing items.
FUNCTION (NF Spark plugs
TOO LEAN) -, Fuel injectors
Diagnostic Proce- Compression
dure with Diagnos- ratio
tic Trouble Code
(DTC).>

EN(S0HC)-169
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICSI

AJ:DTC PO327 - KNOCK SENSOR CIRCUIT LOW INPUT -

DTC DETECTING CONDITION:
Immediately at fault recognition
TROUBLE SYMPTOM:
Poor driving performance
Knocking occurs.
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(S0HC)-40, OPERATION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

SENSOR

I I@
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k

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i
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1
I
I (mECM
EN1089

EN(S0HC)-170
 E

DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)

ENGINE (DIAGNOSTICS)
~~

Step Check Yes No

CHECK HARNESS BETWEEN KNOCK SEN- s the resistance more than ;o to step 2. Repair harness
SOR AND ECM CONNECTOR. 'OO ka? and connector.
1)Turn the ignition switch to OFF. NOTE:
2)Disconnect the connector from ECM. In this case, repair
3)Measure the resistance between ECM har- the following:
ness connector and chassis ground. Open circuit in
Connector & terminal harness between
(8136) No. 4 - Chassis ground: knock sensor and
ECM connector
Poor contact in
knock sensor con-
nector
Poor contact in
couplingconnector
(821)
! CHECK KNOCK SENSOR. s the resistance more than ;o to step 3. Repair harness
1)Disconnect the connector from knock sensor. 700 ka? and connector.
2)Measure the resistance between knock sen- NOTE:
sor connector terminal and engine ground. In this case, repaii
Terminal the following:
-
No. 2 Engine ground: Open circuit in
harness between
knock sensor and
ECM connector
Poor contact in
knock sensor con-
nector
9 Poor contact in
couplingconnector
(8211
1 CHECK CONDITION OF KNOCK SENSOR s the knock sensor installation Replace the knock Tighten knock sen.
INSTALLATION. )olt tightened securely? sensor. <Ref. to sor installationbolt
FU(S0HC)-30, securely.
Knock Sensor.>

EN(S0HC)-171
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

AK:DTC PO328 - KNOCK SENSOR CIRCUIT HIGH INPUT -

DTC DETECTING CONDITION:
Immediately at fault recognition
TROUBLE SYMPTOM:
Poor driving performance
Knocking occurs.
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(S0HC)-40, OPERATION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

SENSOR
I

i
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I
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I
I
I
I
I
I
I
I

ECM

EN1089

EN(S0HC)-172
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE ( DIAG NOSTlCS)

Step Check Yes No

CHECK HARNESS BETWEEN KNOCK SEN- s the resistance less than 400 Go to step 2. Go to step 3.
SOR AND ECM CONNECTOR. A2?
Measure the resistance of harness between I
ECM connector and chassis ground.
Connector & terminal
(8136) No. 4 - Chassis ground:
CHECK KNOCK SENSOR. s the resistance less than 400 Replace the knock Repair ground
1)Disconnectthe connector from knock sensor. :a? sensor. <Ref. to short circuit in har-
2)Measure the resistance between knock sen- FU(S0HC)-30, ness between
sor connector terminal and engine ground. Knock Sensor.> knock sensor con-
Terminal nector and ECM
No. 2 - Engine ground: connector.
NOTE:
The harness be-
tween both con-
nectors is
shielded. Repaii
short circuit of har-
ness together with
shield.
i CHECK INPUT SIGNAL FOR ECM. s the voltage more than 2 V? Even if MIL lights Repair poor con-
j)Connect the connectors to ECM and knock up, the circuit has tact in ECM con-
sensor. returned to a nor- nector.
2)Turn the ignition switch to ON.
3)Measure the voltage between ECM and
chassis ground.
Connector & terminal
(8136) No. 4 (+) - Chassis ground (-):

EN(S0HC)-173
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

AL:DTC PO335 - CRANKSHAFT POSITION SENSOR CIRCUIT MALFUNCTION

DTC DETECTING CONDITION:

Immediately at fault recognition
TROUBLE SYMPTOM:
Engine stalls.
Failure of engine to start
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(S0HC)-40, OPERATION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

EN1090

EN(S0HC)-174
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECKHARNESSBETWEENCRANK- 3 the resistance more than 3epair harness 30 to step 2.
SHAFT POSITION SENSOR AND ECM CON- 00 kR? ind connector.
NECTOR. JOTE:
1)Turnthe ignition switch to OFF. n this case, repair
2)Disconnect the connector from crankshaft he following:
position sensor. Open circuit in
3)Measure the resistance of harness between iarness between
crankshaft position sensor connector and :rankshaft posi-
engine ground. ion sensor and
Connector & terminal ICM connector
(€10) No. 1 - Engine ground: Poor contact in
ICM connector
Poor contact in
:ouplingconnector
821)
! CHECK HARNESS BETWEEN CRANK- 3 the resistance less than 10 3epair ground 30 to step 3.
SHAFT POSITION SENSOR AND ECM CON- I? ;hort circuit in har-
NECTOR. less between
Measure the resistance of harness between rankshaft posi-
crankshaft position sensor connector and ion sensor and
engine ground. ICM connector.
. Connector & terminal IOTE:
(€10) No. 1 - Engine ground: -he harness b e
ween both con-
lectors are
ihielded. Repaii
jround short circuii
n harness togeth.
?rwith shield.
) CHECK HARNESS BETWEEN CRANK- s the resistance less than 5 30 to step 4. 3epair harness
SHAFT POSITION SENSOR AND ECM CON. 2? and connector.
NECTOR. \IOTE:
Measure the resistance of harness between n this case, repai
crankshaft position sensor connector and he following:
engine ground. 1 Open circuit in

Connector & terminal iarness between

(E 10) No. 2 - Engine ground: :rankshaft posi-
ion sensor and
I C M connector
1 Poor contact in

I C M connector
1 Poor contact in

:oupling connect0
:B21)
I CHECK CONDITION OF CRANKSHAFT PO- s the crankshaft position sen- 30 to step 5. righten crank-
SlTlON SENSOR. ior installation bolt tightened shaft position sen,
iecurely? ;or installation bo1
securely.
> CHECK CRANKSHAFT POSITION SENSOR s the resistance between 1 3epair poor con- 3eplace the crank
1)Remove the crankshaft position sensor. rnd 4 kQ? act in crankshaft shaft position sen
2)Measure the resistance between connector losition sensor ;or. <Ref. to
terminals of crankshaft position sensor. :onnecto r. FU(S0HC)-28,
Terminals Srankshaft Posi-
-
NO. 1 NO. 2: :ion Sensor.>

EN(S0HC)-175
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

AM:DTC PO336 - CRANKSHAFT POSITION SENSOR CIRCUIT RANGE/PER-

FORMANCE PROBLEM -
DTC DETECTING CONDITION:
Immediately at fault recognition
TROUBLE SYMPTOM:
Engine stalls.
Failure of engine to start
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(S0HC)-40, OPERATION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

EN1090

EN(S0HC)-176
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)
~~ ~ ~

Step Check Yes No

1 CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Moni- Inspect DTC Go to step 2.
tor or OBD-II general scan tool PO335 using "List
indicate DTC P0335? of Diagnostic Trou-
ble Code (DTC)".
<Ref. to
EN(S0HC)-77,
List of Diagnostic
Trouble Code
(DTC).r
2 CHECK CONDITION OF CRANKSHAFT PO- Is the crankshaft position sen- Go to step 3. Tighten crank-
SlTlON SENSOR. sor installation bolt tightened shaft position sen-
Turn the ignition switch to OFF. securely? sor installation bolt
securely.
3 CHECK CRANKSHAFT SPROCKET. Are crankshaft sprocket teeth Replace the crank- Go to step 4.
Remove the front belt cover. cracked or damaged? s haft sprocket.
<Ref. to
ME(SOHC)-54,
Crankshaft
Sprocket.>
4 CHECK INSTALLATION CONDITION OF Is the timing belt dislocated Repair installation Replace the crank.
TIMING BELT. from its proper position? condition of timing shaft position sen-
R r n the crankshaft using ST, and align align- belt. <Ref. to sor. <Ref. to <Ref.
ment mark on crankshaft sprocket with align- ME(S0HC)-47, to FU(S0HC)-28,
ment mark on cylinder block. Timing Belt Crankshaft Posi-
ST 499987500CRANKSHAFT SOCKET Assembly.> tion Sensor.>

EN(S0HC)-177
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

AN:DTC PO340 - CAMSHAFT POSITION SENSOR CIRCUIT MALFUNCTION -

DTC DETECTING CONDITION:
Immediately at fault recognition
TROUBLE SYMPTOM:
Engine stalls.
Failure of engine to start
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(SOHC)40, OPERATION, Inspec-
tion Mode.>.

n
WIRING DIAGRAM:

CAMSHAFT
POSITION
SENSOR

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k: I

9
EN1091

EN(S0HC)-178
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK HARNESS BETWEEN CAMSHAFT jthe resistance more than 3epair harness 30 to step 2.
POSITION SENSOR AND ECM CONNEC- 00 kR? md connector.
TOR. JOTE:
1)Turnthe ignition switch to OFF. n this case, repair
2)Disconnect the connector from camshaft he following:
position sensor. Open circuit in
3)Measure the resistance of harness between iarness between
camshaft position sensor connector and :amshaft position
engine ground. iensor and ECM
Connector & terminal :onnector
(€15) No. 1 - Engine ground: Poor contact in
iCM connector
Poor contact in
:ouplingconnector
821)
! CHECK HARNESS BETWEEN CAMSHAFT ;the resistance less than 10 3epair ground 30 to step 3.
POSITION SENSOR AND ECM CONNEC- 2? ;hort circuit in har-
TOR. less between
Measure the resistance of harness between :amshaft position
camshaft position sensor connector and iensor and ECM
engine ground. :onnector.
.Connector & terminal JOTE:
(€15) No. 1 - Engine ground: ihe harness be-
ween both con-
lectors are
ihielded. Repaii
lround short circuil
n harness togeth-
?rwith shield.
1 CHECK HARNESS BETWEEN CAMSHAFT 3 the resistance less than 5 So to step 4. 3epair harness
POSITION SENSOR AND ECM CONNEC- l? ind connector.
TOR. JOTE:
Measure the resistance of harness between n this case, repai
camshaft position sensor connector and he following:
engine ground. ' Open circuit in
Connector & terminal iarness between
(€15) No. 2 - Engine ground: :amshaft position
Sensor and ECM
:onnector
I Poor contact in
ECM connector
1 Poor contact in
:oupling connect0
B21)
I CHECK CONDITION OF CAMSHAFT POSI- s the camshaft position sensor So to step 5. righten camshaft
TlON SENSOR. istallation bolt tightened iosition sensor
,ecurely? nstallation bolt
;ecurely.
1 CHECK CAMSHAFT POSITION SENSOR. 3 the resistance between 1 3epair poor con- 3eplace the cam-
1)Remove the camshaft position sensor. md 4 kR? act in camshaft ;haft position sen.
2)Measure the resistance between connector )osition sensor ;or. <Ref. to
terminals of camshaft position sensor. :onnector. W(SOHC)-29,
Terminals ;amshaft Position
NO. 1 -NO. 2: Sensor.>

EN(S0HC)-179
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

A0:DTC PO341 - CAMSHAFT POSITION SENSOR CIRCUIT RANGE/PERFOR-

MANCE PROBLEM -
DTC DETECTING CONDITION:
Immediately at fault recognition
TROUBLE SYMPTOM:
Engine stalls.
Failure of engine to start
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(S0HC)-40, OPERATION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

1
IC
CAMSHAFT
POSITION
SENSOR

71@
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'<

-
- '-I
63ECM I 4
I

EN1091

EN(S0HC)-180
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK ANY OTHER DTC ON DISPLAY. )oes the Subaru Select Moni- Inspect DTC 20 to step 2.
3r or OBD-ll general scan tool PO340 using “List
idicate DTC P0340? 3f Diagnostic Trou-
de Code (DTC)”.
<Ref. to
EN(S0HC)-77,
List of Diagnostic
Trouble Code
(DTC).>
! CHECK HARNESS BETWEEN CAMSHAFT ;the resistance more than Repair harness 30 to step 3.
POSITION SENSOR AND ECM CONNEC- 00 kR? and connector.
TOR. NOTE:
1)Turnthe ignition switch to OFF. In this case, repaii
2)Disconnect the connector from camshaft the following:
position sensor. m Open circuit in
3)Measure the resistance of harness between harness between
camshaft position sensor connector and camshaft position
engine ground. sensor and ECM
Connector & terminal connector
(€15) No. 1 - Engine ground: m Poor contact in
ECM connector
* Poor contact in
couplingconnector
(821)
. I

1 CHECK HARNESS BETWEEN CAMSHAFT s the resistance less than 10

POSITION SENSOR AND ECM CONNEC- 2? short circuit in har-
TOR. ness between
Measure the resistance of harness between camshaft position
camshaft position sensor connector and sensor and ECM
engine ground. connector.
Connector & terminal NOTE:
(E15) No. 1 - Engine ground: The harness be-
tween both con-
nectors are
shielded. Repair
ground short circuit
in harness togeth-
er with shield.
I CHECK HARNESS BETWEEN CAMSHAFT s the resistance less than 5 Go to step 5. Repair harness
POSITION SENSOR AND ECM CONNEC- L? and connector.
TOR. NOTE:
Measure the resistance of harness between In this case, repa
camshaft position sensor connector and the following:
engine ground. Open circuit in
Connector & terminal harness between
(€15) No. 2 - Engine ground: camshaft position
sensor and ECM
connector
Poor contact in
ECM connector
Poor contact in
couplingconnect0
0321)
> CHECK CONDITION OF CAMSHAFT POSI- s the camshaft position sensor Go to step 6. Tighten camshaft
TlON SENSOR. nstallation bolt tightened position sensor
securely? installation bolt
securely.

EN(S0HC)-181
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

6 CHECK CAMSHAFT POSITION SENSOR. Is the resistance between 1 Go to step 7. Replace the cam-
1)Remove the camshaft position sensor. and 4 kQ? shaft position sen-
2)Measure the resistance between connector sor. <Ref. to
terminals of camshaft position sensor. FU(S0HC)-29,
Terminals Camshaft Position
NO. 1 -NO. 2: Sensor.>
7 CHECK CONDITION OF CAMSHAFT POSI- Is the camshaft position sensor Go to step 8. Tighten camshaft
TlON SENSOR. installation bolt tightened position sensor
Turn the ignition switch to OFF. securely? installation bolt
securely.
8 CHECK CAMSHAFT SPROCKET. Are camshaft sprocket teeth Replace the cam- Go to step 9.
Remove the front belt cover. <Ref. to cracked or damaged? shaft sprocket.
ME(S0HC)-46, Belt Cover.> <Ref. to
ME(S0HC)-52,
Camshaft
Sprocket.>
9 CHECK INSTALLATION CONDITION OF Is the timing belt dislocated Repair installation Replace the cam-
TIMING BELT. from its proper position? condition of timing shaft position sen-
Turn the camshaft using ST, and align align- belt. <Ref. to sor. <Ref. to
ment mark on camshaft sprocket with align- ME(S0HC)-47, FU(S0HC)-29,
ment mark on timing belt cover LH. Timing Belt Camshaft Position
ST 499207100 CAMSHAFT SPROCKET Assembly.> Sensor.>
WRENCH

EN(S0HC)-182
 a
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

EN(S0HC)-I 83
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

AP:DTC PO420 - CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD -

DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
TROUBLE SYMPTOM:
Engine stalls.
Idle mixture is out of specifications.
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(SOHC)BO, OPERATION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

A@ C@ ECM

EN1092

EN(S0HC)-184
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK ANY OTHER DTC ON DISPLAY. Ioes the Subaru Select Moni- Inspect the rele- ; to step 2.
o
or or OBD-II general scan tool vant DTC using
ndicate DTC PO130, PO133, “List of Diagnostic
’01 36, PO139, P0037, P0301, Trouble Code
’0302, P0303, P0304, P1130, (DTC)”. <Ref. to
’1 131, P0031, PO032 and EN(S0HC)-77,
’0038? List of Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0420.
! CHECK EXHAUST SYSTEM. s there a fault in exhaust sys- Repair or replace o; to step 3.
Check for gas leaks or air suction caused by em? the exhaust sys-
loose or dislocated nuts and bolts, and open tem. <Ref. to
hole at exhaust pipes. EX(S0HC)-2,
NOTE: General Descrip-
Check the following positions. tion.>
*Between cylinder head and front exhaust pip€
-*Between front exhaust pipe and front catalytic
converter
*Between front catalytic converter and rear cat
alytic converter
1 CHECK REAR CATALYTIC CONVERTER. s there damage at rear face of Replace the front 30 to step 4.
Separate rear catalytic converter from rear ‘ear catalyst? catalytic converter
exhaust pipe. <Ref. to
EC(S0HC)-3,
Front Catalytic
Converter.> and
rear catalytic con-
verter <Ref. to
EC(S0HC)-4,
Rear Catalytic
Converter.>.
I CHECK FRONT CATALYTIC CONVERTER. s there damage at rear face or Replace the front ;ontact with your
Remove the front catalytic converter. ront face of front catalyst? catalytic con- Subaru distributor
verter. <Ref. to rlOTE:
EC(S0HC)-3, nspection by DTA
Front Catalytic s required, be
Converter.> ;ause probabli
:ause is deteriora
ion of multipli
I )arts.

EN(S0HC)-I 85
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

EN(S0HC)-186
 Y!!m

DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)

ENGINE (DIAGNOSTICS)

AQ:DTC PO442 - EVAPORATIVE EMISSION CONTROL SYSTEM MALFUNC-

TION -
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
TROUBLE SYMPTOM:
Gasoline smell
There is a hole of more than 1.O mm (0.04 in) dia. in evaporation system or fuel tank.
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(SOHC)40, OPERATION, Inspec-
tion Mode.>.

EN(S0HC)-187
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

WIRING DIAGRAM:

IAlN RELAY ,

I@
I
I

U U
DF I VALVE PRESSURE CONTROL PURGE CONTROL
SOLENOID VALVE SOLENOID VALVE

EN1093

EN(S0HC)-188
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK ANY OTHER DTC ON DISPLAY. s there any other DTC on dis- nspect the rele- Go to step 2.
day? rant DTC using
List of Diagnostic
rrouble Code
DTC)”. <Ref. to
iN(SOHC)-77,
i s t of Diagnostic
rrouble Code
DTC).>
CHECK FUEL FILLER CAP. s the fuel filler cap tightened 30 to step 3. Tighten fuel filler
1)Turn the ignition switch to OFF. 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.
CHECK FUEL FILLER PIPE PACKING. Is there any damage to the 3epair or replace Go to step 4.
seal between fuel filler cap and he fuel filler cap
bel filler pipe? md fuel filler pipe.
:Ref. to
W(SOHC)-54,
%el Filler Pipe.>
CHECK DRAIN VALVE. Does the drain valve produce 30 to step 5. Replace the drain
1)Connect the test mode connector. Dperating sound? valve. <Ref. to
2)Turn the ignition switch to ON. EC(S0HC)-16,
3)Operate the drain valve. Drain Valve.>
NOTE:
Drain valve operation can also be executed us-
ing Subaru Select Monitor. For the procedure,
refer to “Compulsory Valve Operation Check
Mode”. <Ref. to EN(S0HC)-44, Compulsory
Valve Operation Check Mode.>
CHECK PURGE CONTROL SOLENOID Does the purge control sole- 30 to step 6. Replace the purge
VALVE. noid valve produce operating control solenoid
Operate the purge control solenoid valve. sound? valve. <Ref. to
NOTE: EC(SOHC)B,
Purge control solenoid valve operation can also Purge Control
be executed using Subaru Select Monitor. For Solenoid Valve.>
the procedure, refer to “Compulsory Valve Op-
eration Check Mode”. <Ref. to EN(S0HC)-44,
Compulsory Valve Operation Check Mode.>
CHECK PRESSURE CONTROL SOLENOID Does the pressure control 30 to step 7. Replace the pres-
VALVE. solenoid valve produce operat- sure control sole-
Operate the pressure control solenoid valve. ing sound? noid valve. <Ref.
NOTE: to EC(S0HC)-11,
Pressure control solenoid valve operation can Pressure Control
also be executed using Subaru Select Monitor. Solenoid Valve.>
For the procedure, refer to “Compulsory Valve
Operation Check Mode”. <Ref. to EN(S0HC)-
44, Compulsory Valve Operation Check
Mode.>
. CHECK EVAPORATIVE EMISSION CON- IS there a hole of more than 1.O 3epair or replace Go to step 8.
TROL SYSTEM LINE. mm (0.04 in) dia. on fuel line? he fuel line. <Ref.
Turn the ignition switch to OFF. o FU(S0HC)-68,
%el Delivery,
3eturn and Evapo
ation Lines.>

EN(S0HC)-189
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes

I CHECK CANISTER. Is the canister damaged or is Repair or replace Go to step 9.
there a hole of more than 1.O the canister. <Ref.
mm (0.04 in) dia. in it? to EC(S0HC)-5,
Canister.> ~

1 CHECK FUEL TANK. Is the fuel tank damaged or is Repair or replace

Remove the fuel tank. <Ref. to FU(S0HC)-51, there a hole of more than 1.O the fuel tank. <Ref.
Fuel Tank.> mm (0.04 in) dia. in it? to FU(S0HC)-51, -7
Go to step 10.

IO
BLE IN EVAPORATIVE EMISSION CON-
Fuel Tank.>
CHECK ANY OTHER MECHANICAL TROU- Are there holes of more than Repair or replace
1.O mm (0.04 in) dia., cracks, the hoses or pipes
4
Contact with SOA
(distributor) ser-
TROL SYSTEM. clogging or disconnections of vice.
hoses or pipes in evaporative NOTE:
emission control system? Inspection by DTM
is required, be-
cause probable
cause is deteriora-
tion of multiple
parts.

EN(SOHC)-190
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

EN(S0HC)-191
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

AR:DTC PO444 - EVAPORATIVE EMISSION CONTROL SYSTEM PURGE CON-

TROL VALVE CIRCUIT LOW INPUT -
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(S0HC)-40, OPERATION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

BATIERY

PURGE CONTROL 1
SOLENOID VALVE

EN1094

EN(S0HC)-192
I

1 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)

ENGINE (DIAGNOSTICS)
~

Step Check Yes No

CHECK OUTPUT SIGNAL FROM ECM. s the voltage more than 10 V? iven if MIL lights 30 to step 2.
1)Turn the ignition switch to ON. ip, the circuit has
2)Measure the voltage between ECM and eturned to a nor-
chassis ground. nal condition at
Connector & terminal his time. Contact
(8134) No. 2 (+) - Chassis ground (-): vith SOA (distribu-
Dr) service.
JOTE:
nspection by DTM
; required, be-
:ause probable
:ause is deteriora-
ion of multiple
iarts.
! CHECK HARNESS BETWEEN PURGE CON s the resistance less than 10 Iepair ground 30 to step 3.
TROL SOLENOID VALVE AND ECM CON- 3? ;hort circuit in har-
NECTOR. less between
1)Turn the ignition switch to OFF. ICM and purge
2)Disconnectthe connectors from purge con- :ontrol solenoid
trol solenoid valve and ECM. ralve connector.
3)Measure the resistance of harness between
purge control solenoid valve connector and
engine ground.
Connector & terminal
(€4) No. 2 - Errgine ground:
1 CHECK HARNESS BETWEEN PURGE CON s the resistance less than 1 So to step 4. 3epair open circui
TROL SOLENOID VALVE AND ECM CON- n? n harness
NECTOR. letween ECM anc
Measure the resistance of harness between )urge control sole
ECM and purge control solenoid valve of har- ioid valve connec
ness connector. or.
Connector & terminal \IOTE:
(8134) NO.2 - (E4) NO. 2: n this case, repai
he following:
b Open circuit in
iarness between
ECM and purge
:ontrol solenoid
ialve connector
1 Poor contact in
:oupling connect0
822)
I CHECK PURGE CONTROL SOLENOID s the resistance between 10 20 to step 5. 3eplace the purge
VALVE. m d 100 n? :ontrol solenoid
1)Remove the purge control solenoid valve. ialve. <Ref. to
2)Measure the resistance between purge con- IC(S0HC)-6,
trol solenoid valve terminals. >urge Control
Terminals Solenoid Valve.>
NO. 1 -NO. 2:
) CHECK POWER SUPPLY TO PURGE CON- s the voltage more than 10 V? So to step 6. 3epair open circui
TROL SOLENOID VALVE. n harness
1)Turn the ignition switch to ON. letween main
2)Measure the voltage between purge control 'elay and purge
solenoid valve and engine ground. :ontrol solenoid
Connector & terminal ialve connector.
(E4) No. 1 (+) - Engine ground (-):

EN(S0HC)-193
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

6 CHECK POOR CONTACT. Is there poor contact in purge Repair poor con- Contact with SOA
Check poor contact in purge control solenoid control solenoid valve connec- tact in purge con- (distributor)ser-
valve connector. tor? trol solenoid valve vice.
connector. NOTE:
Inspection by DTM
is required, be-
cause probable
cause is deteriora-
tion of multiple
parts.

EN(S0HC)-194
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

EN(S0HC)-195
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICSI

AS:DTC PO445 - EVAPORATIVE EMISSION CONTROL SYSTEM PURGE CON-

TROL VALVE CIRCUIT HIGH INPUT -
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(SOHC)40, OPERATION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

MAIN RELAY

SOLENOID VALVE

EN1094

EN(S0HC)-196
b DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)
~~

Step Check Yes No

CHECK OUTPUT SIGNAL FROM ECM. )oes the voltage change 30 to step 2. iven if MIL light
1)Turn the ignition switch to OFF. ietween 0 and 10 V? p, the circuit has
2)Connect the test mode connector at the eturned to a nor-
lower portion of instrument panel (on the ial condition at
driver’s side), to the side of the center console lis time. In this
box. ase, repair poor
3)Turn the ignition switch to ON. ontact in ECM
4)While operating the purge control solenoid onnector.
valve, measure voltage between ECM and
chassis ground.
NOTE:
Purge control solenoid valve operation can bc
executed using Subaru Select Monitor. For pro,
cedure, refer to “Compulsory Valve Operatior
Check Mode”. <Ref. to EN(S0HC)-44, Compul
sory Valve Operation Check Mode.>
Connector & terminal
(6134) No. 2 (+) - Chassis ground (-):
CHECK OUTPUT SIGNAL FROM ECM. s the voltage more than 10 VS 20 to step 4. ;o to step 3.
1)Turnthe ignition switch to ON.
2)Measure the voltage between ECM and
chassis ground.
Connector & terminal
(6134) No. 2 (+) - Chassis ground (-):
CHECK POOR CONTACT. s there poor contact in ECM 3epair poor con- leplace the ECM.
Check poor contact in ECM connector. :onnector? act in ECM con- :Ref. to
lector. ’U(SOHC)-47,
3gine Control
nodule.>
CHECK HARNESS BETWEEN PURGE CON s the voltage more than 10 VI 3epair battery 30 to step 5.
TROL SOLENOID VALVE AND ECM CON- short circuit in har-
NECTOR. less between
1)Turn the ignition switch to OFF. X M and purge
2)Disconnect the connector from purge control :ontrol solenoid
solenoid valve. dalve connector.
3)Turn the ignition switch to ON. aifter repair,
4)Measure the voltage between ECM and .eplace the ECM.
chassis ground. :Ref. to
Connector & terminal =U(SOHC)-47,
(6134) No. 2 (+) - Chassis ground (-): Engine Control
Module.>
I CHECK PURGE CONTROL SOLENOID s the resistance less than 1 9eplace the purge 20 to step 6.
VALVE. 3? :ontrol solenoid
1)Turnthe ignition switch to OFF. rlalve <Ref. to
2)Measure the resistance between purge con- EC(S0HC)-6,
trol solenoid valve terminals. Purge Control
Terminals Solenoid Valve.>
NO. 1 -NO. 2: 2nd ECM <Ref. to
FU(S0HC)-47,
Engine Control
Module.>
i CHECK POOR CONTACT. s there poor contact in ECM Repair poor con- 3eplace the ECM.
Check poor contact in ECM connector. :onnector? tact in ECM con- :Ref. to
nector. W(SOHC)-47,
ingine Control
dodule.>

EN(S0HC)-197
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

AT:DTC PO447 - EVAPORATIVE EMISSION CONTROL SYSTEM VENT CON-

TROL LOW INPUT -
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(SOHCk40, OPERATION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

lAlN RELAY

A@ E:@ ECM

Step Check Yes No

1 CHECK OUTPUT SIGNAL FROM ECM. Is the voltage more than 10 V? Go to step 2. Go to step 3.
1)Turn the ignition switch to ON.
2)Measure the voltage between ECM and
chassis ground.
Connector & terminal
(8134) No. 10 (+) - Chassis ground (-):

EN(S0HC)-198
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK POOR CONTACT. there poor contact in ECM iepair poor con- Even if MIL lights
Check poor contact in ECM connector. mector? 3ct in ECM con- JP, the circuit has
lector. ,eturned to a nor-
nal condition at
his time. (How-
wer, the possibility
i f poor contact still
*emains.)
VOTE:
n this case, repair
:he following:
1 Poor contact in

jrain valve con-

qector
1 Poor contact in

ECM connector
1 Poor contact in

soupling connec-
tors (R57 and 898)
CHECK HARNESS BETWEEN DRAIN I the resistance less than 10 3epair ground Go to step 4.
VALVE AND ECM CONNECTOR. 1? ;hort circuit in har.
1)Turn the ignition switch to OFF. less between
2)Disconnect the connectors from drain valve ICM and drain
and ECM. alve connector.
3)Measure the resistance of harness between
drain valve connector and chassis ground.
Connector & terminal
(R69) No. 2 - Chassis ground:
CHECK HARNESS BETWEEN DRAIN i the voltage less than 1 R? 20 to step 5. Repair harness
VALVE AND ECM CONNECTOR. and connector.
Measure the resistance of harness between NOTE:
ECM and drain valve connector. In this case, repaii
Connector & terminal the following:
(B134) NO. 10 - (R69) NO. 2: Open circuit in
harness between
ECM and drain
valve connector
Poor contact in
coupling connec-
tors (R57 and 898
CHECK DRAIN VALVE. ;the resistance between 10 30 to step 6. Replace the drain
Measure the resistance between drain valve nd 100 R? valve. <Ref. to
terminals. EC(S0HC)-16,
Terminals Drain Valve.>
NO. 1 -NO. 2:
CHECK POWER SUPPLY TO DRAIN VALVE j the voltage more than 10 VS 30 to step 7. Repair harness
1)Turnthe ignition switch to ON. and connector.
2)Measure the voltage between drain valve NOTE:
and chassis ground. In this case, repai
Connector & terminal the following:
(R69) No. 1 (+)- Chassis ground (-): Open circuit in
harness between
main relay and
drain valve
Poor contact in
coupling connec-
tors (R57 and 898
Poor contact in
main relay connec
tor

EN(S0HC)-199
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

7 CHECK POOR CONTACT. Is there poor contact in drain Repair poor con- Contact with SOA
Check poor contact in drain valve connector. valve connector? tact in drain valve (distributor) ser-
connector. vice.
NOTE:
Inspection by DTM
is required, be-
cause probable
cause is deteriora
tion of multiple
parts.

EN(S0HC)-PO0
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE [DIAGNOSTICS)

EN(S0HC)-POI
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

AU:DTC PO448 - EVAPORATIVE EMISSION CONTROL SYSTEM VENT CON-

TROL HIGH INPUT -
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to El' SOHC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(SOHC)-4O, OPE1 \TION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

! I 4

EN111

EN(S0HC)-202
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK OUTPUT SIGNAL FROM ECM. Iven if MIL light
1)Turnthe ignition switch to OFF. ip, the circuit has
2)Connect the test mode connector at the eturned to a nor-
lower portion of instrument panel (on the nal condition at
driver’s side), to the side of the center console his time. In this
box. :ase, repair poor
3)Turn the ignition switch to ON. :ontact in ECM
4)While operating the drain valve, measure :onnector.
voltage between ECM and chassis ground.
NOTE:
Drain valve operation can be excecuted usin!
Subaru Select Monitor. For procedure, refer tc
“Compulsory Valve Operation Check Mode”
<Ref. to EN(S0HC)-44, Compulsory Valve Op
eration Check Mode.>
Connector & terminal
(8134) No. 10 (+) - Chassis ground (-):
CHECK OUTPUT SIGNAL FROM ECM. s the voltage more than 10 V? Go to step 4. 20 to step 5.
1)Turn the ignition switch to ON.
2)Measure the voltage between ECM and
chassis ground.
Connector & terminal
(8134) No. 10 (+) - Chassis ground (-):
CHECK POOR CONTACT. s there poor contact in ECM Repair poor con- Ieplace the ECM.
Check poor contact in ECM connector. :onnector? tact in ECM con- :Ref. to
nector. ‘U(SOHC)-47,
Ingine Control
Aodule.>
CHECK HARNESS BETWEEN DRAIN s the voltage more than 10 V? Repair battery ;o to step 5.
VALVE AND ECM CONNECTOR. short circuit in har-
1)Turn the ignition switch to OFF. ness between
2)Disconnectthe connector from drain valve. ECM and drain
3)Turn the ignition switch to ON. valve connector.
4)Measure the voltage between ECM and After repair,
chassis ground. replace the ECM.
Connector & terminal <Ref. to
(8134) No. 10 (+) - Chassis ground (-): FU(S0HC)-47,
Engine Control
Module.>
I CHECK DRAIN VALVE. s the resistance less than 1 Replace the drain So to step 6.
1)Turn the ignition switch to OFF. 2? valve <Ref. to
2)Measure the resistance between drain valve EC(SOHC)-16,
terminals. Drain Valve.> and
Terminals ECM <Ref. to
NO. 1 -NO. 2: FU(S0HC)-47,
Engine Control
Module.>
I CHECK POOR CONTACT. s there poor contact in ECM Repair poor con- Ieplace the ECM.
Check poor contact in ECM connector. :onnector? tact in ECM con- :Ref. to
nector. ’U (S0HC)-47,
Ingine Control
vlodule.>

EN(S0HC)-203
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

AV:DTC PO451 - EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE

SENSOR RANGE/PERFORMANCE PROBLEM
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(S0HC)-40, OPERATION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

nFUELTANK
PRESSURE
SENSOR

EN1095

EN(S0HC)-204
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)
~~ ~

Step Check Yes No

1 CHECK ANY OTHER DTC ON DISPLAY. s there any DTC on display? Inspect the rele- Go to step 2.
vant DTC using
“List of Diagnostic
Trouble Code
(DTC)”. <Ref. to
EN(S0HC)-77,
List of Diagnostic
Trouble Code
(DTC).>
2 CHECK FUEL FILLER CAP. s the fuel filler cap tightened Go to step 3. Tighten fuel filler
1)Turnthe ignition switch to OFF. ,ecurely? cap securely.
2)Open the fuel flap.
3 CHECK PRESSURENACUUMLINE. s there a fault in pressurehac- Repair or replace Replace the fuel
NOTE: ium line? the hoses and tank pressure sen
Check the following items. pipes. sor. <Ref. to
*Disconnection, leakage and clogging of the EC(S0HC)-IO,
vacuum hoses and pipes between fuel tank Fuel Tank Pres-
pressure sensor and fuel tank sure Sensor.>
*Disconnection, leakage and clogging of air
ventilation hoses and pipes between fuel filler
pipe and fuel tank

EN(S0HC)-205
 E

DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)

ENGINE (DIAGNOSTICS)

AW:DTC PO452 - EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE

SENSOR LOW INPUT -
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(SOHC)40, OPERATION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

1
UELTANK
RESSURE
SENSOR

EN1095

EN(S0HC)-206
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)
~~

Step Check Yes No

CHECK CURRENT DATA. ;the value less than -2.8 kPa io to step 2. Even if MIL lights
1)Turnthe ignition switch to OFF. -21.O mmHg, -0.827 inHg)? JP,the circuit has
2)Remove the fuel filler cap. ,eturned to a nor-
3)lnstall the fuel filler cap. nal condition at
4)Turn the ignition switch to ON. :his time.
5)Read the data of fuel tank pressure sensor
signal using Subaru Select Monitor or the
OBD-ll general scan tool.
NOTE:
Gubaru Select Monitor
For detailed operation procedure, refer to the
“READ CURRENT DATA FOR ENGINE. <Ref.
to EN(S0HC)-32, Subaru Select Monitor.>
*OBD-ll general scan tool
For detailed operation procedures, refer to the
OBD-II General Scan Tool Instruction Manual.
CHECK POWER SUPPLY TO FUEL TANK ;the voltage more than 4.5 VI; ;o to step 4. 30 to step 3.
PRESSURE SENSOR.
Measure the voltage between ECM connector
and chassis ground.
Connector & terminal
(8136) No. 15 (+) - Chassis ground (-):
CHECK POWER SUPPLY TO FUEL TANK )oes the voltage change more Iepair poor con- Sontact with SOA
PRESSURE SENSOR. ian 4.5 V by shaking harness act in ECM con- (distributor)ser-
Measure the voltage between ECM connector .ndconnector of ECM while lector. wice.
and chassis ground. ionitoring the value with volt- NOTE:
Connector & terminal .ge meter? Inspection by DTh
(6136) No. 15 (+) - Chassis ground (-): is required, be
cause probablc
cause is deteriora
tion of multiplt
parts.
CHECK INPUT SIGNAL FOR ECM. j the voltage less than 0.2 V? 20 to step 6. Go to step 5.
Measure the voltage between ECM and chas-
sis ground.
Connector & terminal
(6136) No. 12 (+) - Chassis ground (-):
CHECK INPUT SIGNAL FOR ECM. (USING )oes the value change more 3epair poor con- Go to step 6.
SUBARU SELECT MONITOR.) Ian -2.8 kPa (-21 .O mmHg, act in ECM con-
Read the data of fuel tank pressure sensor sig. .0.827 inHg) by shaking har- lector.
nal using Subaru Select Monitor. less and connector of ECM
NOTE: vhile monitoring the value with
*Subaru Select Monitor ;ubaru Select Monitor?
For detailed operation procedure, refer to the
“READ CURRENT DATA FOR ENGINE. <Ref.
to EN(S0HC)-32, Subaru Select Monitor.>
CHECK HARNESS BETWEEN ECM AND s the voltage more than 4.5 VI 30 to step 7. Repair harness
COUPLING CONNECTOR IN REAR WIRING and connector.
HARNESS. NOTE:
1)Turn the ignition switch to OFF. In this case, repai
2)Remove the rear seat cushion (Sedan) or the following:
move rear seat cushion (Wagon). Open circuit in
. 3)Separate rear wiring harness and fuel tank harness between
cord. ECM and rear wir.
4)Turn the ignition switch to ON. ing harness con-
5)Measure the voltage between rear wiring nector (R57)
harness connector and chassis ground. Poor contact in
Connector & terminal couplingconnect0
(R15) No. 9 (+) - Chassis ground (-): 0398)

EN(S0HC)-207
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE lDl AG NOSTICS)

Step Check Yes No

CHECK HARNESS BETWEEN ECM AND s the resistance less than 1 Go to step 8. Repair harness
COUPLING CONNECTOR IN REAR WIRING 3? and connector.
HARNESS. NOTE:
1)Turn the ignition switch to OFF. In this case, repair
2)Disconnect the connector from ECM. the following:
3)Measure the resistance of harness between Open circuit in
ECM and rear wiring harness connector. harness between
Connector & terminal ECM and rear wir-
(8136) NO. 16 - (R15) NO. 11: ing harness con-
nector (R57)
Poor contact in
couplingconnector
P98)
Poor contact in
joint connector
(B122)
CHECK HARNESS BETWEEN ECM AND s the resistance more than Go to step 9. Repair ground
COUPLING CONNECTOR IN REAR WIRING 500 kQ? short circuit in har-
HARNESS. ness between
Measure the resistance of harness between ECM and rear wir-
rear wiring harness connector and chassis ing harness con-
ground. nector (R57).
‘Connector & terminal
(R15) No. 11 - Chassis ground:
CHECK FUEL TANK CORD. s the resistance less than 1 Go to step 10. Repair open circuit
1)Disconnectthe connector from fuel tank 2? in fuel tank cord.
pressure sensor.
2)Measure the resistance of fuel tank cord.
Connector & terminal
(R57) NO. 9 - (R47) NO. 3:
CHECK FUEL TANK CORD. s the resistance less than 1 Go to step 11. Repair open circuit
Measure the resistance of fuel tank cord. 2? in fuel tank cord.
Connector & terminal
(R57) NO. 11 - (R47) NO.2:
CHECK FUEL TANK CORD. s the resistance more than Go to step 12. Repair ground
Measure the resistance of harness between 500 kR? short circuit in fuel
fuel tank pressure sensor connector and chas- tank cord.
sis ground.
Connector & terminal
(R47) No, 1 - Chassis ground:
CHECK POOR CONTACT.
I I
Check poor contact in fuel tank pressure sen-
sor connector.
connector. EC(S0HC)-10,
Fuel Tank Pres-
sure Sensor.>

EN(S0HC)-208
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

EN(S0HC)-209
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

AX:DTC PO453 - EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE

SENSOR HIGH INPUT -
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(S0HC)-40, OPERATION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

nFUELTANK
PRESSURE
SENSOR

I I
@ECM

EN1095

EN(S0HC)-210
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK CURRENT DATA. Is the value more than 2.8 kPa o
; to step 12. 30 to step 2.
1)Turn the ignition switch to OFF. (21.O mmHg, 0.827 inHg)?
2)Remove the fuel filler cap.
3)lnstall the fuel filler cap.
4)Turn the ignition switch to ON.
5)Read the data of fuel tank pressure sensor
signal using Subaru Select Monitor or OBD-ll
general scan tool.
NOTE:
Gubaru Select Monitor
For detailed operation procedure, refer to the
“READ CURRENT DATA FOR ENGINE. <Ref.
to EN(S0HC)-32, Subaru Select Monitor.>
*OBD-ll general scan tool
For detailed operation procedures, refer to the
OBD-ll General Scan Tool Instruction Manual.
! CHECK POWER SUPPLY TO FUEL TANK Is the voltage more than 4.5 V? 30 to step 4. 30 to step 3.
PRESSURE SENSOR.
Measure the voltage between ECM connector
and chassis ground.
Connector & terminal
(8136) No. 15 (+) - Chassis ground (-):
I CHECK POWER SUPPLY TO FUEL TANK Does the voltage change more 3epair poor con- 3eplace the ECM.
PRESSURE SENSOR. than 4.5 V by shaking harness act in ECM con- :Ref. to
Measure the voltage between ECM connector and connector of ECM while lector. W(SOHC)-47,
and chassis ground. monitoring the value with volt- Engine Control
Connector & terminal age meter? Module.>
(8136) No. 15 (+) - Chassis ground (-):
I CHECK INPUT SIGNAL FOR ECM. Is the voltage less than 0.2 V? 30 to step 6. 30 to step 5.
Measure the voltage between ECM and chas-
sis ground.
Connector & terminal
(8136) No. 12 (+) - Chassis ground (-):
k CHECK INPUT SIGNAL FOR ECM. (USING Does the value change more 3epair poor con- 30 to step 6.
SUBARU SELECT MONITOR.) than -2.8 kPa (-21 .O mmHg, act in ECM con-
Read the data of fuel tank pressure sensor sig- -0.827 inHg) by shaking har- lector.
nal using Subaru Select Monitor. ness and connector of ECM
NOTE: while monitoring the value with
*Subaru Select Monitor Subaru Select Monitor?
For detailed operation procedure, refer to the
“READ CURRENT DATA FOR ENGINE. <Ref.
to EN(S0HC)-32, Subaru Select Monitor.>
i CHECK HARNESS BETWEEN ECM AND Is the voltage more than 4.5 V? 30 to step 7. 3epair harness
COUPLING CONNECTOR IN REAR WIRING and connector.
HARNESS. \IOTE:
n this case, repaii
:he following:
1 Open circuit in

iarness between
ECM and rear wir-
ng harness con-
lector (R57)
1 Poor contact in
:oupling connectoi
:B98)

EN(S0HC)-211
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

I
CHECK HARNESS BETWEEN ECM AND s the resistance less than 1 So to step 8. 3epair harness
COUPLING CONNECTOR IN REAR WIRING n? md connector.
HARNESS. \IOTE:
1)Turnthe ignition switch to OFF. n this case, repaii
2)Disconnect the connector from ECM. he following:
3)Measure the resistance of harness between ’ Open circuit in
ECM and rear wiring harness connector. iarness between
Connector & terminal ICM and rear wir-
( 8 1 3 6 ) NO. 1 2 - ( R 1 5 ) NO. 10: ng harness con-
lector (R57)
Poor contact in
:ouplingconnector
898)
I CHECK HARNESS BETWEEN ECM AND s the resistance less than 1 1Go to step 9. 3epair ground
COUPLING CONNECTOR IN REAR WIRING n? ihort circuit in har-
HARNESS. less between

,
Measure the resistance of harness between X M and rear wir-
rear wiring harness connector and chassis I ng harness con-

1
ground.
Connector & terminal
(8136)No. l6-(R15)NO.
CHECK FUEL TANK CORD.
11:

1)Disconnectthe connector from fuel tank

pressure sensor.
2)Measure the resistance of fuel tank cord.
1
s the resistance less than 1 Go to step 10.
lector (R57).

3epair open circuit

n fuel tank cord.

Connector & terminal

(R57) NO. 1 0 - (R47) NO. 2:
0 CHECK FUEL TANK CORD. s the resistance less than 1 I Go to step 11. 3epair open circuit
Measure the resistance of fuel tank cord. R? n fuel tank cord.
Connector & terminal
(R57) NO. 11 - (R47) NO. 2:
I1 CHECK POOR CONTACT. s there poor contact in fuel Repair poor con- 3eplace the fuel
Check poor contact in fuel tank pressure sen- ank pressure sensor connec- tact in fuel tank ank pressure sen-
sor connector. connector.
pressure sensor ior. <Ref. to
IC(S0HC)-10,
%el Tank Pres-
I
iure Sensor.>
2 CHECK HARNESS BETWEEN ECM AND s the value more than 2.8 kPa 1 Repair battery 3eplace the fuel
FUEL TANK PRESSURE SENSOR CONNEC. 121.O mmHg, 0.827 inHg)? short circuit in har. ank pressure sen-
TOR. ness between ior. <Ref. to
1)Turnthe ignition switch to OFF. ECM and fuel tank EC(SOHC)-lO,
2)Disconnect the connector from fuel tank pressure sensor %el Tank Pres-
pressure sensor. connector. jure Sensor.>
3)Turn the ignition switch to ON.
4)Read the data of fuel tank pressure sensor
signal using Subaru Select Monitor or the
OBD-ll general scan tool.
NOTE:
*Subaru Select Monitor
For detailed operation procedure, refer to the
“READ CURRENT DATA FOR ENGINE”. <Ref.
to EN(S0HC)-32, Subaru Select Monitor.>
*OBD-11 general scan tool
For detailed operation procedures, refer to the
OBD-ll General Scan Tool Instruction Manual.

EN(S0HC)-212
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
E NGINE (DIAGNOSTICS)
~

AY:DTC PO456 - EVAPORATIVE EMISSION CONTROL SYSTEM MALFUNC-

TION -
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
TROUBLE SYMPTOM:
Gasoline smell
There is a hole of more than 0.5 mm (0.020 in) dia. in evaporation system or fuel tank.
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(S0HC)-40, OPERATION, Inspec-
tion Mode.>.

EN(S0HC)-213
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

WIRING DIAGRAM:
MAIN RELAY
m

-
-

A @ B:@ ENGINE CONTROL MODULE

h I I

1I
I

I
DR VE PRESSURECONTROL PURGECONTROL
SOLENOID VALVE SOLENOID VALVE

EN1093

EN(S0HC)-214
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK ANY OTHER DTC ON DISPLAY. Is there any other DTC on dis- 7spect the rele- 30 to step 2.
play? ant DTC using
List of Diagnostic
iouble Code
DTC)”. <Ref. to
iN(SOHC)-77,
.ist of Diagnostic
iouble Code
DTC).>
CHECK FUEL FILLER CAP. Is the fuel filler cap tightened $0to step 3. Tighten fuel filler
1)Turn the ignition switch to OFF. securely? sap 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.
CHECK FUEL FILLER PIPE PACKING. Is there any damage to the lepair or replace Go to step 4.
seal between fuel filler cap and he fuel filler cap
fuel filler pipe? ind fuel filler pipe.
:Ref. to
‘U(S0HC)-54,
:uel Filler Pipe.>
CHECK DRAIN VALVE. Does the drain valve produce ;o to step 5. Replace the drain
1)Connectthe test mode connector. operating sound? valve. <Ref. to
2)Turn the ignition switch to ON. EC(S0HC)-16,
3)Operate the drain valve. Drain Valve.>
NOTE:
Drain valve operation can also be executed us.
ing Subaru Select Monitor. For the procedure.
refer to “Compulsory Valve Operation Check
Mode”. <Ref. to EN(S0HC)-44, Compulsor)
Valve Operation Check Mode.>
CHECK PURGE CONTROL SOLENOID Does the purge control sole- ;o to step 6. Replace the purge
VALVE. noid valve produce operating control solenoid
Operate the purge control solenoid valve. sound? valve. <Ref. to
NOTE: EC(SOHC)B,
Purge control solenoid valve operation can alsc Purge Control
be executed using Subaru Select Monitor. Foi Solenoid Valve.>
the procedure, refer to “Compulsory Valve O p
eration Check Mode”. <Ref. to EN(S0HC)-44
Compulsory Valve Operation Check Mode.>
CHECK PRESSURE CONTROL SOLENOID Does the pressure control 50 to step 7. Replace the pres-
VALVE. solenoid valve produce operat- sure control sole-
Operate the pressure control solenoid valve. ing sound? noid valve. <Ref.
NOTE: to EC(S0HC)-6,
Pressure control solenoid valve operation car Purge Control
also be executed using Subaru Select Monitor Solenoid Valve.>
For the procedure, refer to “Compulsory Valve
Operation Check Mode”. <Ref. to EN(S0HC).
44, Compulsory Valve Operation ChecE
Mode.>
. CHECK EVAPORATIVE EMISSION CON- Is there a hole of more than 0.5 3epair or replace Go to step 8.
TROL SYSTEM LINE. mm (0.020 in) dia. on fuel line‘ he fuel line. <Ref.
Turn the ignition switch to OFF. o FU(S0HC)-68,
%el Delivery,
3eturn and Evapo
ation Lines.>

EN(SOHC)-215
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

8 CHECK CANISTER. Is the canister damaged or is Repair or replace Go to step 9.
there a hole of more than 0.5 the canister. <Ref.
mm (0.020 in) dia. in it? to EC(S0HC)-5,
Canister.>
9 CHECK FUEL TANK. Is the fuel tank damaged or is Repair or replace Go to step 10.
Remove the fuel tank. <Ref. to FU(S0HC)-51, there a hole of more than 0.5 the fuel tank. <Ref.
Fuel Tank.> mm (0.020 in) dia. in it? to FU(SOHC)-51,
Fuel Tank.>
10 CHECK ANY OTHER MECHANICAL TROU- Are there holes of more than Repair or replace Contact with SOA
BLE IN EVAPORATIVE EMISSION CON- 0.5 mm (0.020 in) dia., cracks, the hoses or pipes. (distributor) ser-
TROL SYSTEM. clogging or disconnections of vice.
hoses or pipes in evaporative NOTE:
emission control system? Inspection by DTh
is required, be
cause probabk
cause is deteriora
tion of multiplt
parts.

EN(S0HC)-216
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

EN(S0HC)-217
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

AZ:DTC PO461 - FUEL LEVEL SENSOR CIRCUIT RANGE/PERFORMANCE

PROBLEM -
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(S0HC)-40, OPERATION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

BATIERY
SBF-4 SBF-1

KjNmON
SWCH

COMBINATION

A
m
METER

ENIOSE

EN(S0HC)-PI 8
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Moni- Inspect DTC Replace the fuel
tor or OBD-ll general scan tool PO462 or PO463 level sensor <Ref.
indicate DTC PO462 or P0463? using “List of Diag- to FU(S0HC)-62,
nostic Trouble Fuel Level Sen-
Code (DTC)”. s o b and fuel sub
<Ref. to level sensor <Ref.
EN(S0HC)-77, to FU(S0HC)-62,
List of Diagnostic Fuel Level Sen-
Trouble Code sor.>
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect this trou-
ble.

EN(SOHC)-219
 =
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)

BA:DTC PO462 - FUEL LEVEL SENSOR CIRCUIT LOW INPUT -

DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(S0HC)-40, OPERATION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

No.13 SBF-4 SBF-1

@ 0- m

COMBINATION
METER

eg

1
2
B
Step
CHECK SPEEDOMETER AND TACHOME-
TER OPERATION IN COMBINATION
METER.
Check
Does the speedometer and
tachometer operate normally?
Yes
Go to step 2.
PlTPHEa
10 11 12 13 14 15 16 17 18 19 20

No
Repair or replace
the combination
meter. <Ref. to
EN1096

IDI-4, Combina-
tion Meter Sys-
tem.>

EN(S0HC)-220
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK INPUT SIGNAL FOR ECM. ;the voltageless than 0.12 i o to step 6. 30 to step 3.
1)Turnthe ignition switch to ON. (Engine OFF) ,?
2)Measure the voltage between ECM connec-
tor and chassis ground.
Connector & terminal
(6136) No. 27 (+) - Chassis ground (-):
CHECK INPUT SIGNAL FOR ECM. (USING Ioes the value change less iepair poor con- Even if MIL lights
SUBARU SELECT MONITOR.) Ian 0.12 V by shaking har- 3ct in ECM con- JP, the circuit has
Read the data of fuel level sensor signal using ess and connector of ECM lector. ,eturned to a nor-
Subaru Select Monitor. rhile monitoring the value with nal condition at
NOTE: iubaru Select Monitor? :his time. A tempo,
*Subaru Select Monitor ary poor contact
For detailed operation procedure, refer to the 3f the connector
“READ CURRENT DATA FOR ENGINE. <Ref. nay be the cause.
to EN(S0HC)-32, Subaru Select Monitor.> VOTE:
In this case, repai
the following:
b Poor contact in
:ombination meter
:onnector
Poor contact in
ECM connector
Poor contact in
coupling connec-
tors (B99 and R57
1 CHECK INPUT VOLTAGE OF ECM. s the voltage more than 0.12 so to step 4. Go to step 7.
1)Turnthe ignition switch to OFF. ‘?
2)Separate fuel tank cord connector (R57) and
rear wiring harness connector (R15).
3)Turn the ignition switch to ON.
4)Measure the voltage of harness between
ECM connector and chassis ground.
Connector & terminal
(8136) No. 27 (+) - Chassis ground (-):
1 CHECK HARNESS BETWEEN ECM AND s the resistance more than 1 o
; to step 6. Repair ground
COMBINATION METER. An? short circuit in har
1)Turnthe ignition switch to OFF. ness between
2)Disconnect the connector from connector ECM and combi-
(il0) and ECM connector. nation meter con-
3)Measure the resistance between ECM and nector.
chassis ground.
Connector & terminal
(6136) No. 27 - Chassis ground:
i CHECK HARNESS BETWEEN ECM AND s the resistance less than 10 3epair or replace Repair open circui
COMBINATION METER. L? he combination between ECM anc
Measure the resistance between ECM and neter. <Ref. to combination mete
combination meter connector. DI-4, Combina- connector.
Connector & terminal ion Meter Sys- NOTE:
(8136) No. 27 - (i12) No. 2: em.> In this case, repa
the following:
Poor contact in
couplingconnect0
02)

EN(SOHC)-221
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

r
CHECK FUEL TANK CORD. Is the resistance more than 1 So to step 8. 3epair ground
1)Turnthe ignition switch to OFF. MR? ;hort circuit in fuel
2)Disconnect the connector from fuel sub level ank cord.
sensor.
3)Measure the resistance between fuel sub
level sensor and chassis ground.
Connector & terminal
-
(R59) No. 1 Chassis ground:
I CHECK FUEL TANK CORD. Is the resistance more than 1 So to step 9. 3epair ground
1)Disconnect the connector from fuel pump Ma? ;hort circuit in fuel
assembly. ank cord.
2)Measure the resistance between fuel pump
assembly and chassis ground.
Connector & terminal
-
(R59) No. 2 Chassis ground:
1 CHECK FUEL LEVEL SENSOR. Is the resistance between 0.5 So to step 10. 3eplace the fuel
Warning: and 2.5 R? eve1 sensor.
During work procedures, if fuel tank is more
than 3/4 full, be careful because fuel may
spill.
1)Remove the fuel pump assembly. <Ref. to
PU(S0HC)-59, Fuel Pump.>
2)Measure the resistance between fuel level
sensor and terminals with its float set to the full
position.
Terminals
-
NO. 3 NO. 2:
IO CHECK FUEL SUB LEVEL SENSOR. Is the resistance between 0.5 3epair poor con- 3eplace the fuel
Warning: and 2.5 R? act in harness ;ub level sensor.
During work procedures, if fuel tank is more between ECM and
than 3 4 full, be careful because fuel may :ombination meter
spill. :onnector.
1)Removethe fuel sub level sensor. <Ref. to
FU(SOHC)S3, Fuel Sub Level Sensor.>
2)Measure the resistance between fuel sub
level sensor and terminals with its float set to
the full position.
Terminals
NO. 1 -NO. 2:

EN(S0HC)-222
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENG INE (DIAGNOSTICS)

EN(S0HC)-223
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

BB:DTC PO463 - FUEL LEVEL SENSOR CIRCUIT HIGH INPUT -

DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(SOHC)40, OPERATION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

m @3 4

COMBINATION
METER
A@

P€!Etma
10 11 12 13 14 15 16 17 18 19 20

EN1096

Step Check Yes No

1 CHECK SPEEDOMETER AND TACHOME- Does the speedometer and Go to step 2. Repair or replace
TER OPERATION IN COMBINATION tachometer operate normally? the combination
METER. meter. <Ref. to
IDI-4, Combina-
tion Meter Sys-
tem.>

EN(S0HC)-224
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)
~

Step Check Yes No

CHECK INPUT SIGNAL FOR ECM. s the voltage more than 4.75 30 to step 3. Even if MIL lights
1)Turn the ignition switch to ON. (Engine OFF) I? up, the circuit has
2)Measure the voltage between ECM connec- returned to a nor-
tor and chassis ground. mal condition at
Connector & terminal this time. A tempo.
(8136) No. 27 (+) - Chassis ground (-): rary poor contact
of the connector
may be the cause.
NOTE:
In this case, repaii
the following:
Poor contact in
fuel pump connec-
tor
Poor contact in
couplingconnectoi
(B22, B99 and
R57)
CHECK INPUT VOLTAGE OF ECM. s the voltage more than 4.75 30 to step 4. Repair battery
1)Turn the ignition switch to OFF. I? short circuit
2)Disconnectthe combination meter connector between ECM and
(i0)
l and ECM connector. combination meter
3)Turn the ignition switch to ON. connector.
4)Measure the voltage of harness between
ECM and chassis ground.
Connector & terminal
(8136) No. 27 (+) - Chassis ground (-):
CHECK HARNESS BETWEEN ECM AND s the resistance less than 5 30 to step 5. Repair open circuil
FUEL TANK CORD. 2? between ECM and
1)Turn the ignition switch to OFF. fuel tank cord.
2)Separate fuel tank cord connector (R57) and
rear wiring harness connector (R15).
3)Measure the resistance between ECM and
fuel tank cord.
Connector & terminal
-
(8136) NO. 27 (R15) NO. 3:
I CHECK HARNESS BETWEEN FUEL TANK s the resistance less than 5 30 to step 6. Repair open circuii
CORD AND CHASSIS GROUND. 2? between fuel tank
Measure the resistance between fuel tank cord cord and chassis
and chassis ground. ground.
Connector & terminal NOTE:
(R15) No. 8 - Chassis ground: In this case, repai
the following:
Poor contact in
coupling connec-
tors (822 and B99
i CHECK FUEL TANK CORD. s the resistance less than 10 30 to step 7. Repair open circuii
1)Disconnect the connector from fuel level sen- 3? between coupling
sor. connector and fuel
2)Measure the resistance between fuel level level sensor.
sensor and coupling connector.
Connector & terminal
. -
(R57) NO. 8 (R58) NO. 2:
CHECK FUEL TANK CORD. s the resistance less than 10
1)Disconnectthe connector from fuel sub level 2? between fuel level
sensor. sensor and fuel
2)Measure the resistance between fuel level sub level sensor.
sensor and fuel sub level sensor.
Connector & terminal
(R58) NO. 3 - (R59) NO. 2:

EN(S0HC)-225
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

I CHECK FUEL TANK CORD. Is the resistance less than 10 20 to step 9. 3epair open circuit
Measure the resistance between fuel sub level R? ietween coupling
sensor and coupling connector. :onnector and fuel
Connector & terminal sub level sensor.
(R57)NO. 3 - (R59)NO. 1:
CHECK FUEL LEVEL SENSOR. Is the resistance more than 3eplace the fuel 30 to step 10.
Warning: 54.5 R? eve1 sensor. <Ref.
During work procedures, if fuel tank is more o FU(S0HC)-62,
than 3/4 full, be careful because fuel may -uel Level Sen-
spill. ior.>
1)Remove the fuel pump assembly. <Ref. to
FU(S0HC)-59, Fuel Pump.>
2)While moving the fuel level sensor float up
and down, measure resistance between fuel
level sensor terminals.
Terminals
NO. 3 - NO. 2:
0 CHECK FUEL SUB LEVEL SENSOR. Is the resistance more than 3eplace the fuel 3eplace the com-
Warning: 41.5 R? ;ub level sensor. iination meter.
During work procedures, if fuel tank is more :Ref. to :Ref. to IDI-11,
than 3/4 full, be careful because fuel may 'U (SOHC)-63, ;ombination
spill. %el Sub Level deter Assembly.>
1)Remove the fuel sub level sensor. <Ref. to ;ensor.>
FU(S0HC)-63, Fuel Sub Level Sensor.>
2)While moving the fuel sub level sensor float
up and down, measure resistance between
fuel sub level sensor terminals.
Terminals
NO. 1 -NO. 2:

EN(S0HC)-226
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

EN(S0HC)-227
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

BC:DTC PO464 - FUEL LEVEL SENSOR INTERMITTENT INPUT-

* DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(S0HC)-40, OPERATION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

BATTERY
No.13 SBF-4 SBF-1
m

COMBINATION
METER
A
B

10 11 12 13 14 15 16 17 18 19 20

112131415161"171819llOlll
12113114115116117118119120121122123124

LEVEL
SENSOR SENSOR

EN1096

EN(S0HC)-228
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)
~

Step Check Yes No

CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Moni- nspect DTC Go to step 2.
tor or OBD-II general scan tool ’0462 or PO463
indicate DTC PO462 or P0463? Jsing “List of Diag-
iostic Trouble
:ode (DTC)”.
<Ref. to
EN(S0HC)-77,
List of Diagnostic
Trouble Code
(DTC).>
CHECK FUEL LEVEL SENSOR. Does the resistance change Go to step 3. Replace the fuel
smoothly? level sensor. <Ref
Warning:
to FU(S0HC)-62,
than 314 full, be careful because fuel may Fuel Level Sen-
spill. sor.>
1)Remove the fuel pump assembly. <Ref. to
FU(S0HC)-59, Fuel Pump.>
2)While moving the fuel level sensor float up
and down, make sure that the resistance
between fuel level sensor terminals changes
smoothly.
Terminals
NO. 3 - NO. 2:
CHECK FUEL SUB LEVEL SENSOR. I Does the resistance change Repair poor con- Replace the fuel
tact in ECM, com- sub level sensor.
Warning:
During work procedures, if fuel tank is more bination meter and <Ref. to
than 314 full, be careful because fuel may coupling connec- FU(S0HC)-62,
spill. tors. Fuel Level Sen-
sor.>
1)Remove the fuel sub level sensor. <Ref. to
FU(S0HC)-62, Fuel Level Sensor.>
2)While moving the fuel sub level sensor float
up and down, make sure that the resistance
between fuel level sensor terminals changes
smoothly.
Terminals
NO. 1 - NO. 2:

EN(S0HC)-229
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

EN(S0HC)-230
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

BD:DTC PO480 - COOLING FAN RELAY 1 CIRCUIT LOW INPUT -

DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
TROUBLE SYMPTOM:
Radiator fan does not operate properly.
Overheating
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(S0HC)-40, OPERATION, Inspec-
tion Mode.>.

EN(S0HC)-231
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICSI

WIRING DIAGRAM:

MAN FAN I SUB FAN

MOTOR
I MOTOR

EN1097

EN(S0HC)-232
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE lDl AGNOSTICS)
~~ ~

Step Check Yes No

CHECK OUTPUT SIGNAL FROM ECM. Ioes the voltage change lepair poor con- 20 to step 2.
1)Turnthe ignition switch to OFF. letween 0 and 10 V? 3ct in ECM con-
2)Connect the test mode connector at the lector.
lower portion of instrument panel (on the
driver’s side), to the side of the center console
box.
3)Turn the ignition switch to ON.
4)While operating the radiator fan relay, mea-
sure voltage between ECM terminal and
ground.
NOTE:
Radiator fan relay operation can be executed
using Subaru Select Monitor. For procedure,
refer to “Compulsory Valve Operation Check
Mode”.<Ref. to EN(S0HC)-32, Subaru Select
Monitor.>
Connector & terminal
(6134) No. 3 (+) - Chassis ground (-):
CHECK GROUND SHORT CIRCUIT IN RADI- s the resistance less than 10 3epair ground i o to step 3.
ATOR MAIN FAN RELAY CONTROL CIR- 2? ,hart circuit in
CUIT. adiator main fan
1)Turnthe ignition switch to OFF. elay control cir-
2)Disconnect the connectors from ECM. uit.
3)Measure the resistance of harness between
ECM connector and chassis ground.
Connector & terminal
(6134) No. 3 - Chassis ground:
CHECK POWER SUPPLY FOR RELAY. s the voltage more than 10 V? 30 to step 4. 3epair open circui
1)Remove the main fan relay from N C relay n harness
holder. )etween ignition
2)Turn the ignition switch to ON. ;witch and fuse
3)Measure the voltage between fuse and relay md relay box (F/B:
box (F/B) connector and chassis ground. :onnector.
Connector & terminal
(F66) No. 28 (+) - Chassis ground (-):
CHECK MAIN FAN RELAY. s the resistance between 87 o
; to step 5. 3eplace the main
1)Turn the ignition switch to OFF. md 107 R? an relay.
2)Measure the resistance between main fan
relay terminals.
Terminal
NO. 28 - NO. 27:
CHECK OPEN CIRCUIT IN MAIN FAN RE- s the resistance less than 1 20 to step 6. 3epair harness
LAY CONTROL CIRCUIT. 2? and connector.
Measure the resistance of harness between VOTE:
ECM and main fan relay connector. n this case, repai
Connector & terminal he following:
(6134) NO. 3 - (F66) NO. 27: 1Open circuit in
iarness between
ICM and main far
’elay connector
1 Poor contact in
:oupling connect0
:F45)
CHECK POOR CONTACT. s there poor contact in ECM or qepair poor con- :ontact with SOA
Check poor contact in ECM or main fan relay nain fan relay connector? act in ECM or :distributor) ser-
Connector. nain fan relay con dice.
lector.

EN(S0HC)-233
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
E NGI NE (DIAGNOSTICS)

EN(S0HC)-234
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

BE:DTC PO483 - COOLING FAN FUNCTION PROBLEM -

DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
TROUBLE SYMPTOM:
Occurrence of noise
Overheating
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(SOHC)40, OPERATION, Inspec-
tion Mode.>.
NOTE:
If the vehicle, with the engine idling, is placed very close to a wall or another vehicle, preventing normal cool-
ing function, the OBD system may detect malfunction.

EN(S0HC)-235
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

WIRING DIAGRAM:

BAlTERY
SBF-1

1
U IGNITION
SWITCH
SBF-4 N0.17
% , , T-
AIR CONDITIONING I No.18 AIR CONDmONlNG
RELAY HOLDER RELAY HOLDER

t
MAIN FAN I I SUB FAN
MOTOR

n F i

EN1097

EN(S0HC)-236
 iia
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes

1 CHECK ANY OTHER DTC ON DISPLAY. Is there any other DTC on dis- Inspect the rele-
play? vant DTC using and fan motor.
“List of Diagnostic <Ref. to CO-9,
Trouble Code RADIATOR MAIN
(DTC)”. <Ref. to FAN SYSTEM, .>
EN(S0HC)-77, and <Ref. to CO-
List of Diagnostic 17, RADIATOR
Trouble Code SUB FAN SYS-
(DTC).> TEM, .>

EN(S0HC)-237
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

BF:DTC PO500 - VEHICLE SPEED SENSOR MALFUNCTION -

DTC DETECTING CONDITION:
Immediately at fault recognition
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(S0HC)-40, OPERATION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

IGNmON

SBF-4 SBF-1
@ e-

r
COMBINATION
METER I

EN1098

Step Check Yes No

1 CHECK TRANSMISSION TYPE. Is the transmission type AT? Go to step 2. Go to step 3.

EN(S0HC)-238
 Is
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)
~ ~

Step Check Yes No

CHECK DTC PO720 ON DISPLAY. Does the Subaru Select Moni- Check front vehi- i o to step 3.
tor or OBD-ll general scan tool cle speed sensor
indicate DTC P0720? signal circuit.
<Ref. to AT-57,
DTC 33 FRONT
VEHICLE SPEED
SENSOR, Diag-
nostic Procedure
with Diagnostic
Trouble Code
(DTC).>
I CHECK SPEEDOMETER OPERATION IN Does the speedometeroperate Go to step 4. :heck speedome-
COMBINATION METER. er and vehicle
;peed sensor.
:Ref. to IDI-13,
;peedometer.>
ind <Ref. to AT-32,
?ant Vehicle
;peed Sensor.>
ind <Ref. to AT-35,
3ear Vehicle
;peed Sensor.>
ind <Ref. to AT-36,
brque Converter
urbine Speed
;ensor.>
I CHECK HARNESS BETWEEN ECM AND Is the resistance less than 10 tepair poor con- ?epair harness
COMBINATION METER CONNECTOR. R? x t in ECM con- ind connector.
1)Turn the ignition switch to OFF. lector. JOTE:
2)Disconnect the connector from combination n this case, repai
meter. he following:
3)Measure the resistance between ECM and Open circuit in
combination meter. iarness between
Connector & terminal X M and combi-
(8135) NO. 24 - (i10) NO. 2: lation meter con-
lector
Poor contact in
ICM connector
' Poor contact in
:ombination metei
Zonnector
I Poor contact in
:oupling connect0
B37)

EN(S0HC)-239
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

BG:DTC PO506 - IDLE CONTROL SYSTEM RPM LOWER THAN EXPECTED -

DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
TROUBLE SYMPTOM:
Engine is difficult to start.
Engine does not start.
Erroneous idling
Engine stalls.
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(S0HC)-40, OPERATION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

MAIN RELAY

AIR CONTROL
SOLENOID

EN1099

EN(SO HC)-240
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

1 CHECK ANY OTHER DTC ON DISPLAY. loes the Subaru Select Moni- Inspect DTC i o to step 2.
or or OBD-ll general scan tool P1510, P1511,
ndicate DTC P I 510, P I 51 1, P1512, P1513,
’1512, P1513, P1514, P1515, P1514, P1515,
’1 516 or P I 517? PI516 or PI517
using “List of Diag-
nostic Trouble
Code (DTC)”.
<Ref. to
EN(S0HC)-77,
List of Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary tc
inspect DTC
P0506.
2 CHECK AIR BY-PASS LINE. loes air flow out? Replace the idle deplace the throt-
1)Turn the ignition switch to OFF. air controlsolenoid tle body. <Ref. to
2)Remove the idle air control solenoid valve valve. <Ref. to FU(S0HC)-14,
from throttle body. <Ref. to FU(S0HC)-36, FU(S0HC)-36, INSTALLATION,
REMOVAL, Idle Air Control Solenoid Valve.> INSTALLATION, Throttle Body.>
3)Remove the throttle body from intake mani- Idle Air Control
fold. <Ref. to FU(S0HC)-14, REMOVAL, Solenoid Valve.>
Throttle Body.>
4)Using an air gun, force air into the idle air
control solenoid valve installation area. Con-
firm that forced air subsequently escapes from
throttle body interior.

EN(S0HC)-241
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

BH:DTC PO507 - IDLE CONTROL SYSTEM RPM HIGHER THAN EXPECTED -

DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
TROUBLE SYMPTOM:
Engine keeps running at higher revolution than specified idling revolution.
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(S0HC)-40, OPERATION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

AIN RELAY

BATERY
SBF-5

I I
IDLE
AIR CONTROL

I GE9ECM I I

EN1099

EN(S0HC)-242
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK ANY OTHER DTC ON DISPLAY. Ioes the Subaru Select Moni- Inspect DTC 20 to step 2.
or or OBD-II general scan tool P I 510, P I 51 1,
idicate DTC P1510, P1511, P1512, P1513,
V512, P1513, P1514, P1515, P1514, P1515,
’1 516 or P I 517? PI516 or PI517
using “List of Diag-
nostic Trouble
Code (DTC)”.
<Ref. to
EN(S0HC)-77,
List of Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0507.
! CHECK AIR INTAKE SYSTEM. s there a fault in air intake sys- Repair air suction ;o to step 3.
1)Turn the ignition switch to ON. em? and leaks.
2)Start the engine, and idle it.
3)Check the following items.
.Loose installation of intake manifold, idle air
control solenoid valve and throttle body
*Cracks of intake manifold gasket, idle air con-
trol solenoid valve gasket and throttle body
gasket
*Disconnectionsof vacuum hoses
1 CHECK THROTTLE CABLE. Ioes the throttle cable have Go to step 4. idjust throttle
)lay for adjustment? :able. <Ref. to
SP-7, INSTALLA-
TION, Accelerator
Zontrol Cable.>
I CHECK AIR BY-PASS LINE. ire foreign particles in by-pass Remove foreign 3eplace the idle
1)Turn the ignition switch to OFF. iir line? particles from by- iir control solenoid
2)Remove the idle air control solenoid valve pass air line. ralve. <Ref. to
from throttle body. <Ref. to FU(S0HC)-36, W(SOHC)-36,
REMOVAL, Idle Air Control Solenoid Valve.> NSTALLATION,
3)Confirm that there are no foreign particles in dle Air Control
by-pass air line. Solenoid Valve.>

EN(S0HC)-243
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

EN(S0HC)-244
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

BI: DTC PO512 - STARTER SWITCH CIRCUIT HIGH INPUT -

DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
TROUBLE SYMPTOM:
Failure of engine to start
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(S0HC)-40, OPERATION, Inspec-
tion Mode.>.

EN(S0HC)-245
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

WIRING DIAGRAM:

IGNITION
SWITCH

I@ : ATVEHICLES

: MTVEHICLES

STARTER
INTERLOCK

EN1077

EN(S0HC)-246
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

1 CHECK OPERATION OF STARTER MOTOR. Does the starter motor operate Repair battery Check starter
NOTE: when ignition switch is turned short circuit in motor circuit.
Place the inhibitor switch in each position. (AT to “ON”? starter motor cir- <Ref. to
model) cuit. After repair, EN(SOHC)-58,
Depress or release the clutch pedal. (MT replace the ECM. STARTER
model) <Ref. to MOTOR CIR-
FU(S0HC)-47, CUIT, Diagnostics
Engine Control for Engine Start-
Module.> ing Failure.>

EN(S0HC)-247
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

BJ:DTC PO604 - INTERNAL CONTROL MODULE MEMORY CHECK SUM ER-

ROR -
DTC DETECTING CONDITION:
Immediately at fault recognition
TROUBLE SYMPTOM:
Engine does not start.
Engine stalls.
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(S0HC)-40, OPERATION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

AIN RELAY

B:@ C : a

EN1 078

EN(S0HC)-248
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check
I CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Moni-
tor or OBD-II general scan tool <Ref. to to inspect DTC
indicate DTC P0601?
Engine Control

EN(S0HC)-249
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)

BK:DTC PO703 - BRAKE SWITCH INPUT MALFUNCTION -

DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(S0HC)-40, OPERATION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

BATERY

0 0-
-

TO STOP LIGHTS I

EN1101

Step Check Yes No

1 CHECK OPERATION OF BRAKE LIGHT. Does the brake light come on Go to step 2. Repair or replace
when depressing- the brake the brake light cir-
pedal? Icuit.

EN(S0HC)-250
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK HARNESS BETWEEN TCM AND s the resistance less than 1 io to step 3. Repair or replace
BRAKE LIGHT SWITCH CONNECTOR. 2? the harness and
1)Disconnectthe connectors from TCM and connector.
brake light switch. NOTE:
2)Measure the resistance of harness between In this case, repaii
TCM and brake light switch connector. the following:
Connector & terminal Open circuit in
Without cruise control harness between
(B55)NO. 24 - (B64)NO.1: TCM and brake
With cruise control light switch con-
(B55)NO. 24 - (B65)NO. 3 nector
Poor contact in
TCM connector
Poor contact in
brake light switch
connector
CHECK HARNESS BETWEEN TCM AND s the resistance more than 1 30 to step 4. Repair ground
BRAKE LIGHT SWITCH CONNECTOR. im? short circuit in har-
Measure the resistance of harness between ness between
TCM and chassis ground. TCM and brake
Connector & terminal light switch con-
(B55)No. 24 - Chassis ground: nector.
CHECK INPUT SIGNAL FOR TCM. s the voltage less than 1 V ;o to step 5. Adjust or replace
1)Connect the connectors to TCM and brake Hhen releasing the brake the brake light
light switch. iedal? switch. <Ref. to
2)Measure the voltage between TCM and LI-7, STOP LIGHT
chassis ground. SWITCH,
Connector & terminal INSPECTION,
(B55)No. 24 (+) - Chassis ground (-): Stop Light Sys-
tem.>
I CHECK INPUT SIGNAL FOR TCM. s the voltage more than 10 V 20 to step 6. Adjust or replace
Measure the voltage between TCM and chas- Nhen depressing the brake the brake light
sis ground. Iedal? switch. <Ref. to
Connector & terminal LI-7, STOP LIGHT
(B55)No. 24 (+) - Chassis ground (-): SWITCH,
INSPECTION,
Stop Light Sys-
tem.>
I CHECK POOR CONTACT. s there poor contact in TCM qepair poor con- Replace the TCM.
Check poor contact in TCM connector. :onnector? act in TCM con- <Ref. to AT-45,
lector. Transmission Con.
trol Module
(TCM).>

EN(S0HC)-251
 m
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)
~ ~ ~ ~

BL:DTC PO731 - GEAR 1 INCORRECT RATIO -

NOTE:
For the diagnostic procedure, refer to DTC P0734. <Ref. to EN(S0HC)-253, DTC PO734 - GEAR 4 INCOR-
RECT RATIO -, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>

BM:DTC PO732 - GEAR 2 INCORRECT RATIO -

NOTE:
For the diagnostic procedure, refer to DTC P0734. <Ref. to EN(S0HC)-253, DTC PO734 - GEAR 4 INCOR-
RECT RATIO -, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>

BN:DTC PO733 - GEAR 3 INCORRECT RATIO -

NOTE:
For the diagnostic procedure, refer to DTC P0734. <Ref. to EN(S0HC)-253, DTC PO734 - GEAR 4 INCOR-
RECT RATIO -, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>

EN(SOHC)-252
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

B0:DTC PO734 - GEAR 4 INCORRECT RATIO -

DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
TROUBLE SYMPTOM:
Shift point too high or too low; engine brake not effected in “3”range; excessive shift shock; excessive
tight corner “braking”
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(S0HC)-40, OPERATION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

Step Check Yes No

I CHECK ANY OTHER DTC ON DISPLAY. Is there any other DTC on dis- Inspect relevant Go to step 2.
play? DTC using “List of
Diagnostic Trou-
ble Code (DTC)”.
<Ref. to
EN(S0HC)-77,
List of Diagnostic
Trouble Code
(DTC).>
2 CHECK THROTTLE POSITION SENSOR Is there any trouble in throttle Repair or replace Go to step 3.
CIRCUIT. position sensor circuit? the throttle posi-
Check throttle position sensor circuit. <Ref. to tion sensor circuit.
AT-52, DTC 31 THROTTLE POSITION SEN-

r
SOR, Diagnostic Procedure with Diagnostic
Trouble Code (DTC).>
3 CHECK FRONT VEHICLE SPEED SENSOR Is there any trouble in front Repair or replace Go to step 4.
CIRCUIT. vehicle speed sensor circuit? the front vehicle
Check front vehicle speed sensor circuit. <Ref. speed sensor cir-
to AT-57, DTC 33 FRONT VEHICLE SPEED cuit.
SENSOR, Diagnostic Procedure with Diagnos-
tic Trouble Code (DTC).>
I CHECK TORQUE CONVERTER TURBINE Is there any trouble in torque Repair or replace Go to step 5.
SPEED SENSOR CIRCUIT. converter turbine speed sensor the torque con-
Check torque converter turbine speed sensor circuit? verter turbine
circuit. <Ref. to AT-62, DTC 36 TORQUE CON- speed sensor cir-
VERTER TURBINE SPEED SENSOR, Diag- cuit.
nostic Procedure with Diagnostic Trouble Code
(DTC).>
5 CHECK POOR CONTACT. Is there poor contact in TCM Repair poor con- Go to step 6.
Check poor contact in TCM connector. connector? tact in TCM con-
nector.
5 CHECK MECHANICAL TROUBLE. Is there any mechanicaltrouble Repair or replace Replace the TCM.
Check mechanical trouble in automatic trans- in automatic transmission? the automatic <Ref. to AT-45,
mission. transmission. Transmission Con
<Ref. to AT-12, trol Module
INSPECTION, (TCM).>
Road Test.>

EN(S0HC)-253
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

BP:DTC PO741 - TORQUE CONVERTER CLUTCH SYSTEM MALFUNCTION -

DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
TROUBLE SYMPTOM:
No lock-up (after engine warm-up)
No shift or excessive tight corner “braking”
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(S0HC)-40, OPERATION, Inspec-
tion Mode.>.

Step Check Yes No

I CHECK ANY OTHER DTC ON DISPLAY. Is there any other DTC on dis- Inspect the rele- Go to step 2.
play? vant DTC using
‘List of Diagnostic
Trouble Code
(DTC)”. <Ref. to
EN(S0HC)-77,
List of Diagnostic
Trouble Code
(DTC).>
? CHECK LOCK-UP DUTY SOLENOID CIR- Is there any trouble in lock-up Repair or replace Go to step 3.
CUIT. duty solenoid circuit? the lock-up duty
Check lock-up duty solenoid circuit. <Ref. to solenoid circuit.
AT-94, DTC 77 LOCK-UP DUTY SOLENOID,
Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
3 CHECK THROTTLE POSITION SENSOR Is there any trouble in throttle Repair or replace Go to step 4.
CIRCUIT. position sensor circuit? the throttle posi-
Check throttle position sensor circuit. <Ref. to tion sensor circuit.
AT-52, DTC 31 THROTTLE POSITION SEN-
SOR, Diagnostic Procedure with Diagnostic
Trouble Code (DTC).>
1 CHECK TORQUE CONVERTER TURBINE Is there any trouble in torque Repair or replace Go to step 5.
SPEED SENSOR CIRCUIT. converter turbine speed sensor the torque con-
Check torque converter turbine speed sensor circuit? verter turbine
circuit. <Ref. to AT-62, DTC 36 TORQUE speed sensor cir-
CONVERTER TURBINE SPEED SENSOR, cuit.
Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
> CHECK ENGINE SPEED INPUT CIRCUIT. Is there any trouble in engine Repair or replace Go to step 6.
Check engine speed input circuit. <Ref. to AT- speed input circuit? the engine speed
44, DTC 11 ENGINE SPEED SIGNAL, Diag- input circuit.
nostic Procedure with DiagnosticTrouble Code
(DTC).>
5 CHECK INHIBITOR SWITCH CIRCUIT. Is there any trouble in inhibitor Repair or replace Go to step 7.
Check inhibitor switch circuit. <Ref. to AT-1 15, switch circuit? the inhibitor switch
CHECK INHIBITOR SWITCH., Diagnostic Pro- circuit.
cedure for No-DiagnosticTrouble Code
(DTC).>
7 CHECK BRAKE LIGHT SWITCH CIRCUIT. Is there any trouble in brake Repair or replace Go to step 8.
Check brake light switch circuit. <Ref. to AT- light switch circuit? the brake light
112, CHECK BRAKE SWITCH., Diagnostic switch circuit.
Procedure for No-DiagnosticTrouble Code
(DTC).>

EN(S0HC)-254
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

8 CHECK ATF TEMPERATURE SENSOR CIR- Is there any trouble in ATF tem- Repair or replace Go to step 9.
CUIT. perature sensor circuit? the ATF tempera-
Check ATF temperature sensor circuit. <Ref. to ture sensor circuit.
AT-48, DTC 27 ATF TEMPERATURE SEN-
SOR, Diagnostic Procedure with Diagnostic
Trouble Code (DTC).>
9 CHECK POOR CONTACT. Is there poor contact in TCM Repair poor con- Go to step 10.
Check poor contact in TCM connector. connector? tact in TCM con-
nector.
10 CHECK MECHANICAL TROUBLE. Is there any mechanicaltrouble Repair or replace Replace the TCM.
Check mechanical trouble in automatic trans- in automatic transmission? the automatic <Ref. to AT-45,
mission. transmission. Transmission Con-
<Ref. to AT-12, trol Module
INSPECTION, (TCM).>
Road Test.>

EN(S0HC)-255
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

BQ:DTC P I 110 - ATMOSPHERIC PRESSURE SENSOR CIRCUIT LOW INPUT

-
DTC DETECTING CONDITION:
Immediately at fault recognition
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(S0HC)-40, OPERATION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

ATMOSPHERIC
PRESSURE
SENSOR

li

EN110:

EN(SOHC)-256
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

-
1 CHECK CURRENT DATA. ;o to step 2.
1)Start the engine. nmHg, 0 inHg)?
2)Read the data of intake manifold absolute
pressure signal using Subaru Select Monitor or
OBD-ll general scan tool.
NOTE:
*Subaru Select Monitor
For detailed operation procedure, refer to the
“READ CURRENT DATA FOR ENGINE”. <Ref.
to EN(S0HC)-32, Subaru Select Monitor.>
*OBD-II general scan tool
For detailed operation procedures, refer to the
OBD-II General Scan Tool Instruction Manual.
-
2 CHECK POOR CONTACT. s there poor contact in ECM or Repair poor con- Iven if MIL lights
Check poor contact in ECM and pressure sen- xessure sensor connector? tact in ECM or ip, the circuit has
sor connector. atmospheric pres- eturned to a nor-
sure sensor con- nal condition at
nector. his time.
3 CHECK INPUT SIGNAL FOR ECM. s the voltage more than 4.5 V? Go to step 5. 20 to step 4.
Measure the voltage between ECM connector
and chassis ground.
Connector & terminal
(8136) No. 15 (+) - Chassis ground (-):
4 CHECK INPUT SIGNAL FOR ECM. Ioes the voltage change more Repair poor con- >ontact with SOA
Measure the voltage between ECM connector han 4.5 V by shaking harness tact in ECM con- distributor) ser-
and chassis ground. ind connector of ECM while nector. rice.
Connector & terminal nonitoring the value with volt- dOTE:
(6136) No. 15 (+) - Chassis ground (-): ige meter? nspection by DTh
s required, be
:awe probablc
:ause is deteriora
ion of multiplc
)arts.
5 CHECK INPUT SIGNAL FOR ECM. s the voltage less than 0.2 V? Go to step 7. 30 to step 6.
Measure the voltage between ECM and chas-
sis ground.
Connector & terminal
(8136) No. 29 (+) - Chassis ground (-):
6 CHECK INPUT SIGNAL FOR ECM. (USING Ioes the value change more Repair poor con- 30 to step 7.
SUBARU SELECT MONITOR.) han 0 kPa (0 mmHg, 0 inHg) tact in ECM con-
Read the data of atmospheric absolute pres- iy shaking harness and con- nector.
sure signal using Subaru Select Monitor. lector of ECM while monitor-
NOTE: ng the value with Subaru
*Subaru Select Monitor ;elect monitor?
For detailed operation procedure, refer to the
“READ CURRENT DATA FOR ENGINE”. <Ref.
to EN(S0HC)-32, Subaru Select Monitor.>
~

EN(S0HC)-257
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK HARNESS BETWEEN ECM AND AT- s the voltage more than 4.5 V? ;o to step 8. Repair harness
MOSPHERIC PRESSURE SENSOR CON- and connector.
NECTOR . NOTE:
1)Turn the ignition switch to OFF. In this case, repaii
2)Disconnect the connector from atmospheric the following:
pressure sensor. Open circuit in
3)Turn the ignition switch to ON. harness between
4)Measure the voltage between atmospheric ECM and atmo-
pressure sensor connector and engine ground. spheric pressure
Connector & terminal
(B2) No. 3 (+) - Engine groundI)-( .
sensor connector
Poor contact in
joint connector
(B122)
CHECK HARNESS BETWEEN ECM AND AT- s the resistance less than 1 ;o to step 9. Repair harness
MOSPHERIC PRESSURE SENSOR CON- 2? and connector.
NECTOR. NOTE:
1)Turnthe ignition switch to OFF. In this case, repaii
2)Disconnect the connector from ECM. the following:
3)Measure the resistance of harness between Open circuit in
ECM and pressure sensor connector. harness between
Connector & terminal ECM and pressure
(B 136) NO. 16 - (B2) NO. 1I sensor connector
CHECK HARNESS BETWEEN ECM AND AT- s the resistance more than Go to step 10. Repair ground
MOSPHERIC PRESSURE SENSOR CON- 500 kQ? short circuit in har-
NECTOR. ness between
Measure the resistance of harness between ECM and pressure
pressure sensor connector and engine ground. sensor connector.
Connector & terminal
(B2) No. 2 - Engine ground:
0 CHECK POOR CONTACT. s there poor contact in pres- Repair poor con- Replace the atmo-
Check poor contact in pressure sensor con- jure sensor connector? tact in atmospheric spheric pressure
nector. pressure sensor sensor. <Ref. to
connector. FU(S0HC)-35,
Atmospheric Pres-
sure Sensor.>

EN(S0HC)-258
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

EN(S0HC)-259
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

BR:DTC PI 111 - ATMOSPHERIC PRESSURE SENSOR CIRCUIT HIGH INPUT

-
DTC DETECTING CONDITION:
Immediately at fault recognition
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(S0HC)-40, OPERATION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

ATMOSPHERIC

n
PRESSURE
SENSOR

I EN1102

EN(S0HC)-260
I
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

1 CHECK CURRENT DATA. s the value more than 140 kPa ;o to step 10. 30 to step 2.
1)Start the engine. 1,050 mmHg, 41 3 4 inHg)?
2)Read the data of intake manifold absolute
pressure signal using Subaru Select Monitor or
OBD-I1 general scan tool.
NOTE:
*Subaru Select Monitor
For detailed operation procedure, refer to the
“READ CURRENT DATA FOR ENGINE”. <Ref.
to EN(S0HC)-32, Subaru Select Monitor.>
*OBD-I1 general scan tool
For detailed operation procedures, refer to the
OBD-ll General Scan Tool Instruction Manual.
2 CHECK INPUT SIGNAL FOR ECM. s the voltage more than 4.5 V‘? ;o to step 4. o
; to step 3.
Measure the voltage between ECM connector
and chassis ground.
Connector & terminal
(B136) No. 15 (+) - Chassis ground (-):
3 CHECK INPUT SIGNAL FOR ECM. Ioes the voltage change more Iepair poor con- :ontact with SOA
Measure the voltage between ECM connector han 4.5 V by shaking harness x t in ECM con- distributor) ser-
and chassis ground. md connector of ECM while lector. rice.
Connector & terminal nonitoring the value with volt- JOTE:
(8136) No. 15 (+) - Chassis ground (-): ige meter? nspection by DTh
s required, be
:awe probabli
:ause is deteriora
ion of multipli
)arts.
4 CHECK INPUT SIGNAL FOR ECM. s the voltage less than 0.2 V? 30 to step 6. 30 to step 5.
Measure the voltage between ECM connector
and chassis ground.
Connector & terminal
(8136) No. 29 (+) - Chassis groundI)-(
5 CHECK INPUT SIGNAL FOR ECM. (USING loes the value change more 3epair poor con- o; to step 6.
SUBARU SELECT MONITOR.) han 0 kPa (0 mmHg, 0 inHg) act in ECM con-
Read the data of atmospheric absolute pres- iy shaking harness and con- lector.
sure signal using Subaru Select Monitor. lector of ECM while monitor-
NOTE: ng the value with Subaru
*Subaru Select Monitor ;elect monitor?
For detailed operation procedure, refer to the
“READ CURRENT DATA FOR ENGINE”. <Ref.
to EN(S0HC)-32, Subaru Select Monitor.>
6 CHECK HARNESS BETWEEN ECM AND s the voltage more than 4.5 V‘ o
; to step 7. 3epair harness
PRESSURE SENSOR CONNECTOR. ind connector.
1)Turnthe ignition switch to OFF. IOTE:
2)Disconnect the connector from atmospheric n this case, repai
pressure sensor. he following:
3)Turn the ignition switch to ON. b Open circuit in
4)Measure the voltage between atmospheric iarness between
pressure sensor connector and engine ground X M and pressurc
Connector & terminal sensor connector
(82) No. 3 (+) - Engine ground (-): 1 Poor contact in
oint connector
18122)

EN(S0HC)-261
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 30 to step 8. Repair harness
PRESSURE SENSOR CONNECTOR. a? m d connector.
1)Turn the ignition switch to OFF. VOTE:
2)Disconneclthe connector from ECM. n this case, repair
3)Measure the resistance of harness between :he following:
ECM and pressure sensor connector. I Open circuit in

Connector & terminal iarness between

(8136) NO.29 - (82) NO. 2: ECM and pressure
sensor connector
I CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 30 to step 9. Sepair harness
PRESSURE SENSOR CONNECTOR. a? m d connector.
Measure the resistance of harness between YOTE:
ECM and pressure sensor connector. In this case, repair
Connector & terminal the following:
(8136) NO. 16 - (82) NO. 1: 1 Open circuit in

iarness between
ECM and pressure
sensor connector
1 Poor contact in

oint connector,
[BI22)
I CHECK POOR CONTACT. Is there poor contact in pres- 3epair poor con- Replace the atmo-
Check poor contact in pressure sensor con- sure sensor connector? act in atmospheric spheric pressure
nector. iressure sensor sensor. <Ref. to
:onnector. FU(S0HC)-35,
Mmospheric Pres-
sure Sensor.>
0 CHECK CURRENT DATA. Is the value more than 140 kPa 3epair battery Replace the atmo-
1)Turn the ignition switch to OFF. (1,050 mmHg, 41.34 inHg)? ;hort circuit in har- spheric pressure
2)Disconnect the connector from atmospheric less between sensor. <Ref. to
ICM and atmo- FU(S0HC)-35,
spheric pressure 4tmospheric Pres-
;ensor connector. sure Sensor.>

EN(S0HC)-262
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

EN(S0HC)-263
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

BS:DTC P I 112 - ATMOSPHERIC PRESSURE SENSOR CIRCUIT RANGE/PER-

FORMANCE PROBLEM -
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(S0HC)-40, OPERATION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

ATMOSPHERIC

n
PRESSURE
SENSOR

EN1 102

EN(S0HC)-264
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
m
ENGINE (DIAGNOSTICS)

Check Yes No
Does the Subaru Select Moni- Inspect DTC 30 to step 2.
NOTE: tor or OBD-ll general scan tool PO106, P0107,
In this case, it is not necessary to inspect DTC Indicate DTC P0106, PO107, P0108, P1110 or
PO106. P0108, P1110 or P111l ? P1111 using “List
of Diagnostic Trou-
ble Code (DTC)”.
<Ref. to
EN(S0HC)-77,
List of Diagnostic
Trouble Code
(DTC).>
2 CHECK ATMOSPHERIC PRESSURE SEN- Is the atmospheric pressure Replace the atmo- 30 to step 3.
SOR FILTER. sensor filter non-functional? spheric pressure
1)Turn the ignition switch to OFF. (Check for contamination, sensor filter.
2)Disconnect the connector from atmospheric damage, water leakage, etc.)
pressure sensor.
3)Remove the atmospheric pressure sensor.
4)Check the atmospheric pressure sensor fil-
ter.
3 CHECK CURRENT DATA. Is the value between 73.3 kPa Replace the atmo- 3eplace the intakc
1)Turn the ignition switch to ON. (550 mmHg, 21.65 inHg) and spheric pressure sir temperature
2)Read the data of intake manifold absolute 106.6 kPa (800 mmHg, 31 5 0 sensor. <Ref. to md pressure sen-
pressure signal using Subaru Select Monitor 01 inHg)? FU(S0HC)-35, ;or. <Ref. to
OBD-II general scan tool. Atmospheric Pres- -U(SOHC)-34,
NOTE: sure Sensor.> ntake Air Temper,
*Subaru Select Monitor 3ture and Pres-
For detailed operation procedure, refer to the jure Sensor.>
“READ CURRENT DATA FOR ENGINE”. <Ref.
to EN(S0HC)-32, Subaru Select Monitor.>
*OBD-ll general scan tool
For detailed operation procedures, refer to the
OBD-II General Scan Tool Instruction Manual.

EN(S0HC)-265
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)
~~

BT: DTC P I 137 - FRONT OXYGEN (NF) SENSOR CIRCUIT RANGE/PERFOR-

MANCE PROBLEM -
DTC DETECTING CONDITION:
Immediately at fault recognition
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(S0HC)-40, OPERATION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

IAIN RELAY BATrERY

Et-

EN1082

EN(S0HC)-266
 DIAGNOSTIC PROCEDURE WIITH DIAGNOSTIC TROUBLE CODE (DTC)
m
ENGINE (DIAGNOSTICS)
~

Step Check Yes No

CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Moni- Inspect DTC Go to step 2.
tor or OBD-ll general scan tool PO131, P0132,
indicate DTC PO131, PO132, PO031 or PO032
PO031 or P0032? using “List of Diag-
nostic Trouble
Code (DTC)”.
<Ref. to
EN(S0HC)-77,
List of Diagnostic
Trouble Code
(DTC).>
CHECK FRONT OXYGEN (NF) SENSOR DA- s the value equal to or more Go to step 3. Go to step 4.
TA. han 0.85 and equal to less
1)Start the engine. han 1.I 5 in idling?
2)While observing the Subaru Select Monitor
or OBD-ll general scan tool screen, warm-up
the engine until coolant temperature is above
70°C (160°F).
If the engine is already warmed-up, operate at
idle speed for at least 1 minute.
3)Read the data of front oxygen (NF) sensor
signal using Subaru Select Monitor or OBD-II
general scan tool.
NOTE:
*Subaru Select Monitor
For detailed operation procedure, refer to the
“READ CURRENT DATA FOR ENGINE. <Ref
to EN(S0HC)-32, Subaru Select Monitor.>
*OBD-II general scan tool
For detailed operation procedures, refer to the
OBD-ll General Scan Tool Instruction Manual.
CHECK FRONT OXYGEN (NF) SENSOR DA Is the value more than I .I f o r i 30 to step 6. Go to step 4.
TA. moment?
Race the engine at speeds from idling to 5,00(
rpm for a total of 5 cycles.
NOTE:
To increase engine speed to 5,000 rpm, slow1
depress accelerator pedal, taking approximatc
ly 5 seconds, and quickly release acceleratc

1
pedal to decrease engine speed.
CHECK HARNESS BETWEEN ECM AND
FRONT OXYGEN (NF) SENSOR.
1)Turn the ignition switch to OFF.
2)Disconnect the connector from ECM and
front oxygen (NF) sensor connector.
3)Measure the resistance between ECM and
front oxygen (NF) sensor.
Is the resistance less than 5
a?
t
Go to step 5. Repair open circuii
between ECM and
front oxygen (NF)
sensor.

Connector & terminals

(9136) NO. 6 - (€24) NO. 3:
(9136) NO. 7 - (E24) NO. 4:
(9136) NO. 19 - (E24) NO. 1:
-
(9136) NO.20 (E24) NO. 6:

EN(S0HC)-267
I
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE IDIAGNOSTICS)

Step Check Yes No

5 CHECK HARNESS BETWEEN ECM AND Is the resistance more than 1 ;o to step 6. Repair ground
FRONT OXYGEN (AIF) SENSOR. MQ? short circuit
Measure the resistance between ECM and between ECM and
chassis ground. front oxygen (NF)
Connector & terminals sensor.
(8136) No. 6 - Chassis ground:
(8136) No. 7 - Chassis ground:
(8136) No. 19 - Chassis ground:
(8136) No. 20 - Chassis ground:
6 CHECK EXHAUST SYSTEM. Is there a fault in exhaust sys- 3epair or replace Replace the front
Check exhaust system parts. tem? sulty parts. oxygen (NF) sen-
NOTE: sor. <Ref. to
Check the following items. FU(S0HC)-43,
*Loose installation of portions Front Oxygen (A/
*Damage (crack, hole etc.) of parts F) Sensor.>
*Looseness of front oxygen (NF) sensor
*Looseness and ill fitting of parts between front
oxygen (NF) sensor and rear oxygen sensor

EN(S0HC)-268
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

EN(S0HC)-269
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

-
BU:DTC P I 142 THROTTLE POSITION SENSOR CIRCUIT RANGEIPERFOR-
MANCE PROBLEM (LOW INPUT) -
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
Poor driving performance
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(S0HC)-40, OPERATION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

THROTTLE
POSITION
SENSOR

li

P
EN1087

EN(S0HC)-270
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)
__ ~~

Step Check Yes No

1 CHECK ANY OTHER DTC ON DISPLAY. loes the Subaru Select Moni- Inspect DTC Replace the throt-
or or OBD-II general scan tool PO122 or PO123 tle position sen-
ndicate DTC PO122 or PO123? using “List of Diag- sor. <Ref. to
nostic Trouble FU(S0HC)-31,
Code (DTC)”. Throttle Position
<Ref. to Sensor.>
EN(S0HC)-77,
List of Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P1142.

EN(S0HC)-271
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

BV:DTC PI146 - PRESSURE SENSOR CIRCUIT RANGE/PERFORMANCE

PROBLEM (HIGH INPUT) -
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(SOHC)dO, OPERATION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

I
I
INTAKE AIR
TEMPERATURE
AND
PRESSURE
SENSOR

<
I
I
I
I
I
I
I
I
I
I
I
I
I

EN1085

EN(S0HC)-272
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

1 CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Moni- ispect DTC ;o to step 2.
NOTE: tor or OBD-II general scan tool ’0107, PO108 or
In this case, it is not necessary to inspect DTC indicate DTC PO107, PO108 or ’1112 using “List
PO106. P1112? ‘f Diagnostic Trou-
‘le Code (DTC)”.
:Ref. to
iN(S0HC)-77,
.ist of Diagnostic
rouble Code
DTC).
2 CHECK AIR INTAKE SYSTEM. Are there holes, loose bolts or iepair air intake ;o to step 3.
disconnection of hose on air ystem.
intake system?
3 CHECK PRESSURE SENSOR. Is the value within the specifi- i o to step 4. Ieplace the intake
1)Start the engine and warm-up engine until cations? tir temperature
coolant temperature is greater than 60°C ;ensor and pres-
(140°F). iure sensor. <Ref.
2)Place the shift lever in the selector lever in o FU(S0HC)-34,
“N” or “ P position. ntake Air Temper-
3)Turn the A/C switch to OFF. iture and Pres-
4)Turn all accessory switches to OFF. ;ure Sensor.>
5)Read the data of intake manifold pressure
sensor signal using Subaru Select Monitor or
OBD-II general scan tool.
NOTE:
*Subaru Select Monitor
For detailed operation procedure, refer to the
“READ CURRENT DATA FOR ENGINE. <Ref.
to EN(S0HC)-32, Subaru Select Monitor.>
*OBD-ll general scan tool
For detailed operation procedure, refer to the
OBD-II General Scan Tool Instruction Manual.
Specification:
*Intake manifold absolute pressure
Ignition ON
73.3 - 106.6 kPa (550 - 800 mmHg,
21.65 - 31.50 inHg)
Idling
20.0 - 46.7 kPa (150 - 350 mmHg, 5.91
- 13.78 inHg)
4 CHECK THROTTLE POSITION. Is the throttle positioning ratio ;o to step 5. 4djust or replace
Read the data of throttle position signal using equal to or less than 5% when he throttle posi-
Subaru Select Monitor or OBD-II general scan throttle is fully closed? ion sensor. <Ref.
tool. o FU(S0HC)-31,
NOTE: rhrottle Position
*Subaru Select Monitor 3ensor.r
For detailed operation procedure, refer to the
“READ CURRENT DATA FOR ENGINE. <Ref.
to EN(S0HC)-32, Subaru Select Monitor.>
*OBD-ll general scan tool
For detailed operation procedure, refer to the
OBD-II General Scan Tool Instruction Manual.
5 CHECK THROTTLE POSITION. Is the throttle positioning ratio 3eplace the intake Replace the throt-
equal to or more than 85% iir temperature :le position sen-
when throttle is fully open? 2nd pressure sen- sor. <Ref. to
;or. <Ref. to FU(S0HC)-31,
W(SOHC)-34, Throttle Position
ntake Air Temper- Sensor.>
2ture and Pres-
jure Sensor.>

EN(S0HC)-273
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE IDIAGNOSTICS)
~ ~~~~ ~ ~ ~ ~~~~~~~

BW:DTC PI400 - FUEL TANK PRESSURE CONTROL SOLENOID VALVE CIR-

CUIT LOW INPUT -
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(S0HC)-40, OPERATION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

IAlN RELAY
BAITERY
0 -
SBF-5
3 c
n
FUELTANK
PRESSURE
CONTROL
SOLENOID
VALVE

A:@ ECM

B:@

5 6 7 8
5 6

EN1103

Step Check Yes No

I CHECK OUTPUT SIGNAL FROM ECM. Is the voltage more than 10 V? Go to step 2. Go to step 3.
1)Turnthe ignition switch to ON.
2)Measure the voltage between ECM and
chassis ground.
Connector & terminal
(8134) No. 1 (+) - Chassis ground (-):

EN(S0HC)-274
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK POOR CONTACT. s there poor contact in ECM lepair poor con- ;ontact with SOA
Check poor contact in ECM connector. :onnector? act in ECM con- distibutor) ser-
lector. rice.
\IOTE:
nspection by-DTN
s required, be.
:ause probabk
:ause is deteriora
ion of multiple
iarts.
CHECK HARNESS BETWEEN FUEL TANK s the resistance less than 10 lepair ground 20 to step 4.
PRESSURE CONTROL SOLENOID VALVE 3? ;hort circuit in har-
AND ECM CONNECTOR. less between
1)Turn the ignition switch to OFF. X M and fuel tank
2)Disconnect the connectors from fuel tank vessure control
pressure control solenoid valve and ECM. ;olenoid valve
3)Measure the resistance of harness between :onnector.
fuel tank pressure control solenoid valve con-
nector and chassis ground.
Connector & terminal
(R68) No. 2 - Chassis ground:
CHECK HARNESS BETWEEN FUEL TANK s the voltage less than 1 R? 20 to step 5. 3epair harness
PRESSURE CONTROL SOLENOID VALVE and connector.
AND ECM CONNECTOR. VOTE:
Measure the resistance of harness between n this case, repai
ECM and fuel tank pressure control solenoid he following:
valve connector. 1 Open circuit in
Connector & terminal iarness between
(8134) NO. 1 - (R68) NO.2: X M and fuel tank
iressure control
;olenoid valve
:onnector
1 Poor contact in

:oupling connec-
ors (R57 and B98
I CHECK FUEL TANK PRESSURE CONTROL s the resistance between 10 30 to step 6. qeplace the fuel
SOLENOID VALVE. and 100 R? lank pressure con,
Measure the resistance between fuel tank rol solenoid valve.
pressure control solenoid valve terminals. :Ref. to
Terminals ZC(SOHC)-S,
NO. 1 - NO. 2: purge Control
Solenoid Valve.>
I CHECK POWER SUPPLY TO FUEL TANK s the voltage more than 10 V? 30 to step 7. 3epair harness
PRESSURE CONTROL SOLENOID VALVE. and connector.
1)Turn the ignition switch to ON. VOTE:
2)Measure the voltage between fuel tank pres- n this case, repai
sure control solenoid valve and chassis :he following:
ground. 1 Open circuit in

Connector & terminal iarness between

(R68) No. 1 (+) - Chassis ground (-): nain relay and fuel
:ank pressure con.
trol solenoid valve
:onnector
D Poor contact in

:oupling connec-
tors (R57 and 898
1 Poor contact in

nain relay connec

tor

EN(S0HC)-275
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

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 solenoid tact in fuel tank (distributor) ser-
trol solenoid valve connector. dalve connector? pressure control vice.
solenoid valve NOTE:
connector. Inspection by DTh
is required, be
cause probablc
cause is deteriora
tion of multiplc
parts.

EN(SOHC)-276
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

EN(S0HC)-277
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

BX:P1420 - FUEL TANK PRESSURE CONTROL SOLENOID VALVE CIRCUIT

HIGH INPUT-
* DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(S0HC)-40, OPERATION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

.....- . ..
l A l N RFI AV
EATERY
SBF-5

FUELTANK
PRESSURE
CONTROL
SOLENOID
VALVE

A:@ ECM

B:@

m
6 7 8 9 101112

EN1103

EN(S0HC)-278
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK OUTPUT SIGNAL FROM ECM. Ioes the voltage change o
; to step 2. Even if MIL light
1)Turn the ignition switch to OFF. letween 0 and 10 V? up, the circuit has
2)Connect the test mode connector at the returned to a nor-
lower portion of instrument panel (on the mal condition at
driver’s side), to the side of the center console this time. In this
box. case, repair poor
3)Turn the ignition switch to ON. contact in ECM
4)While operating the fuel tank pressure con- connector.
trol solenoid valve, measure voltage between
ECM and chassis ground.
NOTE:
Fuel tank pressure control solenoid valve oper-
ation can be executed using Subaru Seleci
Monitor. For procedure, refer to “Compulsor)
Valve Operation Check Mode”. <Ref. tc
EN(S0HC)-44, Compulsory Valve Operatior
Check Mode.>
Connector & terminal
(8134) No. 1 (+) - Chassis ground (-):
CHECK OUTPUT SIGNAL FROM ECM. s the voltage more than 10 V? Go to step 4. Go to step 3.
1)Turnthe ignition switch to ON.
2)Measure the voltage between ECM and
chassis ground.
Connector & terminal
(8134) No. 1 (+) - Chassis ground (-):
CHECK POOR CONTACT. s there poor contact in ECM 3epair poor con- Replace the ECM
Check poor contact in ECM connector. :onnector? act in ECM con- <Ref. to
lector. FU(S0HC)-47,
Engine Control
Module.>
CHECK HARNESS BETWEEN FUEL TANK s the voltage more than 10 V? 3epair battery Go to step 5.
PRESSURE CONTROL SOLENOID VALVE ;hort circuit in har.
AND ECM CONNECTOR. less between
1)Turnthe ignition switch to OFF. ICM and fuel tank
2)Disconnect the connector from fuel tank xessure control
pressure control solenoid valve. ;olenoid valve
3)Turn the ignition switch to ON. :onnector. After
4)Measure the voltage between ECM and epair, replace the
chassis ground. ICM. <Ref. to
Connector & terminal ‘U(SOHC)-47,
(8134) No. 1 (+) - Chassis ground (-): ingine Control
Aodule.>
CHECK FUEL TANK PRESSURE CONTROL s the resistance less than 1 3eplace the fuel Go to step 6.
SOLENOID VALVE. 2? ank pressure con
1)Turn the ignition switch to OFF. rol solenoid valve
2)Measure the resistance between fuel tank :Ref. to
pressure control solenoid valve terminals. IC(S0HC)-11,
Terminals ’ressure Control
NO. 1 - NO. 2: Solenoid Valve.>
ind ECM <Ref. to
‘U(SOHC)-47,
fngine Control
dodu1e.s
s there poor contact in ECM 3epair poor con- Replace the ECM
Check poor contact in ECM connector. :onnector? act in ECM con- <Ref. to
lector. FU(S0HC)-47,
Engine Control
Module.>

EN(SOHC)-279
I
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENG INE (DIAGNOSTICS)

BY:DTC P1442 - FUEL LEVEL SENSOR CIRCUIT RANGE/PERFORMANCE

PROBLEM 2 -
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(SOHC)BO, OPERATION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

BATERY

0 0 m gq
3 4

Pl3TwE8
10 11 12 13 14 15 16 17 18 19 20

112131415161 171819110111
12113114115116117118 I19120121122123124

EN1096

EN(S0HC)-280
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Moni- Inspect DTC Replace the fuel
tor or OBD-ll general scan tool P0461, PO462 or level sensor <Ref.
indicate DTC P0461, PO462 or PO463 using “List to FU(S0HC)-62,
P0463? of Diagnostic Trou- Fuel Level Sen-
ble Code (DTC)”. sor.> and fuel sub
<Ref. to level sensor. <Ref.
EN(S0HC)-77, to FU(S0HC)-63,
List of Diagnostic Fuel Sub Level
Trouble Code Sensor.>
(DTC).>
NOTE:
In this case, it is
not necessaty tc
inspect this trou-
ble.

EN(SO HC)-281
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

BZ:DTC PI443 - EVAPORATIVE EMISSION CONTROL SYSTEM VENT CON-

TROL FUNCTION PROBLEM -
DTC DETECTING CONDITION:
Immediately after fault occurrence
TROUBLE SYMPTOM:
Improper fuel supply
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(SOHC)40, OPERATION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

IAIN RELAY , ma-=_"

0:o
A: 0134 0 0135 ECM

5 6

EN1112

EN(S0HC)-282
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK ANY OTHER DTC ON DISPLAY. s there any other DTC on dis- Inspect the rele- IGo to step 2.
ilay? vant DTC using
“List of Diagnostic
Trouble Code
(DTC)”. <Ref. to
EN(S0HC)-77,
List of Diagnostic
Trouble Code
(DTC).>
CHECK VENT LINE HOSES. s there a fault in vent line? Repair or replace Go to step 3.
Check the following items. the faulty part.
Clogging of vent hoses between canister and
drain valve
Clogging of vent hose between drain valve
and air filter
Clogging of drain filter
CHECK DRAIN VALVE OPERATION. loes the drain valve produce Contact with SOA Replace the drain
1)Turn the ignition switch to OFF. iperating sound? (distributor) ser- valve. <Ref. to
2)Connect the test mode connector at the vice. EC(SOHC)-16,
lower portion of instrument panel (on the NOTE: Drain Valve.>
driver’s side), to the side of the center console Inspection by DTM
box. is required, be-
3)Turn the ignition switch to ON. cause probable
4)Operate the drain valve. cause is deteriora-
NOTE: tion of multiple
Drain valve operation can also be executed us parts.
ing Subaru Select Monitor. For the procedure
refer to the “Compulsory Valve Operatioi
Check Mode”. <Ref. to EN(S0HC)-44, Compul
sory Valve Operation Check Mode.>

EN(S0HC)-283
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGI NE (DIAGNOSTICS)

EN(S0HC)-284
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

CA:DTC PI480 - COOLING FAN RELAY 1 CIRCUIT HIGH INPUT -

DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
TROUBLE SYMPTOM:
Radiator fan does not operate properly.
Overheating
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(S0HC)-40, OPERATION, Inspec-
tion Mode.>.

EN(S0HC)-285
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

WIRING DIAGRAM:

I- - N0.17

MAJN FAN I I SUB FAN

I- 1

M
FIG3ECM

EN1097

EN(S0HC)-286
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK OUTPUT SIGNAL FROM ECM. loes the voltage change iven if MIL lights Go to step 2.
1)Turn the ignition switch to OFF. letween 0 and 10 V? rp, the circuit has
2)Connect the test mode connector at the eturned to a nor-
lower portion of instrument panel (on the nal condition at
driver's side), to the side of the center console his time. In this
box. :ase, repair poor
3)Turn the ignition switch to ON. :ontact in ECM
4)While operating the radiator fan relay, mea- :onnector.
sure voltage between ECM and chassis
ground.
NOTE:
Radiator fan relay operation can be executec
using Subaru Select Monitor. For procedure
refer to "Compulsory Valve Operation Check
Mode".<Ref. to EN(S0HC)-44, Compulsor)
Valve Operation Check Mode.>
Connector & terminal
(6134) No. 3 (+) - Chassis ground (-):
I
CHECK SHORT CIRCUIT IN RADIATOR FAN s the voltage more than 10 V? 3epair battery Go to step 3.
RELAY CONTROL CIRCUIT. ;hort circuit in
1)Turn the ignition switch to OFF: adiator fan relay
2)Remove the main fan relay and sub fan relay. :ontrol circuit.
(with N C models) Zfter repair,
3)Disconnect the test mode connector. eplace the ECM.
4)Turn the ignition switch to ON. :Ref. to
5)Measure the voltage between ECM and 'U( S0HC)-47,
chassis ground. ingine Control
Connector & terminal vlodule.>
(6134) No. 3 (i) - Chassis ground (-):
I CHECK MAIN FAN RELAY. s the resistance less than 1 3eplace the main Go to step 4.
1)Turn the ignition switch to OFF. n? an relay and
2)Remove the main fan relay. ECM. <Ref. to
3)Measure the resistance between main fan -U(SOHC)-47,
relay terminals. Engine Control
Terminal vlodu1e.z
NO. 26 - NO. 25:
I CHECK SUB FAN RELAY. IS the resistance less than 1 3eplace the sub Go to step 5.
1)Remove the sub fan relay. n? an relay and
2)Measure the resistance between sub fan ECM. <Ref. to
relay terminals. -U(SOHC)-47,
Terminal Engine Control
NO. 18 -NO. 17 vlodule.>
I CHECK POOR CONTACT. 's there poor contact in ECM 3epair poor con- Replace the ECM.
Check poor contact in ECM connector. :onnector? act in ECM con- <Ref. to
lector. FU(S0HC)-47,
Engine Control
Module.>

EN(S0HC)-287
I DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

CB:DTC PI507 - IDLE CONTROL SYSTEM MALFUNCTION (FAIL-SAFE) -

DTC DETECTING CONDITION:
Immediately at fault recognition
TROUBLE SYMPTOM:
Engine keeps running at higher revolution than specified idling revolution.
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(S0HC)-40, OPERATION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

AIN RELAY

-
OL
I U r=z=

- SBF-5
BAlTERY
1

IDLE
AIR CONTROL

I GaEI CM I

I EN1099

EN(SOHC)-288
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Moni- Inspect DTC i o to step 2.
tor or OBD-ll general scan tool P1510, P1511,
indicate DTC P1510, P1511, P1512, P1513,
P1512, P1513, P1514, P1515, P1514, P1515,
P1516 or P1517? P1516 or P1517
using “List of Diag-
nostic Trouble
Code (DTC)”.
<Ref. to
EN(S0HC)-77,
List of Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0507.
! CHECK AIR INTAKE SYSTEM. IS there a fault in air intake sys. Repair air suction 20 to step 3.
1)Turn the ignition switch to ON. tem? and leaks.
2)Start the engine, and idle it.
3)Check the following items.
*Loose installation of intake manifold, idle air
control solenoid valve and throttle body
*Cracks of intake manifold gasket, idle air con-
trol solenoid valve gasket and throttle body
gasket
*Disconnections of vacuum hoses
i CHECK THROTTLE CABLE. Does the throttle cable have Go to step 4. 4djust throttle
play for adjustment? :able. <Ref. to
SP-7, INSTALLA-
TION, Accelerator
;ontrol Cable.>
1 CHECK AIR BY-PASS LINE. Are foreign particles in by-pass Remove foreign 3eplace the idle
1)Turn the ignition switch to OFF. air line? Darticles from by- ir control solenoid
2)Remove the idle air control solenoid valve )ass air line. alve. <Ref. to
from throttle body. <Ref. to FU(S0HC)-36, Idle ‘U(S0HC)-36,
Air Control Solenoid Valve.> Ile Air Control
3)Confirm that there are no foreign particles in ;olenoid Valve.>
by-pass air line.

EN(S0HC)-289
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

CC:DTC PI510 - IDLE AIR CONTROL SOLENOID VALVE SIGNAL 1 CIRCUIT

LOW INPUT -
NOTE:
For the diagnostic procedure, refer to DTC P1516. <Ref. to EN(S0HC)-292, DTC P1516 - IDLE AIR CON-
TROL SOLENOID VALVE SIGNAL 4 CIRCUIT LOW INPUT -, Diagnostic Procedure with Diagnostic Trou-
ble Code (DTC).>

CD:DTC PI511 - IDLE AIR CONTROL SOLENOID VALVE SIGNAL 1 CIRCUIT

HIGH INPUT -
NOTE:
For the diagnostic procedure, refer to DTC P1517. <Ref. to EN(S0HC)-296, DTC P1517 - IDLE AIR CON-
TROL SOLENOID VALVE SIGNAL 4 CIRCUIT HIGH INPUT -, Diagnostic Procedure with Diagnostic Trou-
ble Code (DTC).>

CE:DTC PI512 - IDLE AIR CONTROL SOLENOID VALVE SIGNAL 2 CIRCUIT

LOW INPUT -
NOTE:
For the diagnostic procedure, refer to DTC P1516. <Ref. to EN(S0HC)-292, DTC P1516 - IDLE AIR CON-
TROL SOLENOID VALVE SIGNAL 4 CIRCUIT LOW INPUT -, Diagnostic Procedure with Diagnostic Trou-
ble Code (DTC).>

CF:DTC PI513 - IDLE AIR CONTROL SOLENOID VALVE SIGNAL 2 CIRCUIT

HIGH INPUT -
NOTE:
For the diagnostic procedure, refer to DTC P1517. <Ref. to EN(S0HC)-296, DTC P1517 - IDLE AIR CON-
TROL SOLENOID VALVE SIGNAL 4 CIRCUIT HIGH INPUT -, Diagnostic Procedure with Diagnostic Trou-
ble Code (DTC).>

CG:DTC PI514 - IDLE AIR CONTROL SOLENOID VALVE SIGNAL 3 CIRCUIT

LOW INPUT -
NOTE:
For the diagnostic procedure, refer to DTC P1516. <Ref. to EN(S0HC)-292, DTC P1516 - IDLE AIR CON-
TROL SOLENOID VALVE SIGNAL 4 CIRCUIT LOW INPUT -, Diagnostic Procedure with Diagnostic Trou-
ble Code (DTC).>

CH:DTC PI515 - IDLE AIR CONTROL SOLENOID VALVE SIGNAL 3 CIRCUIT

HIGH INPUT -
NOTE:
For the diagnostic procedure, refer to DTC P1517. <Ref. to EN(S0HC)-296, DTC P1517 - IDLE AIR CON-
TROL SOLENOID VALVE SIGNAL 4 CIRCUIT HIGH INPUT-, Diagnostic Procedure with Diagnostic Trou-
ble Code (DTC).>

EN(S0HC)-290
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

EN(S0HC)-291
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAG NOSTlCS)

CI: DTC PI516 - IDLE AIR CONTROL SOLENOID VALVE SIGNAL 4 CIRCUIT
LOW INPUT -
DTC DETECTING CONDITION:
Immediately at fault recognition
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
Engine breathing
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(S0HC)-40, OPERATION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

MAIN RELAY

EN1099

EN(S0HC)-292
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK POWER SUPPLY TO IDLE AIR CON- s the voltage more than 10 V? io to step 2. Repair harness
TROL SOLENOID VALVE. and connector.
1)Turn the ignition switch to OFF. NOTE:
2)Disconnect the connector from idle air con- In this case, repair
trol solenoid valve. the following:
3)Turn the ignition switch to ON. Open circuit in
4)Measure the voltage between idle air control harness between
solenoid valve connector and engine ground. idle air control
Connector & terminal solenoid valve and
(E7) No. 2 (+) - Engine ground (-): main relay connec-
tor
Poor contact in
couplingconnector
(822)
CHECK POWER SUPPLY TO IDLE AIR CON- s the voltage more than 10 V? $0 to step 3. Repair harness
TROL SOLENOID VALVE. and connector.
Measure the voltage between idle air control NOTE:
solenoid valve connector and engine ground. In this case, repai
Connector & terminal the following:
(E7) No. 5 (+) - Engine groundI)-( Open circuit in
harness between
idle air control
solenoid valve and
main relay connec
tor
Poor contact in
couplingconnect0
(822)
CHECK HARNESS BETWEEN ECM AND s the resistance less than 1 Go to step 4. Repair harness
IDLE AIR CONTROL SOLENOID VALVE I? and connector.
CONNECTOR. NOTE:
1)Turnthe ignition switch to OFF. In this case, repal
2)Measure the resistance between ECM and the following:
idle air control solenoid valve connector. Open circuit in
Connector & terminal harness between
DTC P1510;(8134)NO. 5 - (E7) NO. 4: ECM and idle air
DTC P1512;(8134)NO. 6 - (E7) NO. 1: control solenoid
DTC P1514; (8134)NO. 19 - (E7) NO. 6: valve connector
DTC P1516;(8134)NO. 20 - (E7) NO. 3: Poor contact in
coupling connectc
(821)
. .
CHECK HARNESS BETWEEN ECM AND Is the resistance less than 10 Repair ground Go to step 5.
IDLE AIR CONTROL SOLENOID VALVE a? short circuit in har-
CONNECTOR. ness between
1)Disconnect the connector from ECM. ECM and idle air
2)Measure the resistance between ECM con- control solenoid
nector and chassis ground. valve connector.
Connector & terminal
DTC P1510;(8134)No. 5 - Chassis
ground:
DTC P1512;(8134)No. 6 - Chassis
ground:
DTC P1514;(8134)No. 19 - Chassis
ground:
DTC P1516;(8134)No. 20 - Chassis
ground:

EN(S0HC)-293
 Step Check Yes No
5 CHECK POOR CONTACT. Is there poor contact in ECM Repair poor con- Replace the idle
Check poor contact in ECM connector and idle connector or idle air control tact in ECM con- air control solenoid
air control solenoid valve connector. solenoid valve connector? nector or idle air valve. <Ref. to
control solenoid FU(S0HC)-36,
valve connector. Idle Air Control
Solenoid Valve.>

EN(S0HC)-294
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

EN(S0HC)-295
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

CJ:DTC PI517 - IDLE AIR CONTROL SOLENOID VALVE SIGNAL 4 CIRCUIT

HIGH INPUT -
DTC DETECTING CONDITION:
Immediately at fault recognition
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
Engine breathing
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(S0HC)-40, OPERATION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

MAIN RELAY

E-=-
BATTERY
SBF-5
2 @ 0-

IDLE
AIR CONTROL

I (aECM
1

EN(SOHC)-296
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)
~

Step Check Yes No

CHECK ANY OTHER DTC ON DISPLAY. oes the Subaru Select Moni- 20 to step 2. Go to step 3.
'r or OBD-ll general scan tool
dicate DTC P1511, P1513,
1515 and P1517 at same
ne?
CHECK GROUND CIRCUIT FOR ECM. the resistance less than 5 30 to step 3. Repair harness
1)Turn the ignition switch to OFF. ? and connector.
2)Measure the resistance between ECM con- NOTE:
nector and chassis ground. In this case, repai
Connector & terminal the following:
(8134) No. 7 - Chassis ground: Open circuit in
harness between
ECM connector
and engine grounc
terminal
Poor contact in
ECM connector
Poor contact in
coupling connectc
(822)
CHECK HARNESS BETWEEN ECM AND ;the voltage more than 10 V? Repair battery Replace the ECM
short circuit in har <Ref. to
IDLE AIR CONTROL SOLENOID VALVE
CONNECTOR.
1)Turn the ignition switch to OFF.
ness between
ECM and idle air
1 ~
Engine
o ~ eControl
~>C)-47~

2)Disconnect the connector from idle air con- control solenoid

trol solenoid valve. valve connector.
3)Turn the ignition switch to ON. After repair,
4)Measure the voltage between ECM connec- replace the ECM.
tor and chassis ground. <Ref. to
Connector & terminal FU(SOHC)-47,
DTC P1511; (8134) No. 5 (+) - Chassis Engine Control
ground (-): Module.>
DTC P1513; (8134) No. 6 (+) - Chassis
ground (-):
DTC P1515; (8134) No. 19 (+) - Chassi!
ground (-):
DTC P1517; (8134) No. 20 (+) - Chassi!
ground (-):

EN(S0HC)-297
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

EN(S0HC)-298
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

CK:DTC PI518 - STARTER SWITCH CIRCUIT LOW INPUT -

DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
TROUBLE SYMPTOM:
Failure of engine to start
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(SOHC)40, OPERATION, Inspec-
tion Mode.>.

EN(S0HC)-299
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

WIRING DIAGRAM:

SBF-4 SBF-1

c
-
4 &
-
-

I TO SECURITY SYSTEM I

EN1077

EN(S0HC)-300
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)
~~ ~ ~

Step Check Yes No

1 CHECK OPERATION OF STARTER MOTOR. Does the starter motor operate Repair harness Check starter
NOTE: when ignition switch is turned and connector. motor circuit. <Ref.
Place the inhibitor switch in the “P” or “N” posi- to “ST”? NOTE: to EN(S0HC)-58,
tion. (AT model) In this case, repair STARTER
Depress the clutch pedal. (MT model) the following: MOTOR CIR-
* Open or ground CUIT, Diagnostics
short circuit in har- for Engine Start-
ness between ing Failure.>
ECM and starter
motor connector.
* Poor contact in
ECM connector.
I I

EN(SOHC)-301
I
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

CL:DTC PI540 - VEHICLE SPEED SENSOR MALFUNCTION 2 -

DTC DETECTING CONDITION:
Immediately at fault recognition
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(SOHCb43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(SOHC)40, OPERATION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

IGNmON
BAllERY

No.18

VEHICLE
SPEED
SENSOR

COMBINATION
METER I

I @ECM I I
U L
EN1098

EN(S0HC)-302
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No I

CHECK DTC PO720 ON DISPLAY. Does the Subaru Select Moni- Check front vehi- 50 to step 2.
tor or OBD-ll general scan tool cle speed sensor
indicate DTC P0720? signal circuit.
<Ref. to AT-57,
DTC 33 FRONT
VEHICLE SPEED
SENSOR, Diag-
nostic Procedure
with Diagnostic
Trouble Code
(DTC).>
CHECK SPEEDOMETER OPERATION IN Does the speedometer operate Go to step 3. ;heck speedome-
COMBINATION METER. normally? er and vehicle
;peed sensor.
:Ref. to IDI-13,
3peedometer.z
CHECK HARNESS BETWEEN ECM AND Is the resistance less than 10 Repair poor con- 3epair harness
COMBINATION METER CONNECTOR. a? tact in ECM con- md connector.
1)Turn the ignition switch to OFF. nector. UOTE:
n this case, repair
,he following:
1Open circuit in
iarness between
I C M and combi-
iation meter con-
lector
1 Poor contact in

ECM connector
1 Poor contact in

:ombination meter
:onnector
Poor contact in
:oupling connector
(i2)

EN(S0HC)-303
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENG INE (DIAGNOSTICS)

CM:DTC PI560 - BACK-UP VOLTAGE CIRCUIT MALFUNCTION -

DTC DETECTING CONDITION:
Immediately at fault recognition
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(SOHC)40, OPERATION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

BATTERY
SBF-5
@ 0-

88 I
4

EN1105

Step Check
1 CHECK INPUT SIGNAL FOR ECM. s the voltage more than 10 V?
1)Turn the ignition switch to OFF. tact in ECM con-
2)Measure the voltage between ECM and nector.
chassis ground.
Connector & terminal
(8136) No. 9 (+) - Chassis ground (-):

EN(S0HC)-304
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

! CHECK HARNESS BETWEEN ECM AND Is the resistance less than 10 Repair ground Go to step 3.
MAIN FUSE BOX CONNECTOR. R? short circuit in har-
1)Disconnectthe connector from ECM. ness between
2)Measure the resistance of harness between ECM connector
ECM and chassis ground. and battery termi-
Connector & terminal nal.
(8136) No. 9 - Chassis ground:
I CHECK FUSE SBF-5. Is fuse blown? Replace the fuse. Repair harness
and connector.
NOTE:
In this case, repaii
the following:
B Open circuit in

harness between
ECM and battery
Poor contact in
ECM connector
B Poor contact in

battery terminal

EN(SOHC)-305
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

CN:DTC PI590 - NEUTRAL POSITION SWITCH CIRCUIT HIGH INPUT (AT

MODEL) -
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(S0HC)-40, OPERATION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

INHIBITOR

n
SWITCH ( AT )

#pl
9 10 11 12

B2M3956

EN(S0HC)-306
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)
~~ ___

Step Check Yes No

CHECK DTC PO705 ON DISPLAY. Does the Subaru Select Moni- Inspect DTC So to step 2.
tor or OBD-ll general scan tool PO705 using “List
indicate DTC P0705? of Diagnostic Trou-
ble Code (DTC)”.
<Ref. to
EN(S0HC)-77,
List of Diagnostic
Trouble Code
(DTC).>
! CHECK INPUT SIGNAL FOR ECM. Is the voltage less than 1 V? Go to step 3. Go to step 5.
1)Turn the ignition switch to ON.
2)Measure the voltage between ECM and
chassis ground in selector lever “N” and “P“
positions.
Connector & terminal
(8135) No. 26 (+) - Chassis ground (-):
I CHECK INPUT SIGNAL FOR ECM. I
Is the voltage between 4.5 and Go to step 4. Go to step 5.
Measure the voltage between ECM and chas- 5.5 V?
sis ground in selector lever except for “N” and
“P” positions.
Connector & terminal
(8135) No. 26 (+) - Chassis ground (-):
CHECK POOR CONTACT. Is there poor contact in ECM Repair poor con- Contact with SOA
Check poor contact in ECM connector. connector? tact in ECM con- (distributor)ser-
vice.
NOTE:
Inspection by DTh
is required, be
cause probablc
cause is deteriora
tion of multiplc
parts.
I CHECK INPUT SIGNAL FOR ECM. Go to step 6.
Measure the voltage between ECM and chas-
sis ground.
Connector & terminal
(8135) No. 26 (+) - Chassis ground (-):
i CHECK HARNESS BETWEEN ECM AND IN- Repair harness
HIBITOR SWITCH CONNECTOR. and connector.
1)Turn the ignition switch to OFF. NOTE:
2)Disconnect the connectors from ECM and In this case, repai
inhibitor switch. the following:
3)Measure the resistance of harness between * Open circuit in
ECM and inhibitor switch connector. harness between
Connector & terminal ECM and inhibitor
-
(8135) NO. 26 (77) NO. 12: switch connector
* Poor contact in
coupling connect0

Poor contact in
inhibitor switch
connector
Poor contact in
ECM connector

EN(SOHC)-307
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

r CHECK INHIBITOR SWITCH GROUND LINE Is the resistance less than 5 30 to step 8. Repair open circuit
Measure the resistance of harness between Q? in harness
inhibitor switch connector and engine ground. between inhibitor
Connector & terminal switch connector
(T7) No. 7 - Engine ground: and starter motor
ground line.
NOTE:
In this case, repaii
the following:
Open circuit in
harness between
inhibitor switch
connector and
starter motor
ground line
Poor contact in
starter motor con-
nector
Poor contact in
starter motor
ground
* Starter motor
I CHECK INHIBITOR SWITCH. Is the resistance less than 1 So to step 9. Replace the inhibi-
Measure the resistance between inhibitor n? tor switch. <Ref. to
switch connector receptacle’sterminals in AT-28, Inhibitor
selector lever “N” and “ P positions. Switch.>
Terminals
NO. 7 - NO. 12:
1 CHECK SELECTOR CABLE CONNECTION. Is there any fault in selector 3epair selector Contact with SOA
cable connection to inhibitor :able connection. (distributor)ser-
switch? :Ref. to CS-27, vice.
NSPECTION, NOTE:
;elect Cable.> Inspection by DTM
IS required, be-
cause probable
cause is deteriora-
tion of multiple
parts.

EN(S0HC)-308
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

EN(S0HC)-309
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

C0:DTC PI591 - NEUTRAL POSITION SWITCH CIRCUIT LOW INPUT (AT

MODEL) -
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(SOHC)40, OPERATION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

9 i o 11 12

B2M395f

EN(S0HC)SlO
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK DTC PO705 ON DISPLAY. Ioes the Subaru Select Moni- nspect DTC i o to step 2.
or or OBD-ll general scan tool ’070.5 using “List
ndicate DTC P0705? i f Diagnostic Trou-
)le Code (DTC)”.
:Ref. to
EN(S0HC)-77,
k i t of Diagnostic
rrouble Code
:DTC).>
I
CHECK INPUT SIGNAL FOR ECM. s the voltage between 4.5 and Even if MIL lights ;o to step 3.
1)Turn the ignition switch to ON. 5.5 V at except “N” and “ P -rp, the circuit has
2)Measure the voltage between ECM and iositions? ,eturned to a nor-
chassis ground. nal condition at
Connector & terminal :his time.
(8135) No. 26 (+) - Chassis ground (-):
I CHECK HARNESS BETWEEN ECM AND s the resistance less than 10 3epair ground 20 to step 4.
TRANSMISSION HARNESS CONNECTOR. 2? short circuit in har-
1)Turn the ignition switch to OFF. less between
2)Disconnect the connectors from ECM and ECM and trans-
transmission harness connector (T3). nission harness
3)Measure the resistance of harness between :onnector.
€CM connector and chassis ground.
Connector & terminal
(8135) No. 26 - Chassis ground:
I CHECK TRANSMISSION HARNESS CON- s the resistance less than 10 Repair ground 20 to step 5.
NECTOR. n? short circuit in har-
1)Disconnectthe connector from inhibitor , ness between
switch. transmission har-
2)Measure the resistance of harness between ness and inhibitor
transmission harness connector and engine switch connector.
ground.
Connector & terminal
(T3) No. 12 - Engine ground:
i CHECK INHIBITOR SWITCH. s the resistance more than 1 Go to step 6. 3eplace the inhibi
Measure the resistance between inhibitor Ma at except “N” and “P” posi- or switch. <Ref. tc
switch connector the receptacle’sterminals in :ions? 4T-28, Inhibitor
selector lever except for “N” position. Switch.>
Terminals
NO. 7 - NO. 12:
5 CHECK SELECTOR CABLE CONNECTION. Is there any fault in selector Repair selector 2ontact with SOA
:able connection to inhibitor cable connection. :distributor) ser-
switch? <Ref. to CS-27, lice.
INSPECTION, VOTE:
Select Cable.> nspection by DTA
s required, be
:ause probabl
:ause is deteriori
:ion of multipl
,arts.

EN(S0HC)-311
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

CP:DTC P1592 - NEUTRAL POSITION SWITCH CIRCUIT LOW INPUT (MT

MODEL) -
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(S0HC)-40, OPERATION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

ENllOt

EN(S0HC)-312
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE IDIAGNOSTICS)
~

Step Check Yes No

CHECK INPUT SIGNAL FOR ECM. Is the voltage more than 1OV in i o to step 2. 30 to step 4.
1)Turn the ignition switch to ON. ieutral position?
2)Measure the voltage between ECM and
chassis ground.
Connector & terminal
(9135)No. 26 (+) - Chassis ground (-):
CHECK INPUT SIGNAL FOR ECM. Is the voltage less than 1V in i o to step 3. 30 to step 4.
Measure the voltage between ECM and chas- Dther position?
sis ground.
Connector & terminal
(9135)No. 26 (+) - Chassis ground (-):
CHECK POOR CONTACT. Is the poor contact in ECM iepair poor con- :ontact with SOA
Check poor contact in ECM connector. connector? x t in ECM con- :distributor)ser-
lector. dice.
CHECK NEUTRAL POSITION SWITCH. Is the resistance more than i o to step 5. Repair short circuit
1)Turnthe ignition switch to OFF. 1MR in neutral position? n transmission
2)Disconnectthe connector from transmission iarness or replace
harness. ieutral position
3)Measure the resistance between transmis- switch.
sion harness and connector termials.
Connector & terminal
(T2)NO. 1 - NO. 2:
CHECK NEUTRAL POSITION SWITCH. Is the resistance less than 1R ;o to step 6. Repair short circuit
Measure the resistance between transmission in other positions? in transmissin har-
harness connector terminals. ness or replace
neutral position
switch.
CHECK HARNESS BETWEEN ECM AND Is the resistance less than 10 3epair ground Go to step 7.
NEUTRAL POSITION SWITCH CONNEC- Q? ihort circuit in har-
TOR. less between
Measure the resistance between ECM and X M and trans-
chassis ground. nission harness
Connector & terminal :onnector.
(8135)No. 26 - Chassis ground:
CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 ;o to step 8. Repair open circuit
NEUTRAL POSITION SWITCH CONNEC- Q? in harness
TOR. between ECM and
1)Disconnectthe connector from ECM. transmission har-
2)Measure the resistance of harness between ness connector.
ECM and transmission harness connector.
Connector & terminal
(B135)NO. 26 - (925)NO. 1:
CHECK HARNESS BETWEEN ECM AND Is the resistance less than 5 ;o to step 9. Repair open circuit
NEUTRAL POSITION SWITCH CONNEC- R? between transmis-
TOR. sion harness con-
Measure the resistance of harness between nector and engine
transmission harness connector and engine ground terminal.
ground.
Connector & terminal
(925)No. 2 - Engine ground:
CHECK POOR CONTACT. Is there poor contact in trans- 3epair poor con- Contact with SOA
~ Check poor contact in transmission harness mission harness connector? act in transmis- (distributor) ser-
connector. ;ion harness vice.
:onnector.

EN(S0HC)-313
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

CQ:DTC P I 594 - AUTOMATIC TRANSMISSION DIAGNOSIS INPUT SIGNAL

CIRCUIT MALFUNCTION -
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(S0HC)-40, OPERATION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

71

7
ENllOi

Step Check Yes No

1 CHECK DRIVING CONDITION. Is the AT shift control function- Go to step 2. Replace the TCM.
1)Start and warm-up the engine until the radia- ing properly? <Ref. to AT-45,
tor fan makes one complete rotation. Transmission Con-
2)Drive the vehicle. trol Module
(TCM).>

EN(S0HC)-314
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

2 CHECK ACCESSORY. Are car phone and/or CB Repair grounding Replace the TCM.
installed on vehicle? line of car phone <Ref. to AT-45,
or CB system. Transmission Con-
trol Module
(TCM).>

EN(S0HC)-315
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

CR:DTC PI595 - AUTOMATIC TRANSMISSION DIAGNOSIS INPUT SIGNAL

CIRCUIT LOW INPUT -
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(SOHC)40, OPERATION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

10 71

EN(S0HC)-316
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK HARNESS BETWEEN ECM AND 5 the voltage less than 1 V? 30 to step 2. Even if MIL lights
TCM CONNECTOR. up, the circuit has
1)Turn the ignition switch to ON. returned to a nor-
2)Measure the voltage between ECM and mal condition at
chassis ground. this time.
Connector & terminal NOTE:
(8135) No. 4 (+) - Chassis ground (-): In this case, repai
the following:
Poor contact in
ECM connector
Poor contact in
TCM connector
CHECK HARNESS BETWEEN ECM AND s the resistance less than 10 3epair ground Go to step 3.
TCM CONNECTOR. 2? short circuit in har
1)Turnthe ignition switch to OFF. less between
2)Disconnect the connector from ECM and X M and TCM
TCM. :onnector.
3)Measure the resistance of harness between
ECM and chassis ground.
Connector & terminal
(8135) No. 4 - Chassis ground:
1 .CHECK OUTPUT SIGNAL FOR ECM. s the voltage more than 5 V? 30 to step 4. Repair poor con-
1)Connect the connector to ECM. tact in ECM con-
2)Turn the ignition switch to ON. nector.
3)Measure the voltage between ECM and
chassis ground.
Connector & terminal
(8135) No. 4 (+) - Chassis ground (-):
I CHECK TROUBLE CODE FOR AUTOMATIC loes the trouble code appear Inspect trouble Replace the TCM.
TRANSMISSION. or automatic transmission? :ode for automatic <Ref. to AT-45,
Read the trouble code for automatic transmis- transmission. Transmission Con,
sion. <Ref. to AT-24, Read Diagnostic Trouble <Ref. to AT-44, trol Module
Code (DTC).> Diagnostic Proce- (TCM).>
jure with Diagnos
tic Trouble Code
[ DTC).>

EN(S0HC)-317
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

CS:DTC P I 596 - AUTOMATIC TRANSMISSION DIAGNOSIS INPUT SIGNAL

CIRCUIT HIGH INPUT -
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
CAUTION:
After repair or replacement of faulty parts, conduct Clear lrldmory Mode <Ref. to EP OHC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(SOHC)40,OPEl TION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

F II
EN1IO?

EN(S0HC)-318
 E

DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)

ENGINE (DIAG NOSTICs\
~
-
Step Check Yes No
CHECK HARNESS BETWEEN ECM AND j the voltage more than 10 V? Repair battery Go to step 2.
TCM CONNECTOR. Short circuit in har-
1)Turn the ignition switch to ON. less between
2)Measure the voltage between ECM and ECM and TCM
chassis ground. zonnector. After
Connector & terminal repair, replace the
(8135) No. 4 (+) - Chassis ground (-): ECM. <Ref. to
FU(S0HC)-47,
Engine Control
Module.>
CHECK HARNESS BETWEEN ECM AND s the voltage more than 4 V? Go to step 5. Go to step 3.
TCM CONNECTOR.
Measure the voltage between ECM connector
and chassis ground.
Connector & terminal
(8135) No. 4 (+) - Chassis ground (-):
CHECK HARNESS BETWEEN ECM AND s the voltage less than 1 V? Repair poor con- Go to step 4.
TCM CONNECTOR. tact in ECM con-
Measure the voltage between ECM connector nector.
and chassis ground.
Connector & terminal
. (8135) No. 4 (+) - Chassis ground (-):
CHECK OUTPUT SIGNAL FROM ECM. Ioes the voltage change from Even if MIL lights Contact with SOA
Measure the voltage between ECM and chas- I V to 4 V while monitoring the up, the circuit has (distributor) ser-
sis ground. ralue with voltage meter? returned to a nor- vice.
Connector & terminal mal condition at NOTE:
(8135) No. 4 (+) - Chassis ground (-): this time. Inspection by DTk
NOTE: is required, be
In this case, repai cause probabk
the following: cause is deteriora
Poor contact in tion of multipk
ECM connector parts.
Poor contact in
TCM connector
CHECK HARNESS BETWEEN ECM AND s the voltage more than 4 V? Go to step 6. Repair open circuii
TCM CONNECTOR. in harness
Measure the voltage between TCM and chas- between ECM and
sis ground. TCM connector.
Connector & terminal
(854) No. 4 (+) - Chassis ground (-):
CHECK POOR CONTACT. s there poor contact in TCM Repair poor con- Check TCM powei
Check poor contact in TCM connector. :onnector? tact in TCM con- supply line and
nector. grounding line.

EN(SOHC)=319
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENG INE (DIAGNOSTICS)

CT:DTC P1698 - ENGINE TORQUE CONTROL CUT SIGNAL CIRCUIT LOW IN-
PUT -
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(S0HC)-40, OPERATION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

10 71

EN1108

EN(S0HC)-320
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)
~ ____~

Step Check Yes No

CHECK OUTPUT SIGNAL FROM ECM. Is the voltage more than 3 V? Repair poor con- 30 to step 2.
1)Start the engine, and warm-up the engine. tact in ECM con-
2)Turn the ignition switch to OFF. nector.
3)Turn the ignition switch to ON.
4)Measure the voltage between ECM and
chassis ground.
Connector & terminal
(8134) No. 31 (+) - Chassis ground (-):
CHECK HARNESS BETWEEN ECM AND Is the resistance less than 10 Repair ground 30 to step 3.
TCM CONNECTOR. n? short circuit in har-
1)Turnthe ignition switch to OFF. ness between
2)Disconnect the connectors from ECM and ECM and TCM
TCM. connector.
3)Measure the resistance of harness between
ECM and chassis ground.
Connector & terminal
(8134) No. 31 - Chassis ground:
CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Repair poor con- Repair open circuii
TCM CONNECTOR. Q? tact in ECM or in harness
Measure the resistance of harness betwee TCM connector. Detween ECM and
ECM and TCM connector. TCM connector.
. Connector & terminal
(8134) NO. 31 - (854) NO. 2:

EN(S0HC)-321
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

CU:DTC PI699 - ENGINE TORQUE CONTROL CUT SIGNAL CIRCUIT HIGH IN-
PUT -
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(S0HC)-40, OPERATION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

71

F7
EN1108

EN(S0HC)-322
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)
~~

step Check Yes No

CHECK OUTPUT SIGNAL FROM ECM. IS the voltage less than 3 V? Go to step 2. Repair battery
1)Start the engine, and warm-up the engine. short circuit in har-
2)Turn the ignition swtich to OFF. ness between
3)Disconnect the connector from TCM. ECM and TCM
4)Turn the ignition switch to ON. connector. After
5)Measure the voltage between ECM and repair, replace the
chassis ground. ECM. <Ref. to
Connector & terminal FU(S0HC)-47,
(8134) No. 31 (+) - Chassis ground (-): Engine Control
Module.>
! CHECK HARNESS BETWEEN ECM AND Does the voltage change more Repair battery Contact with SOA
TCM CONNECTOR. than 10 V by shaking harness short circuit in har- (distributor) ser-
1)Turn the ignition switch to OFF. and connector of ECM while ness between vice.
2)Measure the voltage between ECM and monitoring the value with volt- ECM and TCM NOTE:
chassis ground. age meter? connector. After Inspection by DTM
Connector & terminal repair, replace the is required, be-
(8134) No. 31 (+) - Chassis ground (-): ECM. <Ref. to cause probable
FU(SOHC)-47, cause is deteriora
Engine Control tion of multiple
Module.> parts.

EN(SOHC)-323
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

CV:DTC PI701 - CRUISE CONTROL SET SIGNAL CIRCUIT MALFUNCTION

FOR AUTOMATIC TRANSMISSION -
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(S0HC)-40, OPERATION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

10

In
EN1109

EN(SOHC)-324
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check No
CHECK HARNESS BETWEEN TCM AND 3epair open circuil
CCM CONNECTOR. n harness
1)Turn the ignition switch to OFF. jetween TCM and
2)Disconnect the connectors from TCM and ;CM connector.
CCM.
3)Measure the resistance of harness between

!
TCM and CCM connector.
Connector & terminal
(B54) NO. 11- (B94) NO. 3:
CHECK HARNESS BETWEEN TCM AND
CCM CONNECTOR.
Measure the resistance of harness between
TCM and chassis ground.
fi
Is the resistance less than 10
a?
Repair short circuit 20 to step 3.
in harness
between TCM and
CCM connector.

s
Connector & terminal
(854) No. 11 - Chassis ground:
I CHECK INPUT SIGNAL FOR TCM. Is the resistance less than 1 V? Go to step 4. ;heck cruise con-
1)Connect the connector to TCM and CCM. rol command
2)Lift-up the vehicle or set the vehicle on free ;witch circuit.
rollers. :Ref. to CC-7,
CAUTION: NSPECTION,
On AWD models, raise all wheels off 2ruise Control
ground. 2ommand
3)Start the engine. Switch.>
4)Turn the cruise control main switch to ON.
5)Move selector lever to “ D and slowly
increase vehicle speed to 50 km/h (31 MPH).
6)Turn the cruise control command switch to
ON.
7)Measure the voltage between TCM and
chassis ground.
Connector & terminal
(B54) No. 11 (+) - Chassis ground (-):
1 CHECK POOR CONTACT. 3eplace the TCM.
Check poor contact in TCM connector. connector? tact in TCM con- :Ref. to AT-45,
nector. rransmission Con
rol Module
‘TCM).>

EN(S0HC)-325
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE IDIAGNOSTICS)

CW:DTC PI711 - ENGINE TORQUE CONTROL SIGNAL 1 CIRCUIT MALFUNC-

TION -
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
TROUBLE SYMPTOM:
Excessive shift shock
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(S0HC)-40, OPERATION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

I71
I

F7
EN1110

EN(S0HC)-326
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check
CHECK INPUT SIGNAL FOR ECM. s the voltage more than 4.5 V?
1)Turn the ignition switch to ON.
2)Measure the voltage between ECM and
chassis ground.
Connector & terminal
(8135) No. 16 (+) - Chassis ground (-):
CHECK INPUT SIGNAL FOR ECM. Is the voltage more than 10 V? Repair battery I Go to step 3.
Measure the voltage between ECM and chas- short circuit in har-
sis ground. ness between
Connector & terminal ECM and TCM
(8135) No. 16 (+) - Chassis ground (-): connector.
CHECK POOR CONTACT. Is there poor contact in ECM Repair poor con- Replace the ECM.
Check poor contact in ECM connector. :onnector? tact in ECM con- <Ref. to
nector. FU(S0HC)-47,
Engine Control
Module.>
CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Go to step 5. Repair open circuit
TCM CONNECTOR. n? in harness
1)Turn the ignition switch to OFF. between ECM and
2)Disconnect the connectors from ECM and TCM connector.
TCM.
3)Measure the resistance of harness between
ECM and TCM connector.
Connector & terminal
(B 135) NO. 16 - (656) NO. 5:
CHECK HARNESS BETWEEN ECM AND Is the resistance less than 10
TCM CONNECTOR. n? short circuit in har-
Measure the resistance of harness between ness between
ECM and chassis ground. ECM and TCM
Connector & terminal connector.
(B 135) No. 16 - Chassis ground:
CHECK POOR CONTACT. Is there poor contact in TCM
Check poor contact in TCM connector. connector?
nector. Transmission Con-
trol Module
(TCMb

EN(S0HC)-327
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

CX:DTC PI712 - ENGINE TORQUE CONTROL SIGNAL 2 CIRCUIT MALFUNC-

TION -
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
TROUBLE SYMPTOM:
Excessive shift shock
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(S0HC)-43, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(S0HC)-40, OPERATION, Inspec-
tion Mode.>.
WIRING DIAGRAM:

10

in
EN1111

EN(S0HC)-328
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE [DIAGNOSTICS)

Step Check Yes No

1 CHECK INPUT SIGNAL FOR ECM. Is the voltage more than 4.5 V? Go to step 2. Go to step 4.
1)Turnthe ignition switch to ON.
2)Measure the voltage between ECM and
chassis ground.
Connector & terminal
(6135) No. 17 (+) - Chassis ground (-):
2 CHECK INPUT StGNAL FOR ECM. Is the voltage more than 10 V? Repair battery Go to step 3.
Measure the voltage between ECM and chas- short circuit in har,
sis ground. ness between
Connector & terminal ECM and TCM
(6135) No. 17 (+) - Chassis ground (-): connector.
3 CHECK POOR CONTACT. Is there poor contact in ECM Repair poor con- Replace the ECM.
Check poor contact in ECM connector. connector? tact in ECM con- <Ref. to
nector. FU(S0HC)-47,
Engine Control
Module.>
4 CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Go to step 5. Repair open circuit
TCM CONNECTOR. sz? in harness
1)Turn the ignition switch to OFF. between ECM and
2)Disconnect the connectors from ECM and TCM connector.
TCM.
9)Measure the resistance of harness between
ECM and TCM connector.
Connector & terminal
(6135) NO. 17- (654) NO. 21:
5 CHECK HARNESS BETWEEN ECM AND Is the resistance less than 10 Repair ground Go to step 6.
TCM CONNECTOR. sz? short circuit in har
Measure the resistance of harness between ness between
ECM and chassis ground. ECM and TCM
Connector & terminal connector.
(6135) No. 17 - Chassis ground:
6 CHECK POOR CONTACT. Is there poor contact in TCM Repair poor con- Replace the TCM.
Check poor contact in TCM connector. connector? tact in TCM con- <Ref. to AT-45,

rector. Transmission Con-

trol Module
(TCM).>

EN(S0HC)-329
 GENERAL DIAGNOSTIC TABLE
ENGINE (DIAGNOSTICS)

19.General Diagnostic Table

A: INSPECTION
1. ENGINE
NOTE:
Malfunction of parts other than those listed is also possible. <Ref. to ME(S0HC)-89, Engine Trouble in Gen-

I era‘.’
Symptom Problem parts
1) Idle air control solenoid valve
2) Intake air temperature and pressure sensor
3) Ignition parts (*I)
1. Engine stalls during idling. 4) Engine coolant temperature sensor (*2)
5) Crankshaft position sensor (‘3)
6) Camshaft position sensor (*3)
7) Fuel injection parts (*4)
1) Idle air controlsolenoid valve
2) Intake air temperature and pressure sensor
3) Engine coolant temperature sensor (‘2)
4) Ignition parts (*I)
5) Air intake system (*5)
2. Rough idling 6) Fuel injection parts (*4)
7) Throttle position sensor
8 ) Crankshaft position sensor (*3)
9) Camshaft position sensor (*3)
10) Oxygen sensor
111 Fuel pump and fuel pump relay
1) Idle air control solenoid valve
2) Engine coolant temperature sensor
3. Engine does not return to idle. 3) Accelerator cable (‘6)
4) Throttle position sensor
5) Intake air temperature and pressure sensor
~~~

1) Intake air temperature and pressure sensor

2) Throttle position sensor
3) Fuel injection parts (*4)
4) Fuel pump and fuel pump relay
5) Engine coolant temperature sensor (‘2)
4. Poor acceleration
6) Crankshaft position sensor (’3)
7) Camshaft position sensor (*3)
8 ) N C switch and N C cut relay
9) Engine torque control signal circuit
10) Ignition parts (*I)
1) Intake air temperature and pressure sensor
2) Engine coolant temperature sensor (*2)
3) Crankshaft position sensor (*3)
5. Engine stalls or engine sags or hesitates at 4) Camshaft position sensor (*3)
acceleration. 5) Purge control solenoid valve
6) Fuel injection parts (‘4)
7) Throttle position sensor
8 ) Fuel pump and fuel pump relay
1) Intake manifold pressure sensor
2) Intake air temperature sensor
3) Intake air temperature and pressure sensor
4) Engine coolant temperature sensor (‘2)
6. Surge 5) Crankshaft position sensor (*3)
6) Camshaft position sensor (‘3)
7) Fuel injection parts (*4)
8 ) Throttle position sensor
9) Fuel pump and fuel pump relay

EN(S0HC)-330
 GENERAL DIAGNOSTIC TABLE
ENGINE (DIAGNOSTICS)

Symptom Problem parts

1) Intake manifold pressure sensor
2) Intake air temperature sensor
3) Intake air temperature and pressure sensor
7. Spark knock 4) Engine coolant temperature sensor
5) Knock sensor
6) Fuel injection parts (*4)
7 ) Fuel pump and fuel pump relay
1) Intake manifold pressure sensor
2) Intake air temperature sensor
3) Intake air temperature and pressure sensor
8. After burning in exhaust system
4) Engine coolant temperature sensor (*2)
5) Fuel injection parts (*4)
6) Fuel pump and fuel pump relay
*I: Check ignition coil & ignitor assembly and spark plug.
'2: Indicate the symptom occurring only in cold temperatures.
*3: Ensure the secure installation.
*4: Check fuel injector, fuel pressure regulator and fuel filter.
'5: Inspect air leak in air intake system.
'6: Adjust accelerator cable.

2. AUTOMATIC TRANSMISSION
NOTE:
Check general diagnostics table with non-conformitysymptom for automatic transmission. <Ref. to AT-2, Ba-
sic Diagnostic Procedure.>

EN(S0HC)-331
 GENERAL DIAGNOSTIC TABLE
ENGINE (DIAGNOSTICS)

EN(S0HC)-332
2002 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX

ENGINE2 SECTION

This service manual has been prepared

to provide SUBARU service personnel
with the necessary information and data
for the correct maintenance and repair
of SUBARU vehicles.
This manual includes the procedures
for maintenance, disassembling, reas-
sembling, inspection and adjustment of
components and diagnostics for guid-
ance of experienced mechanics.
Please peruse and utilize this manual
fully to ensure complete repair work for
satisfying our customers by keeping
their vehicle in optimum condition.
When replacement of parts during
repair work is needed, be sure to use
SUBARU genuine parts.

All information, illustration and specifi-

cations contained in this manual are
based on the latest product information
available at the time of publication
approval.
FUJI HEAVY INDUSTRIES LTD. G1830BE3
FUEL INJECTION (FUEL SYSTEMS)

FU(D0HC TURB0)m
Page
1. General Description .................................................................................... 2
2 . Throttle Body ............................................................................................. 14
3. Intake Manifold .......................................................................................... 15
4 . Engine Coolant Temperature Sensor ........................................................ 29
5. Crankshaft Position Sensor ....................................................................... 30
6 . Camshaft Position Sensor ......................................................................... 31
7 . Knock Sensor ............................................................................................ 32
8. Throttle Position Sensor ............................................................................ 33
9 . Mass Air Flow and Intake Air Temperature Sensor .................................. 34
10. Pressure Sensor ....................................................................................... 35
11. Idle Air Control Solenoid Valve ................................................................. 36
12. Fuel Injector .............................................................................................. 37
13. Tumble Generator Valve Assembly .......................................................... 40
14. Wastegate Control Solenoid Valve ........................................................... 41
15. Front Oxygen (NF) Sensor ....................................................................... 42
16. Rear Oxygen Sensor ................................................................................. 44
17. Exhaust Temperature Sensor ................................................................... 46
18. Engine Control Module.............................................................................. 47
19. Main Relay ................................................................................................ 48
20 . Fuel Pump Relay ....................................................................................... 49
21 . Fuel Pump Controller ................................................................................ 50
22 . Fuel ........................................................................................................... 51
23 . Fuel Tank .................................................................................................. 52
24 . Fuel Filler Pipe .......................................................................................... 55
25 . Fuel Pump ................................................................................................. 60
26 . Fuel Level Sensor ..................................................................................... 62
27 . Fuel Sub Level Sensor .............................................................................. 63
28 . Fuel Filter .................................................................................................. 65
29 . Fuel Cut Valve ........................................................................................... 66
30. Fuel Damper Valve ................................................................................... 67
31 . Fuel Deliverv. Return and Evaporation Lines ............................................
a . 68
32 . Fuel System Trouble in General ............................................................... 71
 GENERAL DESCRIPTION
FUEL INJECTION (FUEL SYSTEMS)

1. General Description
A: SPECIFICATIONS
Capacity 60 8 (15.9 US gal, 13.2 Imp gal)
Location Under rear seat
Type Impeller
Shutoff discharge pressure 450 - 677 kPa (4.59 - 6.9 kg/cm2, 65.27 - 98.2 psi)
Fuel pump
More than 130 8 (34.3 US gal, 28.6 Imp gal)/h
Discharge flow
[12 V at 300 kPa (3.06 kg/cm2,43.5 psi)]
Fuel filter Cartridge type

FU(D0HC TURBO)-2
GENERAL DESCRIPTION
FUEL INJECTION (FUEL SYSTEMS)

FU(D0HC TURBO)-3
 GENERAL DESCRIPTION
FUEL INJECTION (FUEL SYSTEMS)

B: COMPONENT
1. INTAKE MANIFOLD

EN1135

FU(D0HC TURBO)-4
 GENERAL DESCRIPTION
FUEL INJECTION (FUEL SYSTEMS)

Fuel pipe ASSY Accelerator cable bracket
Fuel hose Fuel injector
Clip Insulator
Purge control solenoid valve Fuel injector pipe
Vacuum hose Pressure regulator
Vacuum control hose Pressure regulator hose
Purge valve Fuel pipe protector RH
Purge hose Blow-by hose stay
Intake manifold gasket Intake manifold
Guide pin Solenoid valve cover
Tumble generator valve ASSY Solenoid valve cover stay
Tumble generator valve gasket Wastegate control solenoid valve
ASSY
(25) Fuel pipe protector LH
(26) Nipple
,
Tightening torque: N.m (kgf-m, ft-lb)
T1: 4.9 (0.5, 3.6)
T2: 6.4 (0.65, 4.7)
T3: 8.25 (0.84, 6.1)
T4: 16 (1.6, 11.8)
T5: 17(1.73, 12.5)
T6: 19 (1.94, 13.7)
T7: 25 (2.5, 18.1)

FU(D0HC TURB0)-5
 GENERAL DESCRIPTION
FUEL INJECTION (FUEL SYSTEMS)

2. AIR INTAKE SYSTEM

EN113
~

(1) Gasket (5) Pressure sensor Tightening torque: N.m (kgf-m, ft-lb)
(2) Throttle position sensor (6) Gasket T1: 1.6 (0.16, 1.2)
(3) Idle air control solenoid valve (7) O-ring T2: 2.8 (0.29, 2.1)
(4) Throttle body T3: 22 (2.2, 15.9)

FU(D0HC TURBO)-6
 GENERAL DESCRIPTION
FUEL INJECTION (FUEL SYSTEMS)

3. CRANKSHAFT POSITION, CAMSHAFT POSITION AND KNOCK SENSORS

(1) Crankshaft position sensor (3) Camshaft position sensor Tightening torque: N.m (kgf-m, ft-lb)
(2) Knock sensor T1: 6.4 (0.65, 4.7)
T2: 24 (2.4, 17.4)

FU(D0HC TURBO)-7
 GENERAL DESCRIPTION
FUEL INJECTION (FUEL SYSTEMS)

4. FUELTANK

EN1119

FU(D0HC TURBO)-8
I
GENERAL DESCRIPTION
FUEL INJECTION (FUEL SYSTEMS)

Heat shield cover Evaporation hose C Fuel sub level sensor gasket
Fuel tank band Evaporation hose B Jet pump filter
Protector LH Evaporation hose D Fuel sub level sensor
Protector RH Evaporation hose E Protector cover
Fuel tank Evaporation pipe ASSY Vent valve hose
Canister hose A Retainer Vent valve
Clamp Quick connector Fuel tank pressure sensor
Fuel pump gasket Jet pump hose A Fuel tank pressure sensor hose
Fuel pump ASSY Fuel return hose A Vent valve gasket
Fuel cut valve gasket Fuel pipe ASSY
Fuel cut valve Jet pump hose B Tightening torque: N-m (kgf-m, ft-lb)
Evaporation hose A Fuel return hose B T1: 4.4 (0.45, 3.3)
Clip Evaporation hose F T2: 7.4 (0.75, 5.4)
Joint pipe Evaporation hose G T3: 33 (3.4, 25)

FU(D0HC TURBO)-9
 GENERAL DESCRIPTION
FUEL INJECTION(FUEL SYSTEMS)

5. FUELLINE

EN1120

FU(D0HC TURBO)-I 0
 GENERAL DESCRIPTION
FUEL INJECTION (FUEL SYSTEMS)

Clamp Evaporation hose J (25) Canister holder

Fuel delivery hose A Evaporation hose K (26) Evaporation hose L
Fuel filter bracket Joint pipe (27) Pressure control solenoid valve
Fuel filter holder Canister hose A (28) Canister hose B
Fuel filter cup Air filter hose A (29) Canister
Fuel filter Drain valve hose (30) Fuel pipe ASSY
Evaporation hose Air filter hose B
Clip Drain filter Tightening torque: N-m (kgf-m, ft-lb)
Fuel delivery hose B Drain valve T1: 25 (2.5, 18.1)
Fuel return hose A Canister upper bracket T2: 23 (2.3, 16.6)
Fuel return hose B Cushion rubber T3: 1.25 (0.13, 0.94)
Fuel damper Canister lower bracket

FU(D0HC TURBO)-I 1
 GENERAL DESCRIPTION
FUEL INJECTION (FUEL SYSTEMS)

6. FUEL FILLER PIPE

EN1121

(1) Fuel filter pipe ASSY (8) Filler pipe packing (15) Fuel filler pipe protector
(2) Evaporation hose holder (9) Filler ring
-
(3) Clamp (10) Filler cap Tightening torque: N.m (kgf-m, ft-lb)
(4) Clamp (11) Shut valve T1: 4.4 (0.45, 3.3)
(5) Evaporation hose A (12) Evaporation hose 6 T2: 7.5 (0.76, 5.5)
(6) Evaporation pipe (13) Evaporation hose C
(7) Evaporation pipe holder (14) Joint pipe

FU(D0HC TURBO)-I 2
 GENERAL DESCRIPTION
FUEL INJECTION (FUEL SYSTEMS)

C: CAUTION Be careful not to burn your hands, because each

Wear working clothing, including a cap, protec- part On the vehicle is hot after running.
tive goggles, and protective shoes during opera- Be sure to tighten fasteners including bolts and

.
tion.
Remove contamination including dirt and corro-
nuts to the specified torque.
Place shop jacks or Safety stands at the specified

.
sion before removal, installation or disassembly.
Keep the disassembled parts in order and pro-
tect them from dust or dirt.
Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary re-
moval, installation, disassembly, and replacement.
points.
Before disconnecting electrical COntleCtOrS Of
sensors or units, be sure to disconnect negative
terminal from battery.
Place “NO FIRE” signs near the working area.
Be careful not to Spill fuel on the floor-

D: PREPARATION TOOL
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
24082AA150 CARTRIDGE Troubleshooting for electrical system.
(Newly adopted
tool)

B2M3876
22771AA030 SELECT MONI- Troubleshooting for electrical systems.
TOR KIT English: 22771AA030 (Without printer)
German: 22771AA070 (Without printer)
French: 22771AA080 (Without printer)
Spanish: 22771AA090 (Without printer)

FU(D0HC TURBO)-13
 THROTTLE BODY
FUEL INJECTION (FUEL SYSTEMS)

2. Throttle Body 5) Disconnect the engine coolant hoses from the

throttle body.
A: REMOVAL
1) Disconnect the battery ground cable.

6) Remove the bolts which secure the throttle body

to intake manifold.
2) Remove the intercooler. <Ref. to IN(D0HC
TURBO)-10, REMOVAL, Intercooler.>
6: INSTALLATION
3) Disconnect the connector from the throttle posi- Install in the reverse order of removal.
tion sensor (A) and idle air cotrol solenoid valve (B) NOTE:
and pressure sensor (C). Always use a new gasket.
Tightening torque:
22 N-m (2.2 kgf-m, 15.9 M b )

4) Disconnect the accelerator cable.

// EN0785

FU(D0HC TURBO)-14
 a
INTAKE MANIFOLD
FUEL INJECTION (FUEL SYSTEMS)

11) Remove the power steering pump.

3. Intake Manifold (1) Remove the front side V-belt.
A: REMOVAL <Ref. to ME(D0HC TURBO)-44, REMOVAL, V-
1) Release the fuel pressure. <Ref. to FU(D0HC belt.>
TURBO)-51, RELEASING OF FUEL PRESSURE, (2) Disconnect the power steering switch con-
OPERATION, Fuel.> nector.
2) Disconnect the battery ground cable.

(3) Remove the bolts which secure the power

3) Lift up the vehicle. steering pipe brackets to the intake manifold.
4) Remove the under cover. NOTE:
5) Drain the coolant about 3.0 0 (3.2 US qt, 2.6 Do not disconnect the power steering hose.
Imp qt).

(4) Remove the bolts which secure the power

6) Remove the air cleaner upper cover and air in- steering pump bracket.
take boot. <Ref. to IN(D0HC TURBO)-7, REMOV-
AL, Air Cleaner.>
7) Remove the air cleaner element.
8) Remove the intercooler. <Ref. to IN(D0HC
TURBO)-10, REMOVAL, Intercooler.>
9) Disconnect the accelerator cable.

10) Remove the coolant filler tank. <Ref. to CO-51,

REMOVAL, Coolant Filler Tank.>

FU(D0HC TURBO)-15
 INTAKE MANIFOLD
FUEL INJECTION (FUEL SYSTEMS)

(5) Remove the power steering tank from the 14) Disconnect the brake booster hose.
bracket by pulling it upward.

(6) Place the power steering pump on the right

side wheel apron.
duct.
- EN0204

15) Disconnect the pressure hose from the intake

16) Disconnect the engine harness connectors

12) Disconnect the emission hose from the PCV from the bulkhead harness connectors.
valve.

13) Disconnect the engine coolant hoses from the

throttle body.

FU(D0HC TURBO)-16
 INTAKE MANIFOLD
FUEL INJECTION (FUEL SYSTEMS)

17) Disconnect the connectors from the engine 21) Disconnect the engine harness fixed by clip (A)
coolant temperature sensor (A), oil pressure switch from the bracket.
(B) and crankshaft position sensor (C).

\\ I II
(6)
S2M2256A
v . 22) Disconnect the fuel delivery hose, return hose
18) Disconnect the knock sensor connector. and evaporation hose.
WARNING:
Catch the fuel from hoses in a container.

S2M1613

19) Disconnect the connector from the camshaft

position sensor.
23) Remove the bolts which secure the intake man-
ifold to the cylinder heads.

20) Disconnect the connector from the ignition coil.

24) Remove the intake manifold.

EN0854

FU(D0HC TURBO)-17
 INTAKE MANIFOLD
FUEL INJECTION (FUEL SYSTEMS)

B: INSTALLATION 4) Connect the connector to the knock sensor.

1) Install the intake manifold onto cylinder heads.
NOTE:
Always use new gaskets.
Tightening torque:
25 N-m (2.5 kgf-m, 18.1 ft-16)

S2M1613

5) Connect the connector to the camshaft position

sensor.

2) Connect the fuel delivery hose, return hose, and

evaporation hose.

6) Connect the connector to the ignition coil.

3) Connect the connector to the oil pressure switch

(B), crankshaft position sensor (C) and engine
coolant temperature sensor (A).

EN0854 I
7) Connect the engine harness with clip (A) to the
bracket.

FU(D0HC TURBO)-I8
 INTAKE MANIFOLD
FUEL INJECTION (FUEL SYSTEMS)

8) Connect the engine harness connector to the 11) Connect the emission hose to the PCV valve.
bulkhead harness connectors.

12) Connect the pressure hose to the intake duct.

EN0787

9) Connect the brake booster vacuum hose. 13) Install the power steering pump.
(1) Install the power steering tank on the brack-
et.

EN0204

10) Connect the engine coolant hoses to the throt- n/

EN0361
tle body.
(2) Connect the connector to the power steering
pump switch.

FU(D0HC TURBO)-19
 INTAKE MANIFOLD
FUEL INJECTION (FUEL SYSTEMS)

(3) Install the power steering pump, and tighten 19) Connect the connector to the fuel pump relay.
the bolts.
Tightening torque:
22 N.m (2.2 kgf-m, 15.9 ff-16)

20) Connect the battery ground cable.

21) Lift up the vehicle.
22) Install the under cover.
23) Fill the coolant. <Ref. to CO-25, FILLING OF
(4) Install the power steering pipe brackets on
COOLANT, Engine Coolant.>
the right side intake manifold.

(5) Install the front side V-belt.

<Ref. to ME(D0HC TURBO)-44, REMOVAL, V-
belt.>
14) Install the cooler filler tank. <Ref. to CO-51 IN-
STALLATION, Coolant Filler Tank.>
15) Connect the accelerator cable.

16) Install the intercooler. <Ref. to IN(D0HC TUR-

BO)-11, INSTALLATION, Intercooler.>
17) Install the air cleaner element.
18) Install the air cleaner upper cover and air intake
duct as a unit. <Ref. to IN(D0HC TURBO)-7, IN-
STALLATION, Air Cleaner.>

FU(D0HC TURBO)-20
 INTAKE MANIFOLD
FUEL INJECTION (FUEL SYSTEMS)

C: DISASSEMBLY 4) Disconnect the connector from the throttle posi-

1) Remove the fuel pipe protector LH. tion sensor (A), idle air control solenoid valve (B)
and pressure sensor (C).
5) Disconnect the engine harness fixed by clip (D)
from the intake manifold.

2) Remove the fuel pipe protector RH.

6) Remove the throttle body from the intake mani-

fold.

3) Remove the engine ground terminal from the in-

take manifold.
// . EN0785

7) Disconnect the connector from the fuel injector.

EN0795

I I EN0798
8) Disconnect the connector from the tumble gen-
erator valve actuator.

\ J EN079E

FU(D0HC TURBO)-21
 INTAKE MANIFOLD
FUEL INJECTION (FUEL SYSTEMS)

9) Disconnect the connector from the tumble gen- 13) Disconnect the evaporation hoses from the
erator valve sensor. purge valve.

I EN0800 ---.
I \ \ \ EN0804

10) Disconnect the connector from the purge con- 14) Remove the two bolts which hold the fuel pipes
trol solenoid valve. on the left side of intake manifold.

11) Remove the purge control solenoid valve.

12) Disconnect the evaporation hose from the in-

take manifold.

EN0803

FU(D0HC TURBO)-22
 INTAKE MANIFOLD
FUEL INJECTION (FUEL SYSTEMS)

15) Remove the bolt which hold the fuel injector 16) Remove the fuel injector.
pipe onto intake manifold.
LH SIDE

EN0806 I 17) Remove the harness bracket which hold the

engine harness onto intake manifold.

I
I ’ EN0807

RH SIDE 18) Remove the engine harness from the intake

manifold.
19) Loosen the clamp which holds the front left side
fuel hose to injector pipe and remove the pipe from
clamp.

I EN0808

I II I I\ EN0812

20) Remove the fuel injector pipe LH.

21) Remove the bolts which installs the fuel pipe on
intake manifold.

FU(D0HC TURBO)-23
 INTAKE MANIFOLD
FUEL INJECTION (FUEL SYSTEMS)
22) Remove the fuel pipe assembly and pressure 2) Install the air intake duct to the intake manifold.
regulator, from the intake manifold. Tightening torque:
23) Remove the intake duct from the intake mani- 19 N-m (1.94 kgf-m, 13.7 ft-lb)
fold.

3) Install the fuel pipe assembly and pressure reg-

24) Remove the tumble generator valve assembly
ulator, to the intake manifold.
from the intake manifold.
7 Tightening torque:
4.9 N.m (0.5 kgf-m, 3.6 ft-lb)

EN0815

D: ASSEMBLY
NOTE: 4) Install the fuel injector pipe LH.
Replace the gasket with a new one.
5 ) Connect the left side fuel hose to injector pipe,
1) Install the tumble generator valve assembly to and tighten the clamp screw.
the intake manifold.
Tightening torque:
8.25 N.m (0.84 kgf-m, 6.08 ft-lb)

/I I I\ EN081;

6) Install the engine harness to the intake manifold.

FU(D0HC TURBO)-24
 m
INTAKE MANIFOLD
FUEL INJECTION (FUEL SYSTEMS)
_ _ _ _ ~

7) Install the harness bracket which hold the engine

- 9). Tighten
- the bolt which install the fuel injector
harness onto intake manifold. pipe onto intake manifold.
Tightening torque: Tightening torque:
19 N.m (1.94 kgf-m, 13.7 ft-lb) 19 N.m (1.94 kgf-m, 13.7 fi-lb)
LH SIDE

EN0806
8) Install the fuel injector

I
ENO~IO EN0807

RH SIDE

FU(D0HC TURBO)-25
 INTAKE MANIFOLD
FUEL INJECTION (FUEL SYSTEMS)

10) Tighten the two bolts which install the fuel pipes 12) Connect the evaporation hose to the intake
on the left side of intake manifold. manifold.
Tightening torque:
4.9 N-m (0.5 kgf-m, 3.6 ff-lb)

EN080:

13) Install the purge control solenoid valve.

Tightening torque:
11) Connect the evaporation hoses to the purge 16 N-m (1.6 kgf-m, 11.8 ff-lb)
valve.
CAUTION:
Carefully connect the evaporation hoses.

14) Connect the hoses to the purge control sole-

noid valve.
CAUTION:
Carefully connect the evaporation hoses.

(D)---

lJ EN0816

(A) To fuel pipe ASSY

(B) To intake duct (A) To intake manifold
(C) To purge control solenoid valve (B) To purge valve
(D) To intake manifold

FU(D0HC TURBO)-26
 INTAKE MANIFOLD
FUEL INJECTION (FUEL SYSTEMS)

15) Connect the connector to the purge control so-
lenoid valve.
19) Install the throttle body to the intake manifold.
NOTE:
Replace gasket with a new one.
Tightening torque:
22 N-m (2.2 kgf-m, 15.9 fl-lb)

16) Connect the connector to the tumble generator

valve sensor.
EN0785

20) Connect the connector to the throttle position

sensor (A), idle air control solenoid valve (B) and
pressure sensor (C).
21) Connect the engine harness with clip (D) to the
intake manifold.

\/ /

EN0800

17) Connect the connector to the tumble generator

valve actuator.

(D, ( D ) S2M2249A

\ J EN0799

18) Connect the connector to the fuel injector.

I I I EN0798

FU(D0HC TURBO)-27
 INTAKE MANIFOLD
FUEL INJECTION(FUEL SYSTEMS)
22) Install the engine ground terminal to the intake E: lNSPECTlON
manifold. Make sure the fuel pipe and fuel hoses are not
Tightening torque: cracked and that connections are tight.
79 N.m (7.94 kgf-m, 73.7 ft-lb)

23) Install the fuel pipe protector RH.

Tightening torque:
79 N-m (7.94 kgf-m, 73.7 ft-lb)

24) Install the fuel pipe protector LH.

Tightening torque:
79 N.m (7.94 kgf-m, 73.7 ft-lb)

FU(D0HC TURBO)-28
 ENGINE COOLANT TEMPERATURE SENSOR
FUEL INJECTION (FUEL SYSTEMS)

4. Engine Coolant Temperature B: INSTALLATION

Install in the reverse order of removal.
Sensor
Tighfening torque:
A: REMOVAL 18 N.m (1.8 kgf-m, 13.3 fi-lb)
1) Disconnect the battery ground cable.

2) Remove the generator <Ref. to SC-13, REMOV-

AL, Generator.>
3) Disconnect the connector from the engine cool-
ant temperature sensor.

4) Remove the engine coolant temperature sensor.

FU(D0HC TURBO)-29
I CRANKSHAFT POSITION SENSOR
FUEL INJECTION (FUEL SYSTEMS)

5. Crankshaft Position Sensor B: INSTALLATION

Install in the reverse order of removal.
A: REMOVAL
1) Disconnect the battery ground cable.
Tightening torque:
T: 6.4 N.m (0.65 kgf-m, 4.7 ff-lb)

2) Remove the bolt which install the crankshaft po-

sition sensor to cylinder block.

3) Remove the crankshaft position sensor, and dis-

connect the connector from it.

FU(D0HC TURBO)-30
 CAMSHAFT POSITION SENSOR
FUEL INJECTION (FUEL SYSTEMS)

6. Camshaft Position Sensor B: INSTALLATION

Install in the reverse order of removal.
A: REMOVAL Tightening torque:
1) Disconnect the battery ground cable.
T: 6.4 Nom(0.65 kgf-m, 4.7 ft-lb)

\ \ 1 IG2M0417
2) Disconnect the connector from the camshaft po-
sition sensor.

3) Remove the hcamshaft position sensor from the

camshaft support LH

FU(D0HC TURBO)-31
 KNOCK SENSOR
FUEL INJECTION (FUEL SYSTEMS)

7. Knock Sensor B: INSTALLATION

1) Install the knock sensor to the cylinder block.
A: REMOVAL
Tightening torque:
1) Disconnect the battery ground cable.
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 60" angle relative to the engine
rear.

2) Remove the intercooler. <Ref. to IN(D0HC

TURBO)-10, REMOVAL, Intercooler.>
3) Disconnect the knock sensor connector.
~~

(A) Front side

2) Connect the knock sensor connector

4) Remove the knock sensor from the cylinder

block.

3) Install the intercooler. <Ref. to IN(D0HC TUR-

BO)-11, INSTALLATION, Intercooler.>
4) Connect the battery ground cable.

FU(D0HC TURBO)-32
 THROTTLE POSITION SENSOR
FUEL INJECTION (FUEL SYSTEMS)

8. Throttle Position Sensor B: INSTALLATION

Install in the reverse order of removal.
A: REMOVAL
1) Disconnect the battery ground cable. Tightening torque:
1.6 N.m (0.16 kgf-m, 1.2 ft-lb)

0
2) Remove the intercooler. <Ref. to IN(D0HC
TURBO)-10, REMOVAL, Intercooler.>
3) Disconnect the connector from the throttle posi-
tion sensor.

4) Remove the throttle position sensor holding

screws, and remove it.

FU(D0HC TURBO)-33
 MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR
FUEL INJECTION (FUEL SYSTEMS)

9. Mass Air Flow and Intake Air B: INSTALLATION

Temperature Sensor Install in the reverse order of removal.
Tightening torque:
A: REMOVAL 7.5 N-m (0.76 kgf-m, 5.5 ft-lb)
1) Disconnect the battery ground cable.

2) Disconnect the connector mass air flow and in-

take air temperature sensor.
3) Remove the mass air flow and intake air temper-
ature sensor.

FU(D0HC TURBO)-34
 #a
PRESSURE SENSOR
FUEL INJECTION (FUEL SYSTEMS)

1O.Pressure Sensor B: INSTALLATION

Install in the reverse order of removal.
A: REMOVAL NOTE:
1) Disconnect the battery ground cable. Replace the O-ring for the pressure sensor with
new ones.
Tightening torque:
1.6 N-m (0.16 kgf-m, 1.2 ft-16)

2) Remove the idle air control solenoid valve. <Ref.

to FU(D0HC TURBO)-36, REMOVAL, Idle Air
Control Solenoid Valve.>
3) Disconnect the connectors from pressure sen-
sor.

4) Remove the pressure sensor from the throttle

body.

FU(D0HC TURBO)-35
 IDLE AIR CONTROL SOLENOID VALVE
FUEL INJECTION (FUEL SYSTEMS)

11.Idle Air Control Solenoid B: INSTALLATION

Install in the reverse order of removal.
Valve
NOTE:
A: REMOVAL Always use a new gasket.
1) Disconnect the battery ground cable.
Tightening torque:
2.8 N-m (0.29 kgf-m, 2.1 fWb)

2) Disconnect the connector from the idle air con- I

trol solenoid valve.

EN0822

3) Remove the idle air control solenoid valve from

the throttle body.

4) Remove the gasket from throttle body.

FU(DOHC TURB0)-36
 FUEL INJECTOR
FUEL INJECTION (FUEL SYSTEMS)

12.Fuel Injector 5) Remove the fuel injector while lifting up the fuel
injector pipe.
A: REMOVAL
1. RH SIDE
1) Remove the intake manifold. <Ref. to FU(D0HC
TURBO)-15, REMOVAL, Intake Manifold.>
2) Remove the fuel pipe protector RH.

2. LH SIDE
1) Remove the intake manifold. <Ref. to FU(D0HC
TURBO)-15, REMOVAL, Intake Manifold.>
2) Remove the fuel pipe protector LH.
I I

3) Disconnect the connector from the fuel injector.

3) Disconnect the connector from the fuel injector.

I I I EN0798 1
4) Remove the bolts which hold the injector pipe to
intake manifold.

n n

I I EN0798

EN0808

FU(D0HC TURBO)-37
 FUEL INJECTOR
FUEL INJECTION (FUEL SYSTEMS)
4) Remove the bolts which hold the injector pipe to B: INSTALLATION
intake manifold.
1. RH SIDE
Install in the reverse order of removal.
NOTE:
Replace the O-ring and insulators with new ones.

(A) O-ring
(B) Fuel injector
(C) insulator

I
Tightening torque:
EN0807
/
J

19 N-m (1.94 kgf-m, 13.7 ff-lb)

I EN0806 I EN0808

5) Remove the fuel injector while lifting up the fuel Tightening torque:
injector pipe. 19 N.m (1.94 kgf-m, 13.7 ff-lb)

EN0824 EN0809

FU(D0HC TURBO)-38
 FUEL INJECTOR
FUEL INJECTION (FUEL SYSTEMS)

Tightening torque: Tightening torque:

19 N-m (1.94 kgf-m, 13.7 ff-lb) 19 N.m (1.94 kgf-m, 13.7 ft-lb)

EN080E

2. LH SIDE Tightening torque:

19 N.m (1.94 kgf-m, 13.7 ft-lb)
Install in the reverse order of removal.
NOTE:
Replace the O-ring and insulators with new ones.

I B

I
EN080:

Tightening torque:
19 N.m (1.94 kgf-m, 13.7 ft-lb)

(A) O-ring
(B) Fuel injector
(C) Insulator

Tightening torque:
4.9 N.m (0.5 kgf-m, 3.6 ff-lb)

FU(D0HC TURBO)-39
 TUMBLE GENERATOR VALVE ASSEMBLY
FUEL INJECTION (FUEL SYSTEMS)

13.Tumble Generator Valve As- 6) Remove the tumble generator valve body from
the intake manifold.
sembly
A: REMOVAL
1) Disconnect the battery ground cable.

B: INSTALLATION
Install in the reverse order of removal.
NOTE:
2) Remove the intake manifold. <Ref. to FU(D0HC Always use new gaskets.
TURBO)-I 5, REMOVAL, Intake Manifold.>
Tightening torque:
3) Disconnect the connector from the tumble gen-
erator valve sensor. 8.25 N.m (0.84 kgf-m, 6.1 ft-lb)

EN0815
EN0800

4) Disconnect the connector from the tumble gen-

erator valve actuator.

\ J EN0799

5) Remove the fuel injector. <Ref. to FU(D0HC

TURBO)-37, REMOVAL, Fuel Injector.>

FU(D0HC TURBO)-40
~

WASTEGATE CONTROL SOLENOID VALVE

FUEL INJECTION (FUEL SYSTEMS)

14.Wastegate Control Solenoid 5) Remove the wastegate control solenoid valve

from the bracket
Valve
A: REMOVAL
1) Disconnect the battery ground cable.

B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
2) Remove the solenoid valve cover. 6.4 N.m (0.65 kgf-m, 4.7 ff-lb)
I

I
/ EN0830

3) Disconnect the connector (A) from the waste-

gate control solenoid valve.
4) Disconnect the pressure hoses (B) from the
wastegate control solenoid valve.
I

FU(D0HC TURBO)-41
 FRONT OXYGEN (NF)SENSOR
FUEL INJECTION (FUEL SYSTEMS)

15.Front Oxygen (NF)Sensor 6) Lift-up the vehicle.

7) Remove the service hole cover
A: REMOVAL
1) Disconnect the battery ground cable.

I1 EN0832

8) Apply SUBARU CRC or its equivalent to the

2) Remove the solenoid valve cover
threaded portion of front oxygen (NF)sensor, and
leave it for one minute or more.
SUBARU CRC (Part No. 004301003)
9) Remove the front oxygen (NF)sensor.
CAUTION:
When removing the oxygen (NF)sensor, wait
until exhaust pipe cools, otherwise it will dam-
age exhaust pipe.

3) Disconnect the connector from the front oxygen

(NF)sensor.

4) Disconnect the engine harness fixed by clip (A)

from the bracket (6).

5 ) Remove the front right side wheel.

FU(D0HC TURBO)-42
 FRONT OXYGEN (NF) SENSOR
FUEL INJECTION (FUEL SYSTEMS)

B: INSTALLATION 7) Connect the connector of front oxygen (NF)sen-

sor.
1) Before installing front oxygen (NF)sensor, apply
the anti-seize compound only to the threaded por-
tion of front oxygen (NF)sensor to make the next
removal easier.
Anti-seize compound:
SS-30 by JET LUBE
CAUTION:
Never apply anti-seize compound to protector
of front oxygen (NF) sensor.
2) Install the front oxygen (NF) sensor.
Tightening torque:
8) Install the solenoid valve cover.
21N.m (2.1 kgf-m, 15.2 ff-lb)
I

I I
9) Connect the battery ground cable.
3) Install the service hole cover.

n
4) Lower the vehicle.
5) Install the front right side wheel.
I
EN0832

6) Connect the engine harness with clip (A) to the

bracket (B).

FU(D0HC TURBO)-43
 REAR OXYGEN SENSOR
FUEL INJECTION (FUEL SYSTEMS)

16.Rear Oxygen Sensor 6) Remove the rear oxygen sensor.

CAUTION:
A: REMOVAL When removing the oxygen sensor, wait until
1) Disconnect the battery ground cable. exhaust pipe cools, otherwise it will damage ex-
haust pipe.

2) Lift-up the vehicle.

3) Disconnect the connector from the rear oxygen B: INSTALLATION
sensor.
1) Before installing rear oxygen sensor, apply the
anti-seize compound only to the threaded portion of
rear oxygen sensor to make the next removal eas-
ier.
CAUTION:
Never apply anti-seize compound to protector
of rear oxygen sensor.
Anti-seize compound:
SS-30 by JET LUBE
2) Install the rear oxygen sensor.
Tightening torque:
4) Remove the clip by pulling out from the upper
side of crossmember. 21 N.m (2.1 kgf-m, 15.2 W b )

I I S2M2254

5) Apply SUBARU CRC or its equivalent to the 3) Connect the connector to the rear oxygen sen-
threaded portion of rear oxygen sensor, and leave sor.
it for one minute or more.
SUBARU CRC (Part No. 004301003)

FU(D0HC TURBO)-44
 REAR OXYGEN SENSOR
FUEL INJECTION (FUEL SYSTEMS)

4) Connect the clip to the crossmember.

S2M2254

5) Lower the vehicle.

6) Connect the battery ground cable.

FU(D0HC TURBO)-45
 EXHAUST TEMPERATURE SENSOR
FUEL INJECTION (FUEL SYSTEMS)
17.Exhaust Temperature Sensor
A: REMOVAL
1) Disconnect the battery ground cable.
2) Remove the joint pipe. <Ref. to EX(D0HC TUR-
BO)-12, REMOVAL, Joint Pipe.>
3) Apply SUBARU CRC or its equivalent to the
threaded portion of exhaust temperature sensor,
and leave it for one minute or more.
SUBARU CRC (Part No. 004301003)
4) Remove the exhaust temperature sensor.
CAUTION:
When removing the oxygen sensor, wait until
exhaust pipe cools, otherwise it will damage ex-
haust pipe.
FU(D0HC TURB0)-46
B: INSTALLATION
1) Before installing exhaust temperature sensor,
apply the anti-seize compound only to the threaded
portion of rear oxygen sensor to make the next re-
moval easier.
CAUTION:
Never apply anti-seize compound to protector
of exhaust temperature sensor.
An ti-seize compound:
SS-30 by JET LUBE
2 ) Install the exhaust temperature sensor.
NOTE:
Align the marking (A) of exhaust temperature sen-
sor to the marking (B) of joint pipe, and tighten the
screws.
Tightening torque:
21 N-m (2.1 kgf-m, 15.2 ft-lb)
S2M2255A
3) Install the joint pipe <Ref. to EX(D0HC TURBO)-
12, INSTALLATION, Joint Pipe.>.
4) Connect the battery ground cable.
I
ENGINE CONTROL MODULE
FUEL INJECTION (FUEL SYSTEMS)

18.Engine Control Module B: INSTALLATION

Install in the reverse order of removal.
A: REMOVAL CAUTION:
1) Disconnect the battery ground cable. When replacing ECM, be careful not to use the
wrong spec. ECM to avoid any damage to the
fuel injection system.

2) Remove the lower inner trim of the passenger

side.
<Ref. to El-46, REMOVAL, Lower Inner Trim.>
3) Detach the floor mat of the front passenger seat.
4) Remove the protect cover.

I EN118E

5) Remove the nuts (A) which hold ECM to the

bracket.
6) Remove the clip (B) from the bracket.

7) Disconnect the ECM connectors and take out

the ECM.

FU(DOHC TURB0)-47
 MAIN RELAY
FUEL INJECTION (FUEL SYSTEMS)

19.Main Relay
A: REMOVAL
1) Disconnect the battery ground cable.

2) Remove the passenger’s side front side sill cov-

er.
3) Remove the bolt which holds the main relay
bracket on the body.
4) Disconnect the connectors from the main relay.

B: INSTALLATION
Install in the reverse order of removal.

FU(D0HC TURBO)-48
 FUEL PUMP RELAY
FUEL INJECTION (FUEL SYSTEMS)

2O.Fuel Pump Relay

A: REMOVAL
1) Disconnect the battery ground cable.

2) Remove the passenger’s side front side sill cov-

er.
3) Remove the bolt which holds fuel pump relay
bracket on the body.
4) Disconnect the connector from the fuel pump re-
lay.

5) Remove the fuel pump relay from the mounting

bracket.
B: INSTALLATION
Install in the reverse order of removal.

FU(D0HC TURBO)-49
 FUEL PUMP CONTROLLER
FUEL INJECTION (FUEL SYSTEMS)

21 .Fuel Pump Controller

A: REMOVAL
1) Disconnect the battery ground cable.

2) Remove the rear quarter trim. <Ref. to El-47,

REMOVAL, Rear Quarter Trim.>
3) Disconnect the connector from the fuel pump
control unit.

4) Remove the fuel pump control unit.

B: INSTALLATION
Install in the reverse order of removal.

FU(D0HC TURBO)-50
 FUEL
FUEL INJECTION (FUEL SYSTEMS)

22.Fuel 3) Lift-up the vehicle.

4) Drain the fuel from the fuel tank.
A: OPERATION Set a container under the vehicle and remove drain
plug from the fuel tank.
1. RELEASING OF FUEL PRESSURE
WARNING:
Place “NO FIRE” signs near the working area.
Be careful not to spill fuel on the floor.
1) Disconnect the connector from the fuel pump re-
lay.

5 ) Tighten the fuel drain plug.

Tightening torquer
26 N-m (2.65 kgf-m, 19.2 ff-lb)

2) Start the engine and run it until it stalls.

3) After the engine stalls, crank it for five more sec-
onds.
4) Turn the ignition switch to OFF.
2. DRAINING FUEL
WARNING:
Place “NO FIRE” signs near the working area.
Be careful not to spill fuel on the floor.
1) Set the vehicle on the lift.
2) Disconnect the battery ground cable.

FU(D0HC TURBO)-51
 FUEL TANK
FUEL INJECTION(FUEL SYSTEMS)

23.Fuel Tank 9) Disconnect the connector from the pressure con-

trol solenoid valve.
A: REMOVAL 10) Disconnect the connector from the drain valve.
WARNING:
Place “NO FIRE” signs near the working area.
Be careful not to spill fuel on the floor.
1) Set the vehicle on the lift.
2) Release the fuel pressure. <Ref. to FU(D0HC
TURBO)-51, RELEASING OF FUEL PRESSURE,
OPERATION, Fuel.>
3) Drain the fuel from the fuel tank. <Ref. to
FU(D0HC TURBO)-51, DRAINING FUEL, OPER-
ATION, Fuel.> B2M174:
4) Remove the rear seat.
5) Disconnect the connector (A) of fuel tank cord to 11) Loosen the clamp and disconnect the fuel filler
the rear harness. hose (A) and air vent hose (B) from fuel filler pipe
6) Push the grommet (B) which holds the fuel tank and air vent pipe.
cord on floor panel into under the body.

S2M0193A

12) Move the clips, and disconnect the quick con-

7) Remove the rear crossmember. <Ref. to RS-19, nector. <Ref. to FU(D0HC TURBO)-68, REMOV-
REMOVAL, Rear Crossmember.> AL, Fuel Delivery, Return and Evaporation Lines.>
8) Move the clamp, and disconnect the evaporation 13) Disconnect the fuel hoses.
hose from canister.

\ I I I
S2M0949j

FU(D0HC TURBO)-52
 FUEL TANK
FUEL INJECTION (FUEL SYSTEMS)

14) Support the fuel tank with transmission jack, re-
move the bolts from bands and dismount the fuel
tank from vehicle.
WARNING:
A helper is required to perform this work.
4) Connect the fuel hoses, and hold them with clips
and quick connector. <Ref. to FU(D0HC TURBO)-
69, INSTALLATION, Fuel Delivery, Return and
Evaporation Lines.>

5) Connect the connector to the drain valve.

B: INSTALLATION
1) Support the fuel tank with transmission jack and
push the fuel tank harness into the access hole with
grommet.
2) Set the fuel tank and temporarily tighten the bolts
of fuel tank bands.
WARNING:
A helper is required to perform this work.
02M 1743

6) Connect the connector to the pressure control

solenoid valve.
7) Connect the evaporation hose to the canister,
and hold them with clamp.

3) Connect the fuel filler hose and air vent hose.

\ I / I
S2M0949A

S2M0193A

FU(D0HC TURBO)-53
 FUEL TANK
FUEL INJECTION (FUEL SYSTEMS)

8) Tighten the band mounting bolts. C: INSPECTION

Tightening torque: 1) Make sure there are no cracks, holes, or other
33 N-m (3.4 kgf-m, 25 ft-lb) damage on the fuel tank.
2) Make sure that the fuel hoses and fuel pipes are
not cracked and that connections are tight.

2M2246

9) Install the rear crossmember. <Ref. to RS-19,

INSTALLATION, Rear Crossmember.>
10) Connect the connector (A) to the fuel tank cord
and plug the service hole with gromment (B).

EN053i

11) Set the rear seat and floor mat.

12) Connect the connector to the fuel pump relay.

FU(D0HC TURBO)-54
 FUEL FILLER PIPE
FUEL INJECTION (FUEL SYSTEMS)

24.Fuel Filler Pipe 8) Drain the fuel from fuel tank. Set a container un-
der the vehicle and remove the drain plug from fuel
A: REMOVAL tank.
WARNING:
Place “NO FIRE” signs near the working area.
Be careful not to spill fuel on the floor.
1) Release the fuel pressure. <Ref. to FU(D0HC
TURBO)-51, RELEASING OF FUEL PRESSURE,
OPERATION, Fuel.>
2) Open the fuel filler flap lid and remove the filler
cap.
3) Disconnect the battery ground cable.

9) Tighten the fuel drain plug and then install the

front right side tank cover.
Tightening torque:
26 N-m (2.65 kgf-m, 19.2 ff-lb)

4) Remove the screws holding packing in place.

IO) Remove the fuel filler pipe protector.

’ EN0542

5) Lift-up the vehicle.

6) Remove the rear right side wheel nuts.
7) Remove the rear right side wheel.

EN0544

11) Separate the evaporation hoses from the clip of

fuel filler pipe.

FU(D0HC TURBO)-55
I
FUEL FILLER PIPE
FUEL INJECTION (FUEL SYSTEMS)

12) Disconnect the evaporation hoses from the 17) Remove the air vent pipe together with clip from
pipes. the body.

13) Remove the bolts which hold fuel filler pipe B: INSTA LLATlON
bracket on the body. 1) t Ad the fuel filler flap open.
I
2) Set the fuel saucer (A) -with rubber packing (C)
and insert the fuel filler pipe into the hole from the
inner side of apron.

EN1124

14) Loosen the clamp and separate the fuel filler

hose (A) from fuel filler pipe.
15) Move the clip and separate the evaporation
hose (B).
3) Align the holes in fuel filler pipe neck and set the
cup (B), and tighten the screws.
NOTE:
If edges of rubber packing are folded toward the in-
side, straighten it with a screwdriver.

16) Remove the fuel filler pipe to under side of the

vehicle.

FU(D0HC TURBO)-56
 FUEL FILLER PIPE
FUEL INJECTION (FUEL SYSTEMS)

4) Install the evaporation pipes. 7) Insert the air vent hose approximately 25 to 30
mm (0.98 to 1.18 in) into the lower end of air vent
pipe and hold clip.
L = 27.5e.5 mm (1.083fo.098 in)

5) Connect the evaporation hose to pipes.

L
B2M1195A

(1) Hose
(2) Clip
(3) Pipe

8) Tighten the bolt which holds fuel filler pipe brack-

et on the body.
Tightening torque:
Ill EN1123
7.4 N.m (0.75 kgf-m, 5.4 ft-lb)
6) Insert the fuel filler hose (A) approximately 35 to
40 mm (1.38 to 1.57 in) over the lower end of fuel
filler pipe and tighten the clamp.
CAUTION:
Do not allow clips to touch air vent hose (B) and
rear suspension crossmember.

EN1124

9) Tighten the bolts which hold evaporation hoses

onto the clip of fuel filler pipe.

FU(DOHC TURBO)-57
 FUEL FILLER PIPE
FUEL INJECTION (FUEL SYSTEMS)

10) Install the fuel filler pipe protector. C: DISASSEMBLY

1) Move the clip, and disconnect the evaporation
hose from joint pipe.

EN0544
I

11) Install the rear right wheel.

EN112E

2) Remove the bolt which installs the joint pipe on

fuel filler pipe.

12) Lower the vehicle.

13) Tighten the wheel nuts.
14) Connect the connector to the fuel pump relay.
3) Disconnect the evaporation hose from the fuel
filler pipe.

15) Connect the battery ground terminal.

4) Remove the shut valve from the fuel filler pipe.

<Ref. to EC(D0HC TURBO)-16, REMOVAL, Shut
Valve.>

FU(D0HC TURBO)-58
 FUEL FILLER PIPE
FUEL INJECTION (FUEL SYSTEMS)

D: ASSEMBLY
1) Install the shut valve on the fuel filler pipe. <Ref.
to EC(D0HC TURBO)-16, INSTALLATION, Shut
Valve.>
2) Connect the evaporation hose to the fuel filler
pipe.

3) Connect the evaporation hose to the evaporation

pipe.

4) Install the evaporation pipe to the fuel filler pipe.

FU(D0HC TURBO)-59
 FUEL PUMP
FUEL INJECTION (FUEL SYSTEMS)

25.Fuel Pump 6) Tighten the fuel drain plug.

Tightening torque:
A: REMOVAL 26 N.m (2.65 kgf-m, 19.2 ff-lb)
WARNING:
Place “NO FIRE” signs near the working area.
Be careful not to spill fuel on the floor.
NOTE:
Fuel pump assembly consists of fuel pump and fuel
level sensor.
1) Release the fuel pressure. <Ref. to FU(D0HC
TURBO)-51, RELEASING OF FUEL PRESSURE,
OPERATION, Fuel.>
2) Open the fuel filler flap lid and remove the fuel
filler cap.
3) Disconnect the battery ground cable. 7) Raise the rear seat and turn the floor mat up.
8) Remove the access hole lid.

I I \ \ I I I 1 I

. EN0552
4) Lift-up the vehicle.
5) Drain the fuel from fuel tank. Set a container un- 9) Disconnect the connector from the fuel pump.
der the vehicle and remove the drain plug from fuel
tank.

10) Disconnect the quick connector and then dis-

connect the fuel delivery hose (A). <Ref. to
FU(D0HC TURBO)-68, Fuel Delivery, Return and
Evaporation Lines.>

FU(D0HC TURBO)-60
 FUEL PUMP
FUEL INJECTION (FUEL SYSTEMS)

11) Move the clips, and then disconnect the fuel re-
turn hose (6)and jet pump hose (C).
B: INSTALLATION
Install in the reverse order of removal. Do the fol-
lowing:
(1) Always use new gaskets.
(2) Ensure the sealing portion is free from fuel or
foreign particles before installation.
(3) Tighten the nuts in alphabetical sequence
shown in figure to specified torque.
Tightening torque:
4.4 N.m (0.45 kgf-m, 3.3 ft-lb)

12) Remove the nuts which install the fuel pump

assembly onto fuel tank.

S2M0063A

C: INSPECTION
Connect the lead harness to the connector terminal
of fuel pump and apply battery power supply to
S2M0061 I check whether the pump operate.
13) Take off the fuel pump assembly from the fuel WARNING:
tank. Wipe off the fuel completely.
Keep battery as far apart from fuel pump as
possible.
Be sure to turn the battery supply ON and
OFF on the battery side.
Do not run fuel pump for a long time under
non-load condition.

FU(D0HC TURBO)-61
 FUEL LEVEL SENSOR
FUEL INJECTION (FUEL SYSTEMS)

26.Fuel Level Sensor

A: REMOVAL
WARNING:
Place “NO FIRE” signs near the working area.
Be careful not to spill fuel on the floor.
NOTE:
Fuel level sensor is built in fuel pump assembly.
1) Remove the fuel pump assembly. <Ref. to
FU(D0HC TURBO)-60, REMOVAL, Fuel Pump.>
2) Disconnect the connector from the fuel pump
bracket.

3) Remove the bolt which installs the fuel level sen-

sor on mounting bracket.

B: INSTALLATION
Install in the reverse order of removal.

FU(D0HC TURBO)-62
 FUEL SUB LEVEL SENSOR
FUEL INJECTION (FUEL SYSTEMS)

27.Fuel Sub Level Sensor 6) Remove the service hole cover.

A: REMOVAL
WARNING:
Place “NO FIRE” signs near the working area.
Be careful not to spill fuel on the floor.
1) Disconnect the battery ground cable.

/ G2M0863

7 ) Disconnect the connector from the fuel sub

meter.
8) Disconnect the fuel jet pump hose.

2) Lift-up the vehicle.

3) Drain the fuel from the fuel tank. Set a container
under the vehicle and remove drain plug from fuel
tank.

// / S2M0151

9) Remove the bolts which install the fuel sub meter

unit on fuel tank.

4) Tighten the fuel drain plug.

Tightening torque:
26 N.m (2.65 kgf-m, 79.2 ft-lb)

10) Remove the fuel sub meter unit.

5) Remove the rear seat.

FU(D0HC TURBO)-63
 FUEL SUB LEVEL SENSOR
FUEL INJECTION(FUEL SYSTEMS)

B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
4.4 N-m (0.45 kgf-m, 3.3 ff-lb)

FU(D0HC TURBO)-64
 FUEL FILTER
FUEL INJECTION (FUEL SYSTEMS)

28. Fuel Filter

A: REMOVAL
WARNING:
Place “NO FIRE” signs near the working area.
Be careful not to spill fuel on the floor.
1) Release the fuel pressure. <Ref. to FU(D0HC
TURBO)-51, RELEASING OF FUEL PRESSURE,
OPERATION, Fuel.>
2) Disconnect the fuel delivery hoses from the fuel
filter.

3) Remove the filter from the holder.

B: INSTALLATION
CAUTION:
If fuel hoses are damaged at the connecting
portion, replace it with a new one.
If clamps are badly damaged, replace with
new ones.
1) Install in the reverse order of removal.
2) Tighten the hose clamp screws.
Tightening torque:
1.25 Nom(0.13 kgf-m, 0.94 ft-lb)

17

C: INSPECTION
1) Check the inside of fuel filter for dirt and water
sediment.
2) If it is clogged, or if replacement interval has
been reached, replace it.
3) If water is found in it, shake and expel the water
from the inlet port.

FU(D0HC TURBO)-65
 FUEL CUT VALVE
FUEL INJECTION(FUEL SYSTEMS)

29.Fuel Cut Valve

A: REMOVAL
1) Remove the fuel tank. <Ref. to FU(D0HC TUR-
BO)-52, REMOVAL, Fuel Tank.>
2) Remove the protect cover.

I EN105C

3) Move the clip and disconnect the evaporation

hose from fuel cut valve.

I EN1131 I
4) Remove the bolts which install the fuel cut valve.
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
4.4 N-m (0.45 kgf-m, 3.3 fWb)

EN1132

FU(DOHC TURB0)-66
 FUEL DAMPER VALVE
FUEL INJECTION (FUEL SYSTEMS)

30.Fuel Damper Valve

A: REMOVAL
1) Release the fuel pressure. <Ref. to FU(D0HC
TURBO)-51, RELEASING OF FUEL PRESSURE,
OPERATION, Fuel.>
2) Remove the fuel damper valve from the fuel re-
turn line.

B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
1.25 N.m (0.13 kgf-m, 0.94 ft-lb)

FU(D0HC TURBO)-67
 FUEL DELIVERY, RETURN AND EVAPORATION LINES
FUEL INJECTION (FUEL SYSTEMS)

31 .Fuel Delivery, Return and
Evaporation Lines
A: REMOVAL
1) Set the vehicle on the lift.
2) Release the fuel pressure. <Ref. to FU(D0HC
TURBO)-51, RELEASING OF FUEL PRESSURE,
OPERATION, Fuel.>
3) Open the fuel filler flap lid and remove the fuel
filler cap.
4) Remove the floor mat. <Ref. to El-55, REMOV-
AL, Floor Mat.>
5) Remove the fuel delivery pipes and hoses, fuel
return pipes and hoses, evaporation pipes and hos-

EN1133

6) In engine compartment, detach the fuel delivery

hoses, return hoses and evaporation hose.

7) Lift-up the vehicle.

FU(D0HC TURBO)-68
 FUEL DELIVERY, RETURN AND EVAPORATION LINES
FUEL INJECTION (FUEL SYSTEMS)

8) Separate the quick connector on the fuel delivery (1) Set the new retainer (B) to connector (A).
and return line. (2) Push the pipe into the connector completely.
(1) Clean the pipe and connector, if they are NOTE:
covered with dust. At this time, two clicking sounds are heard.
(2) Hold the connector (A) and push retainer (B)
down.
(3) Pull out the connector (A) from retainer (B).
CAUTION:
Replace retainer with new ones.
(C)
I

S2M0230E

(C) (A) Connector

(B) Retainer
(C) Pipe
S2M0228P
CAUTION:
(A) Connector Pull the connector t o ensure it is connected
(6) Retainer securely.
(C) Pipe Ensure the two retainer pawls are engaged in
their mating positions in the connector.
B: INSTALLATION Be sure to inspect hoses and their connec-
1) Connect the quick connector on the fuel delivery tions for any leakage of fuel.
line.
CAUTION:
Always use a new retainer.
Make sure that the connected portion is not
damaged or has dust. If necessary, clean seal
surface of pipe.

(A) Connector
(6) Retainer
(C) Pipe

I S2M0229f

FU(D0HC TURBO)-69
 FUEL DELIVERY, RETURN AND EVAPORATION LINES
FUEL INJECTION (FUEL SYSTEMS)

2) Connect the fuel delivery hose to the pipe with an C: INSPECTION

overlap of 20 to 25 mm (0.79 to 0.98 in).
Type A: When the fitting length is specified.
Type B: When the fitting length is not specified.
Q :2.5H.5 mm (0.098-M.059 in)
L: 22.5f2.5 mm (0.886M.098in)
1) Make sure that there are no cracks on the fuel
pipes and fuel hoses.
2) Make sure that the fuel pipe and fuel hose con-
nections are tight.

*Y B2M1194B

(1) Fitting
(2) Clamp
(3) Hose

3) Connect the return hose and evaporation hose

to the pipe by approx. 15 mm (0.59 in) from the
hose end.
Fuel return hose:
L = 22.532.5 mm (0.885-M.098 in)
Fuel evaporation hose:
L = 17.5f2.5 mm (0.689M.098 in)
CAUTION:
Be sure to inspect hoses and their connections
for any leakage of fuel.
I

B2M1195A

(1) Hose
(2) Clip
(3) Pipe

FU(D0HC TURBO)-7O
 FUEL SYSTEM TROUBLE IN GENERAL
FUEL INJECTION (FUEL SYSTEMS)

32.Fuel System Trouble in Gen-

eral
A: INSPECTION
Trouble and possible cause 1 Corrective action
1. Insufficient fuel supply to the injector
1) Fuel pump will not operate.
Inspect connections, especially ground, and tighten
0 Defective terminal contact.
securely.
0 Trouble in electromaanetic 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) Damaaed diaphraam of pressure reaulator. Replace.
2.Fakacle or blow out fuel
1) 1 I Loosened joints of the fuel pipe. I Retightening.
2) I I Cracked fuel pipe, hose and fuel tank. I 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

1)
2) I
I
1 I
1
Loose joints at air breather tube, air vent tube and fuel
filler Dioe.
I .

I Defective Dackina air tiahtness on the fuel saucer.

I
Retightening,
1 Correct or replace packina.
3) 1- I Cracked fuel separator. I Replace separator.
4) 1 I Inoperative fuel pump modulator or circuit. I Replace.
4. Defective fuel meter indicator
1) Defective operation of fuel level sensor. Replace.
2) Defective operation of fuel meter. Replace.

1-
~~
I r I Larae operation noise or vibration of fuel pump. 1 Replace.
NOTE: ing system. Refueling will also complement the
When the vehicle is left unattended for an ex- effect of anti-freeze solution each time the fuel
tended period of time, water may accumulate in the level drops to about one-half. After the winter
fuel tank. season, drain the water which may have accu-
To prevent water condensation. mulated 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 the water condensation from the fuel (4) Affected areas
filter. When the water condensation is notched in the
Refilling the fuel tank. fuel filter, drain the water from both the fuel filter
Refill the fuel tank while there is still some fuel left in and fuel tank or use a water removing agent (or
the tank. anti-freeze solution) in the fuel tank.
Protecting the fuel system against freezing and Observe the instructions, notes, etc., indicated
water condensation. on the label affixed to the anti-freeze solution (wa-
(3) Cold areas ter removing agent) container before use.
In snow-covered areas, mountainous areas, ski-
ing areas, etc. where ambient temperatures
drop below 0°C (32°F) throughout the winter
season, use an anti-freeze solution in the cool-

FU(D0HC TURBO)-71
 FUEL SYSTEM TROUBLE IN GENERAL
FUEL INJECTION (FUEL SYSTEMS)

FU(D0HC TURBO)-72
EMISSION CONTROL
(AUX
. . EMISSION CONTROL DEVICES)
EC(D0HC TURBO)m
Page
1. General Description .................................................................................... 2
2. Front Catalytic Converter ............................................................................ 3
3. Rear Catalytic Converter ............................................................................. 4
4. Precatalytic Converter ................................................................................. 5
5. Canister ....................................................................................................... 6
6. Purge Control Solenoid Valve ..................................................................... 7
7. Main Fuel Level Sensor .............................................................................. 8
8. Fuel Temperature Sensor ........................................................................... 9
9. Fuel Sub Level Sensor .............................................................................. IO
10. Fuel Tank Pressure Sensor ...................................................................... 11
11. Pressure Control Solenoid Valve .............................................................. 12
12. Drain Filter................................................................................................. 14
13. Vent Valve ................................................................................................. 15
14. Shut Valve ................................................................................................. 16
15. Drain Valve ................................................................................................ 17
 GENERAL DESCRIPTION
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

1. General Description
A: CAUTION
Wear working clothing, including a cap, protec-
tive goggles, and protective shoes during opera-
tion.
Remove contamination including dirt and corro-
sion before removal, installation or disassembly.
Keep the disassembled parts in order and pro-
tect them from dust or dirt.
Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary re-
moval, installation, disassembly, and replacement.
Be careful not to burn your hands, because each
part on the vehicle is hot after running.
Be sure to tighten fasteners including bolts and
nuts to the specified torque.
Place shop jacks or safety stands at the specified
points.
Before disconnecting electrical connectors of
sensors or units, be sure to disconnect the negative
terminal from battery.

EC(D0HC TURBO)-2
I a
FRONT CATALYTIC CONVERTER
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

2. Front Catalytic Converter

A: REMOVAL
1) Remove the center exhaust pipe. <Ref. to
EX(D0HC TURBO)-8, REMOVAL, Center Exhaust
Pipe.>
2) Separate the front catalytic converter (A) from
rear catalytic converter (B).

EN099:

B: INSTALLATION
NOTE:
Replace the gaskets with new ones.
Install in the reverse order of removal.
C: INSPECTION
1) Make sure there are no exhaust leaks from con-
nections and welds.
2) Make sure there are no holes or rusting.

EC(D0HC TURBO)-3
I REAR CATALYTIC CONVERTER
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

3. Rear Catalytic Converter

A: REMOVAL
1) Remove the center exhaust pipe. <Ref. to
EX(D0HC TURBO)-8, REMOVAL, Center Exhaust
Pipe.>
2) Separate the rear catalytic converter (B) from
front catalytic converter (A).

I EN0993

B: INSTALLATION
NOTE:
Replace the gaskets with new ones.
Install in the reverse order of removal.
C: INSPECTION
1) Make sure there are no exhaust leaks from con-
nections and welds.
2) Make sure there are no holes or rusting.

EC(D0HC TURBO)-4
 PRECATALYTIC CONVERTER
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

4. Precatalytic Converter
A: REMOVAL
Precatalytic converter (A) is built in the joint pipe.
Refer to the removal of joint pipe for removal
procedure. <Ref. to EX(D0HC TURBO)-12, RE-
MOVAL, Joint Pipe.>

EN0991

B: INSTALLATION
Precatalytic converter is built in the joint pipe. Refer
to the installation of joint pipe for installation proce-
dure. <Ref. to EX(D0HC TURBO)-12, INSTALLA-
TION, Joint Pipe.>
C: INSPECTION
1) Make sure there are no exhaust leaks from con-
nections and welds.
2) Make sure there are no holes or rusting.

EC(D0HC TURBO)-5
 CANISTER
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

5. Canister C: INSPECTION
Make sure the canister and canister hoses are not
A: REMOVAL cracked or loose.
1) Lift-up the vehicle.
2) Loosen the two clamps which hold two canister
hoses, and disconnect the evaporation three hoses
from canister

\ I I / S2M0950
3) Remove the canister from body.

B: INSTALLATION
1) Install in the reverse order of removal.
Tightening torque:
23 N.m (2.3 kgf-m, 17 ff-lb)

EC(D0HC TURBO)-6
 PURGE CONTROL SOLENOID VALVE
31
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

6. Purge Control Solenoid Valve B: INSTALLATION

Install in the reverse order of removal.
A: REMOVAL
1) Disconnect the ground terminal from battery.
Tightening torque:
76 N.m (7.6 kgf-m, 7 7.6 ft-16)

9 EN0899
2) Disconnect the connector and hoses from purge
control solenoid valve. CAUTION:
3) Remove the bolt which installs the purge control Carefully connect the evaporation hoses.
solenoid valve onto intake manifold.

EN0899
(A) To intake manifold
(B) To purge value

C: INSPECTION
Make sure the hoses are not cracked or loose.

EC(D0HC TURBO)-7
 MAIN FUEL LEVEL SENSOR
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

7. Main Fuel Level Sensor

A: REMOVAL
For work procedures, refer to “FU” section. <Ref. to
FU(D0HC TURBO)-62, REMOVAL, Fuel Level
Sensor.>
B: INSTALLATION
For work procedures, refer to “FU” section.
<Ref. to FU(D0HC TURBO)-62, INSTALLATION,
Fuel Level Sensor.>

EC(D0HC TURBO)-8
I
FUEL TEMPERATURE SENSOR
a
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

8. Fuel Temperature Sensor B: INSTALLATION

Install in the reverse order of removal.
A: REMOVAL WARNING:
'1 Remove the fuel pump <Ref. to Spark may occur and ignite if fuel is nearby.
FU(D0HC TURBO)-60, REMOVAL, Fuel Pump.>
2) Disconnect the connector from fuel pump brack-
et.

3) Remove the main fuel level sensor from fuel

pump assembly. <Ref. to FU(D0HC TURBO)-62,
REMOVAL, Fuel Level Sensor.>

S2M085E

NOTE:
Fuel temperature sensor is a unit with the fuel
pump. If replacing it, replace as a fuel pump.

EC(D0HC TURBO)-9
 la
FUEL SUB LEVEL SENSOR
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

9. Fuel Sub Level Sensor

A: REMOVAL
For work procedures, refer to “FU(D0HC TURBO)”
section. <Ref. to FU(D0HC TURBO)-63, REMOV-
AL, Fuel Sub Level Sensor.>
B: INSTALLATION
For work procedures, refer to “FU(D0HC TURBO)’’
section. <Ref. to FU(D0HC TURBO)-64, INSTAL-
LATION, Fuel Sub Level Sensor.>

EC(D0HC TURBO)-IO
 FUEL TANK PRESSURE SENSOR
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

10.Fuel Tank Pressure Sensor 6) Disconnect the pressure hose from fuel tank
pressure sensor.
A: REMOVAL
1) Remove the fuel tank. <Ref. to FU(D0HC TUR-
BO)-52, REMOVAL, Fuel Tank.>
2) Remove the protector cover.

G3 B2M1779

B: INSTALLATION
Install in the reverse order of removal.
EN10% Tightening torque:
3) Disconnect the connector from fuel pressure
7.4 N-m (0.75 kgf-m, 5.4 ft-lb)
sensor, then remove the fixing nut.

C: INSPECTION
4) Release the clips which hold fuel pipes onto fuel Make sure the hoses are not cracked or loose.
tank.

I Clip EN1052 I
5) Remove the clip, and disconnect pressure hose
from fuel tank.

EC(D0HC TURBO)-I 1
 PRESSURE CONTROL SOLENOID VALVE
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

11.Pressure Control Solenoid 5 ) Disconnect the connector from pressure control

solenoid valve.
Valve
A: REMOVAL
1) Disconnect the ground terminal from battery.

6) Disconnect the two evaporation hoses from

pressure control solenoid valve.
7) Remove the pressure control solenoid valve with
bracket.
2) Remove the canister. <Ref. to EC(D0HC TUR-
BO)-6, REMOVAL, Canister.>
3) Disconnect the evaporation hoses (A) from joint
pipes.

8) Remove the pressure control solenoid valve

from bracket.

4) Remove the bolt which installs pressure control

solenoid valve holding bracket on body.
>

I B2M1786 I

9) Disconnect the vacuum hose from pressure con-

trol solenoid valve.

EC(D0HC TURBO)-I 2
 PRESSURE CONTROL SOLENOID VALVE
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
17.6 N.m (1.8 kgf-m, 13.0 R-lb)

C: INSPECTION
Make sure the hoses are not cracked or loose.

EC(D0HC TURBO)-13
 DRAIN FILTER
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

12.Drain Filter 6) Remove the bolt which installs the drain filter and
drain valve brackets on body, and remove them as
A: REMOVAL a unit.
1) Disconnect the ground terminal from battery.

7) Disconnect the evaporation hoses, and remove

2) Lift-up the vehicle. the drain filter.
3) Remove the canister. <Ref. to EC(D0HC TUR-
BO)-6, REMOVAL, Canister.>
4) Disconnect the connector from drain valve.

I B2M 1791C

/
B: INSTALLATION
Install in the reverse order of removal.
0 H2M3611
Tightening torque:
5) Disconnector the evaporation hoses (A) from
23 N-m (2.3 kgf-m, 17 ff-lb)
joint pipes.

C: INSPECTION
1) Make sure all hoses are installed correctly.
2) Make sure the hoses are not cracked or loose.

EC(D0HC TURBO)-14
 VENT VALVE
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

13.Vent Valve B: INSTALLATION

A: REMOVAL
1) Remove the fuel tank. <Ref. to FU(D0HC TUR-
BO)-52, REMOVAL, Fuel Tank.>
2) Remove the protector cover.
Install in the reverse order of removal.
CAUTION:
Replace the rubber seat with a new one.
Tightening torque:
T: 4.4 N.m (0.45 kgf-m, 3.3 ft-lb)

I EN1050 I

3) Remove the clips, and disconnect the hoses

from vent valve. C: INSPECTION
Make sure the hoses are not cracked or loose.

4) Remove the nuts which install the vent on fuel

tank.

-I

EC(D0HC TURBO)-15
 SHUT VALVE
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)
14.Shut Valve B: INSTALLATION
Install in the reverse order of removal.
A: REMOVAL
1) Disconnect the ground terminal from battery. Tightening torque:
4.5 N.m (0.46 kgf-m, 3.3 ft-lb)

EN1 5E
I -
-
2) Drain fuel from the fuel tank. <Ref. to FU(D0HC
TURBO)-52, REMOVAL, Fuel Tank.> C: INSPECTION
3) Remove the fuel filler pipe. <Ref. to FU(D0HC Make sure the hoses are not cracked or loose.
TURBO)-55, REMOVAL, Fuel Filler Pipe.>
4) Disconnect the evaporation hoses from shut
valve.

EN1057

5 ) Remove the shut valve from fuel filler pipe.

I I
EN105.5

EC(D0HC TURBO)-16
 m
DRAIN VALVE
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

15.Drain Valve 6) Remove the bolt which installs the drain filter and
drain valve brackets on body, and remove them as
A: REMOVAL a unit.
1) Disconnect the ground terminal from battery.

7) Remove the drain valve from bracket.

2) Lift-up the vehicle.
3) Remove the canister. <Ref. to EC(D0HC TUR-
BO)-6, REMOVAL, Canister.>
4) Disconnect the connector from drain valve.

EN1055

B: INSTALLATION
/
Install in the reverse order of removal.
0 0- H2M3611 Tightening torque:
5) Disconnect the evaporation hoses from drain
23 N-m (2.3 kgf-m, 17 ft-16)
valve.

EN1055

------- H2M3612AI C: INSPECTION

1) Make sure all hoses are installed correctly.
2) Make sure the hoses are not cracked or loose.

EC(D0HC TURBO)-17
 DRAIN VALVE
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

EC(D0HC TURBO)-18
INTAKE (INDUCTION)

IN(D0HC TURBO)
Page
1. General Description .................................................................................... 2
2. Air Cleaner .................................................................................................. 7
3. Air Intake Duct............................................................................................. 8
4. Intake Duct .................................................................................................. 9
5. Intercooler ................................................................................................. 10
6. Turbocharger............................................................................................. 12
7. Air By-pass Valve ...................................................................................... 14
 GENERAL DESCRIPTION
INTAKE (INDUCTION)

1. General Description
A: COMPONENT
1. AIR CLEANER

EN117E

(1) Mass air flow sensor (8) Cushion rubber Tightening torque: N.m (kgf-m, ft-lb)
(2) Air cleaner upper cover (9) Air intake duct T1: 7.5 (0.76, 5.5)
(3) Air cleaner element (10 ) Resonator chamber ASSY T2: 33 (3.4,25)
(4) Spacer (1 1) Cushion rubber T3: Z.s(O.25, 1.8)
(5) Bush (12) Clamp T4: 1.7(0.17, 1.2)
(6) Clip (13) Air intake boot
(7) Air cleaner lower case (14) Cushion

IN(D0HC TURBO)-2
 GENERAL DESCRIPTION
INTAKE (INDUCTION)

2. INTAKE DUCT

EN1114

(1) Clamp (5) Air by-pass hose D Tightening torque: N.m (kgf-m, ft-lb)
(2) PCV hose ASSY (6) Intake duct T l : l S ( 1 . 6 , 11.7)
(3) Air by-pass hose B (7) Clamp
(4) Air by-pass hose C

IN(D0HC TURBO)-3
I
GENERAL DESCRIPTION
INTAKE (INDUCTION)

3. INTERCOOLER

. /
GL
/
\

EN090,

(1) Intercooler (7) Gasket (13) Clamp

(2) Intercooler bracket RH (8) Clamp
(3) Intercooler bracket LH (9) Air by-pass hose A Tightening torque: N.m (kgf-m, ft-lb)
(4) Clamp (IO) Intercooler duct A T1: 3 (0.22, 1.6)
(5) Air intake duct (11) Intercooler duct B T2: 16 (1.6, 11.71
(6) Air by-pass valve (12) Intercooler duct C

IN(D0HC TURBO)-4
 GENERAL DESCRIPTION
INTAKE (INDUCTION)

4. TURBOCHARGER

-
I /
&.-I

EN111E

(1) Oil inlet pipe (8) Oil outlet pipe Tightening torque: N.m (kgf-m, ft-lb)
(2) Metal gasket (9) Clip T l : 4.4 (0.45, 3.3)
(3) Turbocharger (10) Oil outlet hose T2: 4.9 (0.50, 3.6)
(4) Water pipe (1 1) Turbocharger bracket RH T3: 29 (3.0, 21.7)
(5) Clamp (12) Turbocharger bracket LH T4: 30 (3.1,22.4)
(6) Engine coolant hose T5: 33 (3.4,24.6)
(7) Gasket T6: lS(1.6, 11.7)

IN(D0HC TURBO)-5
 GENERAL DESCRIPTION
INTAKE (INDUCTION)

B: CAUTION
Wear working clothing, including a cap, protec-
tive goggles, and protective shoes during opera-
tion.
Remove contamination including dirt and corro-
sion before removal, installation or disassembly.
Keep the disassembled parts in order and pro-
tect them from dust or dirt.
Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary re-
moval, installation, disassembly, and replacement.
Be careful not to burn your hands, because each
part on the vehicle is hot after running.
Be sure to tighten fasteners including bolts and
nuts to the specified torque.
Place shop jacks or safety stands at the specified
points.
Before disconnecting electrical connectors of
sensor or units, be sure to disconnect negative ter-
minal from battery.

IN(D0HC TURBO)-6
 AIR CLEANER
INTAKE (INDUCTION)

2. Air Cleaner 7) Remove the air cleaner lower case.

A: REMOVAL
1) Disconnect the ground terminal from battery.

B: INSTALLATION
Install in the reverse order of removal.

2) Disconnect the connector from mass air flow

Tightening torque:
sensor. 33 N.m (3.4 kgf-m, 25 ft-lb)
I

3) Loosen the clamp (A) which connects air intake CAUTION:

boot to intake duct. Before installing the air cleaner upper cover,
4) Remove the two clips (B) from air cleaner upper align holes with protruding portions of air
cover. cleaner lower case, then secure the upper cov-
er to lower case.

5) Remove the air cleaner upper cover.

6) Remove the air cleaner element. C: INSPECTION
Replace if excessively damaged or dirty.

IN(D0HC TURBO)-7
 AIR INTAKE DUCT
INTAKE (INDUCTION)

3. Air Intake Duct

A: REMOVAL
1) Remove the bolts which install air intake duct on
the front side of body.

B: INSTALLATION
Install in the reverse order of removal.
C: INSPECTION
1) Inspect for cracks and loose connections.
2) Inspect that no foreign objects are mixed in the
air intake duct.

IN(D0HC TURBO)-8
 INTAKE DUCT
INTAKE (INDUCTION)

4. Intake Duct
A: REMOVAL
1) Disconnect the ground terminal from battery.

2) Remove the intake manifold. <Ref. to FU(D0HC

TURBO)-15, REMOVAL, Intake Manifold.>
3) Remove the sensor, engine harness, and fuel
pipe attached to the intake manifold. <Ref. to
FU(D0HC TURBO)-21, DISASSEMBLY, Intake
Manifold.>
4) Remove the intake duct from intake manifold.

ENIll!

B: INSTALLATION
Install in the reverse order of removal.

IN(D0HC TURBO)-9
I INTERCOOLER
INTAKE (INDUCTION)

5. Intercooler 5 ) Separate the intercooler from throttle body.

A: REMOVAL
1) Disconnect the air by-pass hoses from intercool-
er.

2) Separate the air by-pass valve from intercooler.

3) Remove the bolts which secure intercooler to

bracket.

4) Separate the intercooler air duct from turbo-

charger.

IN(D0HC TURBO)-10
 INTERCOOLER
INTAKE (INDUCTION)

B: INSTALLATION C: DISASSEMBLY
Install in the reverse order of removal. 1) Loosen the clamps, then remove intercooler
duct.
Tightening torque:
16 N-m (1.6 kgf-m, 11.7 ff-lb)

MI884

2) Remove the intercooler ducts from intercooler.

r

D: ASSEMBLY
'M

Assemble in the reverse order of disassembly.

Tightening torque:
16 N-m (1.6 kgf-m, 11.7 ff-lb)
1

IN(D0HC TUR 30)-I 1

 TURBOCHARGER
INTAKE (INDUCTION)

6. Turbocharger 7) Loosen the clamp which secures turbocharger to

air inlet duct.
A: REMOVAL
1) Set the vehicle on the lift.
2) Disconnect the ground terminal from battery.

8) Remove the bolt which secures bracket of oil

pipe to turbocharger.
9) Remove the oil pipe from turbocharger.
3) Remove the center exhaust pipe. <Ref. to
EX(D0HC TURBO)-8, REMOVAL, Center Exhaust
Pipe.>
4) Lower the vehicle.
5) Separate the turbocharger joint pipe from turbo-
charger.

10) Remove the turbocharger bracket.

6) Disconnect the engine coolant hose which is

connected to coolant filler tank.

11) Disconnect the oil outlet hose from pipe.

12) Take out the turbocharger from engine com-

partment.

IN(D0HC TURBO)-12
 TURBOCHARGER
INTAKE (INDUCTION)

B: INSTALLATION 5 ) Install the turbocharger bracket.

1) Connect the oil outlet hose to outlet pipe.

6) Connect the engine coolant hose which is con-

nected to coolant filler tank.
2) Install the turbocharger to air intake duct.

I .
7) Lift-up the vehicle.
3) Install the oil pipe to turbocharger
8) Install the center exhaust pipe. <Ref. to
EX(D0HC TURBO)-9, INSTALLATION, Center
Exhaust Pipe.>

/ II /ENOW:

4) Install the joint pipe to turbocharger.

NOTE:
Replace the gasket with a new one.
Tightening torque:
30 N.m (3.1 kgf-m, 22.4 ft-lb)

I EN0911

IN(D0HC TURBO)-I 3
 AIR BY-PASS VALVE
INTAKE (INDUCTION)

7. Air By-pass Valve B: INSTALLATION

Install in the reverse order of removal.
A: REMOVAL
1) Remove the air by-pass valve from intercooler. Tightening torque:
76 N*m (7.6 kgf-m, 7 7.7 fi-lb)

2) Disconnect the air by-pass hoses from air by-

pass valve.

IN(D0HC TURBO)-14
MECHANICAL

ME(D0HC TURBO)
1. General Description .................................................................................... 2
2. Compression ............................................................................................. 22
3. Idle Speed ................................................................................................. 23
4. Ignition Timing ........................................................................................... 24
5. Intake Manifold Vacuum ............................................................................ 25
6. Engine Oil Pressure .................................................................................. 26
7. Fuel Pressure ............................................................................................ 27
8. Valve Clearance ........................................................................................ 28
9. Engine Assembly ...................................................................................... 33
10. Engine Mounting ....................................................................................... 42
11. Preparation for Overhaul ........................................................................... 43
12. V-belt ......................................................................................................... 44
13. Crankshaft Pulley ...................................................................................... 46
14. Belt Cover ................................................................................................. 47
15. Timing Belt Assembly ................................................................................ 48
16. Camshaft Sprocket.................................................................................... 57
17. Crankshaft Sprocket.................................................................................. 58
18. Camshaft ................................................................................................... 59
19. Cylinder Head Assembly ........................................................................... 64
20 . Cylinder Block ........................................................................................... 72
21 . Engine Trouble in General ........................................................................ 91
22 . Engine Noise ............................................................................................. 96
 GENERAL DESCRIPTION
MECHANICAL

1. General Description
A: SPECIFICATIONS
Horizontally opposed, liquid cooled, 4-cylinder,
Type 4-stroke aasoline enaine
Valve arrangement I Belt driven, double overhead camshaft, 4-valve/cvlinder
Bore x Stroke mm (in) I 92 x 75 (3.62 x 2.95)
Piston displacement cm3 (cu in\ I 1.994 (1 21.67)
Compression ratio 8.0
Compression pres-
sure (at 200 - 300 kPa (kgf/cm2, psi) 981 - 1,177 (10- 12, 142- 171)
rPm)
Number of piston rings Pressure ring: 2, Oil ring: 1
Opening 10" BTDC
Engine intake valve timing
Closing 50" ABDC
Opening 53" BBDC
Exhaust valve timing
Closing 7" ATDC

Valve clearance
Intake mm (in) I 0.20f0.02 (0.0079kO.0008)
Exhaust mm (in) I 0.25+0.02 (0.0098kO,0008)
750k100 (No load)
MT
800k150 (NC switch ON)
Idling speed [At neutral position] rPm
750k100 (No load)
AT
825k150 (NC switch ON)
Firing order 1+ 3 + 2 3 4
Ignition timing BTDC/rpm 12"k3"/750 rpm

ME(D0HC TURBO)-2
 GENERAL DESCRIPTION
MECHANICAL

NOTE:
STD: Standard I.D.: Inner Diameter O.D.: Outer Diameter OS: Oversize US: Undersize

%It ten-
;ion Protrusion of adjuster rod 5.2 - 6.2 mm (0.205 - 0.244 in)
idjuster
Spacer O.D. 17.955 - 17.975 mm (0.7069 - 0.7077 in)
Tensioner bush I.D. 18.0 - 18.08 mm (0.7087 - 0.71 18 in)
3elt ten- STD 0.025 - 0.125 mm (0.0010 - 0.0049 in)
Clearance between spacer and bush
jioner Limit 0.175 mm (0.0069 in)
STD 0.2 - 0.55 mm (0.0079 - 0.0217 in)
Side clearance of spacer
Limit 0.81 mm (0.0319 in)
Bend limit 0.020 mm (0.0079 in)
I STD 0.015 - 0.070 mm (0.0006 - 0.0028 in)
Thrust clearance

I STD 46.25 - 46.35 mm (1.821 - 1.825 in)

Intake
I Limit
I

46.15 mm (1.817 in)

Cam lobe height
STD 46.1 5 - 46.25 mm (1.817 - 1.821 in)
Camshaft Exhaust
Limit 46.05 mm (1.813 in)
Front 37.946 - 37.963 mm (1.4939 - 1.4946 in)
Jounal O.D. STD Center 29.946-29.963" (1.1790-1.1796 in)
rear

Oil clearance
I STD 0.037 - 0.072 mm (0.0015 - 0.0028 in)
I Limit 0.10 mm (0.0039 in)
Surface warpage limit 0.05 mm (0.0020 in)
Cylinder 0.3 mm (0.012 in)
Surface grinding limit
head
Standard height 127.5 mm (5.02 in)
Refacing angle 90"
STD 1.O mm (0.039 in)
Intake Limit
Valve seat I .7 mm (0.067 in)
Contacting width
STD 1.5 mm (0.059 in)
Exhaust
Limit 2.2 mm (0.087 in)
Inner diameter 6.000 - 6.012 mm (0.2362 - 0.2367 in)
Valve guide
Protrusion above head 12.0 - 12.4 mm (0.472 - 0.488 in)
. .
Intake
I STD 1.2 mm (0.047 in)
Limit 0.8 mm (0.031 in)
Head edge thickness
STD 1.5 mm (0.059 in)
Exhaust
Limit 0.8 mm (0.031 in)
I Intake 5.950 - 5.965 mm (0.2343 - 0.2348 in)
Valve
Stem diameter
I Exhaust
I
I 5.945 - 5.960 "(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 104.4 mm (4.1 10 in)
Overall length
Exhaust 104.7 mm (4.122 in)
Free length 44.67 mm (1.7587 in)
Valve Squareness 2.5", 2.0 mm (0.079 in)
spring 220.7k15.7 N (22.5k1.6 kgf, 49.6f3.5 lb)/36.0 mm (1.417 in)
Tensionlspring height
510.9k25.5 N (52.1k2.6 kgf, 114.9k5.7 lb)/26.6 mm (1.0.47 in

ME(D0HC TURBO)-3
 GENERAL DESCRIPTION
MECHANICAL

Surface warpage limit (mating with cylinder head) I 0.05 mm (0.0020 in)
Surface grinding limit I 0.1 mm (0.004 in)
A 92.005 - 92.015 mm (3.6222 - 3.6226 in)
Cylinder bore STD
I
B 91.995 - 92.005 mm (3.6218 - 3.6222 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 - 0.001 2 in)
Limit 0.050 mm (0.0020 in)
Enlaraina (borina) limit 0.5 mm (0.020 in)

STD
IA I 91.985 - 91.995 mm (3.6214 - 3.6218 in)
IB I 91.975 - 91.985 mm (3.621 1 - 3.6214 in)
0.25 mm (0.0098 in)
Piston Outer diameter 92.225 - 92.235 mm (3.6309 - 3.6313 in)
os
0.50 mm (0.0197 in)
92.475 - 92.485 mm (3.6407 - 3.6411 in)
os
Standard clearance between piston STD 0.004 - 0.008 mm (0.0002 - 0.0003 in)
pin and hole in piston Limit 0.020 mm (0.0008 in)
Piston pin
Degree of fit

STD 0.20 - 0.35 mm (0.0079 - 0.0138 in)

Top ring
Limit I 1.O mm (0.039 in)

Piston ring gap

Second STD I 0.35 - 0.50mm (0.0138 - 0.0197 in)
ring Limit 1.O 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)
STD 1 0.040 - 0.080 mm (0.0016 - 0.0031 in)
Clearance between piston Top ring
ring and piston ring
Limit I 0.15 mm (0.0059 in)
groove Second STD I 0.030 - 0.070 mm (0.0012 - 0.0028 in)
ring Limit I 0.15 mm (0.0059 in)

Connecting
Bend twist per 100 mm (3. 4 in) in
lenath
Limit I 0.10 mm (0.0039 in)

rod STD I 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 0.05mm (0.0020 in)
STD 1.492 - 1.501 mm (0.0587 - 0.0591 in)
0.03 mm
(0.0012 1.510 - 1.513 mm (0.0594 - 0.0596 in)
Connecting in) US
rod bearing 0.05 mm
Thickness at center portion
(0.0020 1.520 - 1.523 mm (0.0598 - 0.0600 in)
in) US
0.25 mm
(0.0098 1.620 - 1.623 mm (0.0638 - 0.0639 in)
in) US
Connecting Clearance between piston pin and STD 0 - 0.022 mm (0 - 0.0009 in)
rod bushing bushing Limit I 0.030 mm (0.0012 in)

ME(D0HC TURBO)-4
 GENERAL DESCRIPTION
MECHANICAL

lend limit 0.035 mm (0.0014 in)

:rank pin and crank jour- Out-of-ro~ndness 0.020 mm (0.0008 in) or less
tal Grinding limit 0.25 mm (0.0098 in)

0.0012 47.954 - 47.970 mm (1.8879 - 1.8886)

;rank pin outer diameter

0.0020 I 47.934 - 47.950 mm (1.8872 - 1.8878)

1.25 mm
0.0098 47.734 - 47.750 mm (1.8793 - 1.8799)

mm
:0.0012
lo3 1 59.962 - 59.978 mm (2.3607- 2.3613 in)

:ranks haft
#1, #3, #5
mm
:0.0020
n) US
1 59.942 - 59.958 mm (2.3599- 2.3605 in)

3.25 mm
(0.0098 59.742 - 59.758 mm (2.3520- 2.3527 in)
:rank journal outer diam- in) US
Bter STD 59.992 - 60.008 mm (2.3619 - 2.3625 in)
0.03 mm
(0.0012 59.962 - 59.978 mm (2.3607- 2.3613 in)
in) US
0.05 mm
#2. #4
(0.0020 59.942 - 59.958 mm (2.3599- 2.3605 in)

0'25 mm
(0.0098
in) US
I 59.742 - 59.758 mm (2.3520- 2.3527 in)

0.030 - 0.1 15 mm (0.0012 - 0.0045 in)

~

STD
Thrust clearance
Limit 0.25 mm (0.0098 in)
STD 0.01 0 - 0.030 mm (0.0004 - 0.0012 in)
Oil clearance
Limit 0.040 mm (0.0016 in)
STD 1.998 - 2.011 mm (0.0787 - 0.0792 in)
0.03 mm
(0.0012 2.017 - 2.020 mm (0.0794- 0.0795 in)
in) US
0.05 mm
#l. #3
(0.0020 2.027 - 2.030 mm (0.0798- 0.0799 in)

Crankshaft Crankshaft bearing thick-

0.25mm
(0.0098
in) US
I 2.127 - 2.130 mm (0.0837- 0.0839 in)

bearing ness STD 2.000 - 2.013 mm (0.0787- 0.0793 in)

~

0.03 mm
(0.0012 2.019 - 2.022 mm (0.0795 - 0.0796 in)
in) US
#2, #4, #5 0.05 mm
(0.0020 2.029 - 2.032 mm (0.0799 - 0.0800 in)

0.25mm
(0.0098 I 2.129 - 2.132 mm (0.0838- 0.0839 in)

ME(D0HC TURBO)-5
 GENERAL DESCRIPTION
MECHANICAL

B: COMPONENT
1. TIMING BELT

EN1136

(1) Right-hand belt cover No. 2 (9) Right-hand intake camshaft (17) Right-hand belt cover
(2) Timing belt guide (MT vehicles sprocket (18) Crankshaft pulley
only)
.. (IO) Left-hand intake camshaft
(3) Crankshaft sprocket sprocket Tightening torque: N.m (kgf-m, ff-lb)
(4) Left-hand belt cover No. 2 (11) Left-hand exhaust camshaft T l : 5 (0.5, 3.6)
(5) Tensioner bracket sprocket T2: l O ( 1 . 0 , 7)
(6) Automatic belt tension adjuster (12) Timing belt T3: 25 (2.5, 18.1)
ASSY (13) Belt idler No. 2 T4: 39 (4.0, 28.9)
(7) Belt idler (14) Belt idler T5: 98 (10, 72.4)
(8) Right-hand exhaust camshaft (15) Left-hand belt cover T6: <Ref. to ME(D0HC TURBO)-46,
sprocket (16) Front belt cover INSTALLA TION, Crankshaft
Pullev.>

ME(D0HC TURBO)-6
GENERAL DESCRIPTION
MECHANICAL

ME(D0HC TURBO)-7
 GENERAL DESCRIPTION
MECHANICAL

2. CYLINDER HEAD AND CAMSHAFT

S2M1188A

ME(D0HC TURBO)-8
 GENERAL DESCRIPTION
MECHANICAL

Rocker cover (RH) Cylinder head (RH) (29) Oil filler cap
Rocker cover gasket (RH) Cylinder head gasket (RH) (30) Gasket
Oil separator cover Cylinder head gasket (LH) (31) Oil filler duct
Gasket Cylinder head (LH) (32) O-ring
Intake camshaft cap (Front RH) Intake camshaft (LH) (33) Stud bolt
Intake camshaft cap (Center RH) Exhaust camshaft (LH)
Intake camshaft cap (Rear RH) Intake camshaft cap (Front LH) Tightening torque: N.m (kgf-m, ft-lb)
Intake camshaft (RH) Intake camshaft cap (Center LH) T l : <Ref, to ME(D0HC TURBO)-64,
Exhaust camshaft cap (Front RH) Intake camshaft cap (Rear LH) INSTALLATION, Cylinder Head
Exhaust camshaft cap (Center Exhaust camshaft (Front LH) Assembly>
RH) (25) Exhaust camshaft cap (Center T2: 5 (0.5, 3.6)
Exhaust camshaft cap (Rear RH) LH) T3: 10 (1.0, 7)
Exhaust camshaft (RH) (26) Exhaust camshaft cap (Rear LH) T4: 6.4 (0.65, 4.7)
Cylinder head bolt (27) Rocker cover gasket (LH)
Oil seal (28) Rocker cover (LH)

ME(D0HC TURBO)-9
I
GENERAL DESCRIPTION
MECHANICAL

3. CYLINDER HEAD AND VALVE ASSEMBLY

(1 o i

S2M1197A

(1) Exhaust valve (6) Valve spring (11) Exhaust valve oil seal
(2) Intake valve (7) Retainer (12) Intake valve guide
(3) Cylinder head (8) Retainer key (13) Exhaust valve guide
(4) Valve spring seat (9) Valve lifter
(5) Intake valve oil seal (IO) Shim

ME(D0HC TURBO)-IO
 I
GENERAL DESCRIPTION
MECHANICAL

4. CYLINDER BLOCK

EN0144

Oil pressure switch Oil cooler Tightening torque: N.m (kgf-m, ft-lb)
Cylinder block (RH) Waster by-pass pipe T1: 5 (0.5, 3.6)
Service hole plug Connector T2: 6.4 (0.65, 4.7)
Gasket Oil strainer T3: lO(1.0, 7)
Oil separator cover Gasket T4: 25 (2.5, 18.1)
Water by-pass pipe Oil pan T5: 47 (4.8, 34.7)
Oil pump Drain plug T6: 69 (7.0, 50.6)
Front oil seal Metal gasket T7: First 12 (1.2, 8.7)
Rear oil seal Oil level gauge guide Second 12 (1.2, 8.7)
O-ring Oil filter T8: 16 (1.6, 11.6)
Service hole cover Gasket T9r 44 (4.5, 33)
Cylinder block (LH) Water pump hose TlO: 25 (2.5, 18.1)
Water pump Plug T11: 55 (5.5, 40)
Baffle plate

ME(D0HC TURBO)-I 1
 GENERAL DESCRIPTION
MECHANICAL

5. CRANKSHAFT AND PISTON

EN0415

(1) Flywheel (MT vehicles only) (9) Piston pin (17) Crankshaft bearing # I , #3
(2) Ball bearing (MT vehicles only) (IO) Circlip (18) Crankshaft bearing #2, #4
(3) Reinforcement (AT vehicles only) (11) Connecting rod bolt (19) Crankshaft bearing #5
(4) Drive plate (AT vehicles only) (12) Connecting rod
(5) Top ring (13) Connecting rod bearing Tightening torque: N.m (kgf-m, I?-lb)
(6) Second ring (14) Connecting rod cap T1: 44.6 (4.55, 32.9)
(7) Oil ring (15) Crankshaft T2: 72 (7.3, 52.8)
(8) Piston (16) Woodruff key

ME(D0HC TURBO)-12
 GENERAL DESCRIPTION
MECHANICAL

6. ENGINE MOUNTING

\
Q

S2M1783A

(1) Hear shield cover (3) Front engine mounting bracket Tightening torque: N.m (kgf-myft-lb)
(2) Front cushion rubber T1: 35 (3.6,25.8)
T2: 42 (4.3, 30.9)
T3: 85 (8.7, 62.7)

ME(D0HC TURBO)-13
 GENERAL DESCRIPTION
MECHANICAL

C: CAUTION Rotating parts and sliding parts such as piston,

Wear working clothing, including a cap, protec-
tive goggles, and protective shoes during opera-
tion.
Remove contamination including dirt and corro-
sion before removal, installation or disassembly.
Keep the disassembled parts in order and pro-
tect them from dust or dirt.
Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary re-
moval, installation, disassembly, and replacement.
Be careful not to burn your hands, because each
part in the vehicle is hot after running.
Be sure to tighten fasteners including bolts and
nuts to the specified torque.
Place shop jacks or safety stands at the specified
points.
Before disconnecting electrical connectors of
sensors or units, be sure to disconnect the negative
terminal from battery.
All parts should be thoroughly cleaned, paying
special attention to the engine oil passages, pis-
tons and bearings.
bearing and gear should be coated with oil prior to
assembly.
Be careful not to let oil, grease or coolant contact
the timing belt, clutch disc and flywheel.
All removed parts, if to be reused, should be re-
installed in the original positions and directions.
Bolts, nuts and washers should be replaced with
new ones as required.
Even if necessary inspections have been made
in advance, proceed with assembly work while
making rechecks.
Remove or install the engine in an area where
chain hoists, lifting devices, etc. are available for
ready use.
Be sure not to damage coated surfaces of body
panels with tools or stain seats and windows with
coolant or oil. Place a cover over fenders, as re-
quired, for protection.
Prior to starting work, prepare the following:
Service tools, clean cloth, containers to catch cool-
ant and oil, wire ropes, chain hoist, transmission
jacks, etc.
Lift-up or lower the vehicle when necessary.
Make sure to support the correct positions.

D: PREPARATION TOOL
1. SPECIAL TOOLS
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
498267600 CYLINDER Used for replacing valve guides.
HEAD TABLE Used for removing and installing valve springs.

EN0147
498457000 ENGINE STAND Used with ENGINE STAND (499817000).
ADAPTER RH

82M3851

ME(D0HC TURBO)-14
 GENERAL DESCRIPTION
MECHANICAL

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

498457100 ENGINE STAND Used with ENGINE STAND (499817000).
ADAPTER LH

498497100 CRANKSHAFT Used for stopping rotation of flywheel when loos-

STOPPER ening and tightening crankshaft pulley bolt, etc.

02M3853
398744300 PISTON GUIDE Used for installing piston in cylinder for 2000 cc
(Newly adopted engine.
tool)

498857100 VALVE OIL SEAL Used for press-fitting of intake and exhaust valve
GUIDE guide oil seals.

02M3855

ME(D0HC TURBO)-15
 GENERAL DESCRIPTION
MECHANICAL

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

499017100 PISTON PIN Used for installing piston pin, piston and connect-
GUIDE ing rod.

B2M3856
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
499207400 CAMSHAFT Used for removing and installing camshaft
(Newly adopted SPROCKET sprocket.
tool) WRENCH

B2M4158

ME(D0HC TURBO)-16
 GENERAL DESCRIPTION
MECHANICAL

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

499587700 CAMSHAFT OIL Used for installing cylinder head plug for DOHC
(Newly adopted SEAL engine.
tool) INSTALLER

499587200 CRANKSHAFT Used for installing crankshaft oil seal.

OIL SEAL Used with CRANKSHAFT OIL SEAL GUIDE
INSTALLER (499597100).

B2M3861
499597100 CRANKSHAFT m Used for installing crankshaft oil seal.
OIL SEAL GUIDE m Used with CRANKSHAFT OIL SEAL
INSTALLER (499587200).

82M3863
499718000 VALVE SPRING Used for removing and installing valve spring.
REMOVER

B2M3864

ME(D0HC TURBO)-17
 GENERAL DESCRIPTION
MECHANICAL

I ILLUSTRATION r o o L NUMBER DESCRIPTION I REMARKS

498267700 IALVE GUIDE Used for installing intake and exhaust valve
(DJUSTER guides.

I B2M3865
499767200 JALVE GUIDE Jsed for removing valve guides.
3EMOVER

499767400 TALVE GUIDE Jsed for reaming valve guides.

3EAMER

t B2M386t
499817000 ENGINE STAND
~~

Stand used for engine disassembly and assem-

bly.
@ Used with ENGINE STAND ADAPTER RH
(498457000) & LH (498457100).

I B2M386!

ME(D0HC TURBO)-18
 GENERAL DESCRIPTION
MECHANICAL

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

~~ ~

499977300 CRANK PULLEY Used for stopping rotation of crankshaft pulley

WRENCH when loosening and tightening crankshaft pulley
301tS.

B2M4157
499987500 CRANKSHAFT Used for rotating crankshaft.
SOCKET

B2M3871
498547000 OIL FILTER Used for removing and installing oil filter.
WRENCH

B2M3872
499587100 OIL SEAL Used for installing oil pump oil seal.
INSTALLER

ME(D0HC TURBO)-19
 GENERAL DESCRIPTION
MECHANICAL

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

499587600 OIL SEAL GUIDE k e d for installing camshaft oil seal for DOHC
(Newly adopted 'ngine.
tool)

SlH0136
499597200 I I L SEAL GUIDE Used for installing camshaft oil seal for DOHC
(Newly adopted mgine.
tool) Used with OIL SEAL GUIDE (499587600).

EN0168
498187200 SHIM Jsed for correct valve clearance.
(Newly adopted 3 EPLACER
tool)

ENOI6E
~

498277200 STOPPER SET Used for installing automatic transmission assem-

bly to engine.

ME(D0HC TURBO)-20
 GENERAL DESCRIPTION
MECHANICAL

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

24082AA150 CARTRIDGE Troubleshootingfor electrical systems.

02M3076
22771AA030 SELECT MONI- Troubleshootingfor electrical systems.
TOR KIT m English: 22771AA030 (Without printer)
* German: 22771AA070 (Without printer)
m French: 22771AA080 (Without printer)

m Spanish: 22771AA090 (Without printer)

2. GENERAL PURPOSE TOOLS

TOOL NAME REMARKS

Compression Gauge Used for measuring compression.
Timing Light Used for measuring ignition timing.

ME(D0HC TURBO)-21
 COMPRESSION
MECHANICAL

2. Compression
A: INSPECTION
CAUTION:
After warming-up, engine becomes very hot. Be
careful not to burn yourself during measure-
ment.
1) After warming-up the engine, turn the ignition
switch to OFF.
2) Make sure that the battery is fully charged.
3) Release fuel pressure. <Ref. to FU(D0HC TUR-
BO)-51, RELEASING OF FUEL PRESSURE, OP-
ERATION, Fuel.,
4) Remove all the spark plugs. <Ref. to IG(D0HC
TURBO)-4, REMOVAL, Spark Plug.>
5) Fully open the 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.

9) Perform at least two measurements per cylinder,

and make sure that the values are correct.
Compression (350 rpm and fully open throttle):
Standard;
951- 1,147kPa(9.7- 11.7kgf/cn?, 138-
166 psi)
Limit;
834 kPa (8.5 kgf/cd, 121 psi)
Difference between c linders;
49 kPa (0.5 k g f / c d 7 psi)

ME(D0HC TURBO)-22
 IDLE SPEED
MECHANICAL

3. Idle Speed
A: INSPECTION
1) Before checking the idle speed, check the follow-
ing:
(1) Ensure the 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 the malfunction indicator light
(CHECK ENGINE light) does not illuminate.
2) Warm-up the engine.
3) Stop the engine, and turn the ignition switch to
OFF.
4) Insert the cartridge to the SUBARU SELECT
MONITOR.
5) Connect the SUBARU SELECT MONITOR to
the data link connector.
6) Turn the ignition switch to ON, and SUBARU SE-
LECT MONITOR switch to ON.
7) Select (2. Each System Check} in Main Menu.
8) Select {Engine Control System} in Selection
Menu.
9) Select (1. Current Data Display & Save} in En-
gine Control System Diagnosis.
IO) Select (1.12 Data Display} in Data Display
Menu.
11) Start the engine, and read engine idle speed.
12) Check the idle speed when unloaded. (With
headlights, heater fan, rear defroster, radiator fan,
air conditioning, etc. OFF)
Idle speed (No load and gears in neutral:
7502100 rpm
13) Check the idle speed when loaded. (Turn the
air conditioning switch to “ON” and operate the
compressor for at least one minute before mea-
surement.)
Idle speed [A/C“ON”, no load and gears in neu-
tral]:
8002150 rpm (MT model)
8252150 rpm (AT model)
CAUTION:
Never rotate the idle adjusting screw. If the idle
speed is out of specifications, refer to General
On-board Diagnosis Table under “Engine Con-
trol System”. <Ref. to EN(D0HC TURBO)-2, Ba-
sic Diagnostic Procedure.>

ME(D0HC TU RB0)-23
 zz1
IGNITION TIMING
MECHANICAL

4. lgnition Timing
A: INSPECTION
1) Before checking the ignition timing speed, check
the following:
(1) Ensure the air cleaner element is free from
clogging, spark plugs are in good condition, and
that hoses are connected properly.
(2) Ensure the malfunction indicator light
(CHECK ENGINE light) does not illuminate.
2) Warm-up the engine.
3) Stop the engine, and turn the ignition switch to
OFF.
4) Insert the cartridge to the SUBARU SELECT
MONIT0R.
5 ) Connect the SUBARU SELECT MONITOR to
the data link connector.
6) Turn the ignition switch to ON, and SUBARU SE-
LECT MONITOR switch to ON.
7) Select (2. Each System Check} in Main Menu.
8) Select {Engine Control System} in Selection
Menu.
9) Select (1. Current Data Display & Save} in En-
gine Control System Diagnosis.
10) Select (1.12 Data Display} in Data Display
Menu.
11) Start the engine, at idle speed and check the ig-
nition timing.
lgnition timing [BTDC/rpm]:
12"23"/750
If the timing is not correct, check the ignition control
system. Refer to Engine Control System. <Ref. to
EN(D0HC TURBO)-2, Basic Diagnostic Proce-
dure.>

ME(D0HC TURBO)-24
 INTAKE MANIFOLD VACUUM
MECHANICAL

5. Intake Manifold Vacuum 3) Keep the engine at the idle speed and read the
vacuum gauge indication.
A: INSPECTION By observing the gauge needle movement, the in-
1) Warm-uD the enuine. ternal condition of the engine can be diagnosed as
2) Disconnect the b a k e vacuum hose and install described below.

Vacuum pressure (at idling, A/C “OFF):

Less than -60.0 kPa (-450 mmHg, -1 7.72 in-

I 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
dencv becomes more evident as enaine temperature rises. damaaed 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

Weak or broken valve springs

vibrate rapidly at certain speed, and then vibration increases as
enaine speed increases.
6. Needle vibrates above and below normal position in narrow Defective ignition system or throttle chamber idle adjustment
range.

ME(D0HC TURBO)-25
 ENGINE OIL PRESSURE
MECHANICAL

6. Engine Oil Pressure 5) After measuring the oil pressure, install the oil
pressure switch. <Ref. to LU-23, INSTALLATION,
A: INSPECTION Oil Pressure Switch.>
1) Remove the oil pressure switch from engine cyl- Tightening torque:
inder block. <Ref. to LU-22, REMOVAL, Oil Pres- 25 N.m (2.5 kgf-m, 18.I W b )
sure Switch.>
2) Connect the oil pressure gauge hose to cylinder
block.
3) Connect the battery ground terminal to battery.

4) Start the engine, and measure oil pressure.

Oil pressure:
98 kPa (1.0 k g / c d , 14 psi) or more at 800 rpm
294 kPa (3.0 k s / c d , 43 psi) or more at 5,000
rpm
CAUTION:
If the oil pressure is out of specification,
check oil pump, oil filter and lubrication line.
<Ref. to LU-28, INSPECTION, Engine Lubrica-
tion System Trouble in General.>
If the oil pressure warning light is turned ON
and oil pressure is in specification, replace the
oil pressure switch. <Ref. t o LU-28, INSPEC-
TION, Engine Lubrication System Trouble in
General.>
NOTE:
The specified data is based on an engine oil tem-
perature of 80°C (176°F).

ME(D0HC TURBO)-26
 FUEL PRESSURE
MECHANICAL

7. Fuel Pressure 4) Connect the connector of fuel pump relay.

A: INSPECTION
WARNING:
Before removing the fuel pressure gauge, re-
lease the fuel pressure.
NOTE:
If out of specification, check or replace the pressure
regulator and pressure regulator vacuum hose.
1) Release the fuel pressure. <Ref. to FU(D0HC
44
TURBO)-51, RELEASING OF FUEL PRESSURE, I
0PERATION, Fuel.> 5) Start the engine.
2) Open the fuel flap lid, and remove the fuel filler 6) Measure fuel pressure while disconnecting the
cap. pressure regulator vacuum hose from intake man-
ifold.
Fuel pressure:
Standard; 284 - 314 kPa (2.9 - 3.2 kgf/cd,
41 - 46 psi)

3) Disconnect the fuel delivery hoses from fuel fil-

ter, and connect the fuel pressure gauge.

7) Iter connecting the pressure regulator vacuum

hose, measure fuel pressure.
Fuel pressure:
Standard; 230 -260 kPa (2.35 -2.65 kgf/
cm’, 33 - 38 psi)

NOTE:
The fuel pressure gauge registers 10 to 20 kPa (0.1
to 0.2 kgf/cm2, 1 to 3 psi) higher than standard Val-
ues during high-altitude operations.

ME(D0HC TU RB0)-27
 VALVE CLEARANCE
MECHANICAL

8. Valve Clearance 10) When inspecting #2 and #4 cylinders:

(1) Disconnect the battery terminal, and then
A: INSPECTION remove the battery and battery carrier.
CAUTION:
Inspection and adjustment of valve clearance
should be performed while engine is cold.
1) Set the vehicle onto the lift.
2) Disconnect the ground terminal from battery.

H6M0426

(2) Remove the bolt which secures the engine

harness bracket onto body.

3) Remove the air intake duct. <Ref. to IN(D0HC

TURBO)-8, REMOVAL, Air Intake Duct.>
4) Remove one bolt which secures the timing belt
cover (RH).
5) Lift-up the vehicle.
6) Remove the under cover.
7) Loosen the remaining bolts which secure the -16M0429
timing belt cover (RH), then remove the belt cover.
8) Lower the vehicle. (3) Disconnect the washer motor connectors.
9) When inspecting #1 and #3 cylinders:
(1) Pull out the engine harness connector with
acket from air cleaner upper cover.

(4) Remove the washer tank mounting bolts.

(2) Remove the air cleaner case. <Ref. to

IN(D0HC TURBO)-7, REMOVAL, Air Cleaner.>
(3) Disconnect the spark plug cords from spark
plugs (#1 and #3 cylinders).
(4) Place a suitable container under the vehicle.
(5) Disconnect the PCV hose from rocker cover
(RH).
(6) Remove the bolts, then remove the rocker
cover (RH).

ME(D0HC TURBO)-28
 VALVE CLEARANCE
m
MECHANICAL

(5) Move the washer tank upward. NOTE:

If the measured value is not within specification,
take notes of the value in order to adjust the valve
clearance later on.

(6) Disconnect the spark plug cords from spark

plugs (#2 and #4 cylinders).
(7) Place a suitable container under the vehicle.
(8) Disconnect the PCV hose from rocker cover
w-0.
(9) Remove the bolts, then remove the rocker
cover (LH).
11) Turn the crankshaft pulley clockwise until arrow
mark on the camshaft sprocket is set to position
shown in the figure.
NOTE:
Turn the crankshaft using ST.
ST 499987500 CRANKSHAFT SOCKET
13) If necessary, adjust the valve clearance. <Ref.
to ME(D0HC TURBO)-30, ADJUSTMENT, Valve
Clearance.>
14) Further turn the crankshaft pulley clockwise.
Using the same procedures described previously,
then measure valve clearances again.
(1) Set the arrow mark on camshaft sprocket to
position shown in the figure, and measure #2
cylinder exhaust valve and #3 cylinder intake
valve clearances.

#I IN. #2 EX.
#3 EX. #3 IN.
\J

S2M1192B I
r
S2M1194B I
12) Measure #1 cylinder intake valve and #3 cylin- (2) Set the arrow mark on camshaft sprocket to
der exhaust valve clearance by using thickness position shown in the figure, and measure #2
cylinder intake valve and #4 cylinder exhaust
gauge (A). valve clearances.
CAUTION:
Insert the thickness gauge in as horizontal a
direction as possible with respect to the shim.
Measure the exhaust valve clearances while
lifting-up the vehicle.
Valve clearance:
Intake: 0.20fo.02 mm (0.0079H0008 in)
Exhaust: 0.25fo.02 mm (0.0098M.0008 in)
II #2 IN
#4 EX.
S2M1195B

ME(D0HC TURBO)-29
I VALVE CLEARANCE
MECHANICAL

(3) Set the arrow mark on camshaft sprocket to B: ADJUSTMENT

position shown in the figure, and measure #I
cylinder exhaust valve and #4 cylinder intake
valve clearances.
CAUTION:
Adjustment of valve clearance should be per-
formed while engine is cold.
1) Measure all valve clearances. <Ref. to
ME(D0HC TURBO)-28, INSPECTION, Valve
Clearance.>
NOTE:
Record each valve clearance after it has been
measured.

#I EX.
#4 IN. S2M 11960

15) After inspection, install the related parts in the

reverse order of removal.
Tightening torques
32 N-m (3.3 kgf-m, 24 ft-lb)

B2M1234

2) Remove the shim from valve lifter.

(1) Prepare the ST.
ST 498187200 SHIM REPLACER

H2M3622

(2) Rotate the notch of the valve lifter outward

by 45".

ME(D0HC TURBO)-30
 VALVE CLEARANCE
MECHANICAL

(3) Adjust the SHIM REPLACER notch to valve (6) Insert tweezers into the notch of the valve
lifter and set it. lifter, and take the shim out.

NOTE: NOTE:
When setting, be careful the SHIM REPLACER By using a magnet (A), the shim (B) can be taken
edge does not touch shim. out without dropping it.
(4) Tighten bolt (A) and install it to the cylinder
head.
(5) Tighten bolt (B) and insert the valve lifter.

B)
H2M3624A

3) Measure the thickness of shim with a microme-

ter.
H2M3623A

B2M1240

4) Select a shim of suitable thickness using mea-

sured valve clearance and shim thickness, by refer-
ring to the following table.
5) Set the suitable shim selected in step 4) to valve
lifter.
Unit: mm
Intake valve:S =(V + T)- 0.20
Exhaust valve:S =(V + T)- 0.25
S: Shim thickness to be used
V: Measured valve clearance
T: Shim thickness required

ME(D0HC TURBO)-31
 VALVE CLEARANCE
MECHANICAL

13218 AKOlO 2.00 (0.0787)

13218 AK020 2.02 (0.0795)
13218 AK030 2.04 (0.0803)
13218 AK040 2.06 (0.081 1)
13218 AK050 2.08 (0.0819)
13218 AK060 2.10 (0.0827)
I 13218 AK070 I 2.12 (0.0835) 1
13218 AK080

13218 AK100 2.18 (0.0858)

I 13218 AE730 I 2.24 (0.0882) 1

13218 AE750

13218 AE790 2.30 (0.0906)

I 13218 AE850 I 2.36 (0.0929) 1

13218 AE870

13218 AE910 2.42 (0.0953)

I 13218 AE940 I 2.45 (0.0965) 1

13218 AE950

13218 AE970 2.48 (0.0976)

I 132 18 AFOOO I 2.51 (0.0988) 1

13218 AFO10 2.52 (0.0992)
132 18 AF020 2.53 (0.0996)
13218 AF030 2.54 (0.1 000)
13218 AF040 2.55 10.10041
13218 AF050 2.56 (0.1008)
I 13218 AF060 I 2.57 (0.1012) 1
13218 AF070 2.58 (0.1 016)
13218 AF090 2.60 (0.1024)
13218 AF110 2.62 (0.1031)
13218 AF130 2.64 (0.1039)
13218 AFl50 2.66 (0.1 047)
I 13218 AF170 I 2.68 (0.1055) 1
13218 AF190 2.70 (0.1063)

ME(D0HC TURBO)-32
 ENGINE ASSEMBLY
MECHANICAL

9. Engine Assembly 9) Collect refrigerant, and remove the pressure

hoses.
A: REMOVAL (1) Place and connect the attachment hose to
1) Set the vehicle on lift arms. the refrigerant recycle system.
2) Open the front hood fully and support with stay. (2) Collect the refrigerant from A/C system.
3) Raise the rear seat, and turn the floor mat up. (3) Disconnect the A/C pressure hoses from A/
4) Release the fuel pressure. C compressor.
(1) Disconnect the fuel pump relay connector.

I 10) Remove the intercooler. <Ref. to IN(D0HC

(2) Start the engine, and run until stalls. TURBO)-10, REMOVAL, Intercooler.>
(3) After the engine stalls, crank it for five sec- 11) Disconnect the following connectors and cable.
onds more. (1) Engine harness connector
(4) Turn the ignition switch to "OFF".
5) Remove the filler cap.
6) Disconnect the ground terminal from battery.

(2) Engine ground terminal

7) Remove the radiator from vehicle. <Ref. to CO-

37, REMOVAL, Radiator.>
8) Remove the coolant filler tank. <Ref. to CO-51,
REMOVAL, Coolant Filler Tank.>

ME(D0HC TURB0)-33
 ENGINE ASSEMBLY
MECHANICAL

(3) Engine harness connector 12) Disconnect the following hoses.

(1) Brake booster vacuum hose

I l l '
' S2M1930
(4) Generator connector, terminal and A/C
compressor connectors
-
(2) Heater inlet outlet hose
EN0204

(A) A/C compressor connector

13) Remove the power steering pump from brack-
et.
(B) Generator connector and terminal
(1) Loosen lock bolt and slider bolt, and remove
(5) Accelerator cable the front side V-belt. <Ref. to ME(D0HC TUR-
BO)-44, FRONT SIDE BELT, REMOVAL, V-
belt.>
(2) Disconnect the power steering switch con-
nector.

(6) Clutch release spring

ME(D0HC TURBO)-34
 ENGINE ASSEMBLY
MECHANICAL

(3) Remove the pipe with bracket from intake 15) Remove the nuts which hold lower side of
manifold. transmission to engine.

(4) Remove the power steering pump from en- 16) Remove the nuts which install the front cushion
gine. rubber onto front crossmember.
I

(5) Remove the power steering tank from the 17) SeDarate the clutch release fork from release
bracket by pulling it upward. bearing. (MT vehicles)
(1) Remove the clutch operating cylinder from
transmission.
(2) Remove the plug using a 10 mm hexagon
wrench.
I

I I

(6) Place the power steering pump on the right

side wheel apron.
S2M193:

14) Remove the center exhaust pipe. <Ref. to

EX(D0HC TURBO)-8, REMOVAL, Center Exhaust
Pipe.>

ME(D0HC TURBO)-35
 ENGINE ASSEMBLY
MECHANICAL

(3) Screw the 6 mm dia. bolt into release fork 19) Remove the pitching stopper.
shaft, and remove it.

20) Disconnect the fuel delivery hose, return hose

and evaporation hose.
CAUTION:
Catch fuel from hose into container.
Disconnect the hose with its end wrapped
with cloth to prevent fuel from splashing.

S2M 1936A

(A) Shaft
(6) Bolt

(4) Raise the release fork and unfasten the re-

lease bearing tabs to free release fork. I I ' .
CAUTION: 21) Remove the fuel filter and bracket.
Step (4) is required to prevent interference with
engine when removing the engine from trans-
mission.
18) Separate the torque converter clutch from drive
plate. (AT vehicles)
(1) Lower the vehicle.
(2) Remove the service hole plug.
(3) Remove the bolts which hold torque con-
verter clutch to drive plate.
(4) Remove the other bolts while rotating the
engine using ST.
ST 499977300 CRANK PULLEY WRENCH 22) Support the engine with a lifting device and wire
ropes.

ME(D0HC TURBO)-36
 ENGINE ASSEMBLY
MECHANICAL

23) Support the transmission with a garage jack.
CAUTION:
Before moving the engine away from transmis-
sion, check to be sure no work has been over-
looked. Doing this is very important in order to
facilitate re-installation and because transmis-
sion lowers under its own weight.
25) Remove the engine from vehicle.
(1) Slightly raise the engine.
(2) Raise the transmission with garage jack.
(3) Move the engine horizontally until the main-
shaft is withdrawn from clutch cover.
(4) Slowly move the engine away from engine
compartment.
CAUTION:
Be careful not t o damage adjacent parts or
body panels with crank pulley, oil pressure
gauge, etc.
26)Remove the front cushion rubbers.

24) Separation of engine and transmission.

(1) Remove the starter. <Ref. to SC-6, RE-
MOVAL, Starter.>
(2) Install the ST to torque converter clutch
case. (AT vehicles)
ST 498277200 STOPPER SET

(3) Remove the bolts which hold right upper

side of transmission to engine.

B3M2044

ME(D0HC TURBO)-37
I ENGINE ASSEMBLY
MECHANICAL

B: INSTALLATION (4) Apply grease to the specified points.

1) Install the clutch release fork and bearing onto Spline ~ x 2 2 0 0
transmission. (MT vehicles) Shaft SUNLIGHT 2
(1) Remove the release bearing from clutch
cover with flat type screw driver. m \

(2) Install the release bearing on transmission.

(3) Install the release fork into release bearing
tab.

S2M1938A

(A) Spline (FX2200)

(B) Shaft (SUNLIGHT 2)

(5) Insert the release fork shaft into release

S2M1937A
fork.
(A) Release fork CAUTION:
(B) Release bearing Make sure the cutout portion of release fork
shaft contacts spring pin.

(A) Release fork

(B) Release shaft
(C) Spring pin

ME(D0HC TURBO)-38
 ENGINE ASSEMBLY
MECHANICAL

(6) Tighten the plug. 6) Remove the garage jack.

Tightening torque:
44 N-m (4.5 kgf-m, 32.5 ff-lb)

7) Install the pitching stopper.

Tightening torques
2) Install the front cushion rubbers to engine. T I : 50 N-m (5.1 kgf-m, 37 ff-lb)
T2: 58 N.m (5.9kgf-m, 43 ff-lb)
Tightening torque:
34 N-m (3.5 kgf-m, 25.3 ft-lb)
3) Install the engine onto transmission.
(1) Position the engine in engine compartment
and align it with transmission.
CAUTION:
Be careful not to damage adjacent parts or
body panels with crank pulley, oil pressure
gauge, etc.
(2) Apply a small amount of grease to splines of
mainshaft. (MT vehicles)
4) Tighten the bolts which hold right upper side of 8) Remove the ST from torque converter clutch
transmission to engine case. (AT vehicles)
Tightening torque: NOTE:
50 N.m (5.1 kgf-m, 36.9 ff-lb) Be careful not to drop the ST into the torque con-
verter clutch case when removing ST.
ST 498277200 STOPPER SET
9) Install the starter. <Ref. to SC-7, INSTALLA-
TION, Starter.>

B2M2791

5 ) Remove the lifting device and wire ropes.

ME(D0HC TURBO)-39
 ENGINE ASSEMBLY
MECHANICAL

IO) Install the torque converter clutch onto drive (2) Install the power steering pump.
plate. (AT vehicles)
Tightening torque:
(1) Tighten the bolts which hold torque convert-
er clutch to drive plate.
20.1 N.m (2.05 kgf-m, 14.8 ft-lb)
(2) Tighten other bolts while rotating the engine
by using ST.
CAUTION:
Be careful not to drop bolts into the torque con-
verter clutch housing.
ST 499977300 CRANK PULLEY WRENCH
Tightening torque:
25 N-m (2.5 kgf-m, 18.1 ft-lb)

(3) Install the power steering pipe bracket on

right side intake manifold, and install the spark
plug codes.

(3) Clog the service hole with plug.

11) Install the fuel filter and bracket.

(4) Connect the power steering switch connec-

tor.

12) Install the power steering pump on bracket.

(1) Install the power steering tank on bracket.

(5) Install the front side V-belt, and adjust it.

<Ref. to ME(D0HC TURBO)-44, FRONT SIDE
BELT, INSTALLATION, V-belt.>

n/
EN0361

ME(D0HC TURBO)-40
 m
ENGINE ASSEMBLY
MECHANICAL

13) Tighten the nuts which hold lower side of trans- 19) Install the air intake system.
mission to engine. (1) Install the intercooler. <Ref. to IN(D0HC
TURBO)-1 1, INSTALLATION, Intercooler.>
Tightening torque: (2) Install the air cleaner element and air clean-
50 N.m (5.1 kgf-m, 36.9 ft-lb) er upper cover.
(3) Install the engine harness connector brack-
et.
(4) Install the filler hose to air cleaner case.
20) Install the A/C pressure hoses.
CAUTION:
Use new O-rings.
Tightening torque:
25 N-m (2.5 kgf-m, 18.1 ft-lb)

14) Tighten the nuts which install the 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.

21) Install the radiator. <Ref. to CO-41, INSTALLA-

TION, Radiator.>
22) Install the coolant filler tank. <Ref. to CO-51,
INSTALLATION, Coolant Filler Tank.>
23) Install the window washer tank.
24) Install the battery in the vehicle, and connect
cables.
25) Fill coolant.
<Ref. to CO-25, FILLING OF ENGINE COOLANT,
REPLACEMENT, Engine Coolant.>
15) Install the center exhaust pipe. 26) Charge the A/C system with refrigerant.
<Ref. to EX(D0HC TURBO)-9, INSTALLATION, <Ref. to AC-17, OPERATION, Refrigerant Charg-
Center Exhaust Pipe.> ing Procedure.>
16) Connect the following hoses: 27) Remove the front hood stay, and close the front
(1) Fuel delivery hose, return hose and evapo- hood.
ration hose 28) Take off the vehicle from lift arms.
(2) Heater inlet and outlet hoses
(3) Brake booster vacuum hose
17) Connect the following connectors and termi-
nals:
(1) Engine ground terminal
(2) Engine harness connectors
(3) Generator connector and terminal
(4) A/C compressor connectors
18) Connect the following cables:
(1) Accelerator cable
(2) Clutch release spring
CAUTION:
After connecting each cable, adjust them.

ME(D0HC TURBO)-41
 ENGINE MOUNTING
MECHANICAL

10.Engine Mounting
A: REMOVAL
1) Remove the engine assembly. <Ref. to
ME(D0HC TURBO)-33, REMOVAL, Engine As-
sembly.>
2) Remove the engine mounting from engine as-
sembly.
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
Engine mounting;
35 N-m (3.6 kgf-m, 25.8 ft-lb)
C: INSPECTION
Make sure there are no cracks or other damage

ME(D0HC TURBO)-42
 PREPARATION FOR OVERHAUL
MECHANICAL

11.Preparation for Overhaul

A: PROCEDURE
1) After removing the engine from the body, secure
it in the ST shown below.
ST1 498457000 ENGINE STAND ADAPTER
RH
ST2 498457100 ENGINE STAND ADAPTER
LH
ST3 499817000 ENGINE STAND

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(D0HC TURBO)-43
 V-BELT
MECHANICAL

12.V-belt 4) Remove the A/C belt tensioner.

A: REMOVAL
1. FRONT SIDE BELT
NOTE:
Perform the following procedures 1) to 4) with the
engine installed to the body.
1) Remove the V-belt cover.

\ S2M0113

2) Loosen the lock bolt (A).
3) Loosen the slider bolt (B).
4) Remove the front side belt (C).
B: INSTALLATlON
1. FRONT SIDE BELT
CAUTION:
Wipe off any oil or water on the belt and pulley.
1) Install a belt, and tighten the slider bolt so as to
obtain the specified belt tension <Ref. to
ME(D0HC TURBO)-45, INSPECTION, V-belt.>
2) Tighten the lock bolt (A)
3) Tighten the slider bolt (B).
Tightening torque:
Lock bolt through bolt:
25 N.m (2.5 kgf-m, 18 ft-lb)
Slider bolt:
8 N.m (0.8 kgf-m, 5.5 ff-lb)

2. REAR SIDE BELT

1) Loosen the lock nut (A).
2 ) Loosen the slider bolt (B).

EN0226

3) Remove the A/Cbelt.

ME(D0HC TURBO)-44
 V-BELT
MECHANICAL

2. REAR SIDE BELT C: INSPECTION

1) Install a belt, and tighten the slider bolt (B) so as
to obtain the specified belt tension. <Ref. to
ME(D0HC TURBO)-45, INSPECTION, V-belt.>
2) Tighten the lock nut (A).
Tightening torque:
Lock nut (A);
22.6 Nom(2.3 kgf-m, 16.6 ff-lb)
1) Replace the belts, if cracks, fraying Or Wear is
found.
2) Check the drive belt tension and adjust it if nec-
essary by changing generator installing position
and/or idler pulley installing position.
Belt tension
(A)
replaced: 7 - 9 mm (0.276 - 0.354 in)
reused: 9 - 11 mm (0.354 - 0.433 in)
(B)*
replaced: 7.5 - 8.5 mm (0.295 0.335 in) -
reused: 9.0 - 10.0 mm (0.354 - 0.394 in)
*: With Air conditioner

I 98 N (10 kgf, 22 Ib)

C/P Crankshaft pulley

GEN Generator
P/S Power steering oil pump pulley
N C Air conditioning compressor pulley
I/P Idler pulley

ME(D0HC TURBO)-&
 CRANKSHAFT PULLEY
MECHANICAL

13.Crankshaft Pulley 3) Confirm that the tightening angle of the crank-

shaft pulley bolt is 45 degrees or more. If not, con-
A: REMOVAL duct the following procedures (1) through (4).
1) Remove the V-belt. <Ref. to ME(D0HC TUR- CAUTION:
BO)-44, REMOVAL, V-belt.> If the tightening angle of crankshaft pulley bolt
2) Remove the crankshaft pulley bolt. To lock is less than 45 degrees, the bolt should be dam-
crankshaft, use ST. aged. In this case, the bolt must be replaced.
ST 499977300 (1) Replace the crankshaft pulley bolts and
CRANKSHAFT PULLEY WRENCH clean them.
Crankshaft pulley bolt:
12369AA011
(2) Clean the crankshaft thread using an air
gun.
(3) Tighten the bolts temporarily with tightening
torque of 44 N.m (4.5 kgf-m, 33 ft-lb).
(4) Tighten the crankshaft pulley bolts keeping
them in an angle between 65 degrees and 75
degrees.
CAUTION:
3) Remove the crankshaft pulley. Conduct the tightening procedures by confirm-
ing the turning angle of the crankshaft pulley
B: INSTALLATION bolt referring to the gauge indicated on the belt
1) Install the crankshaft pulley. cover.
2) Install the pulley bolt. 4) Install the A/C belt tensioner.
To lock the crankshaft, use ST.
ST 499977300 CRANKSHAFT PULLEY
WRENCH
(1) Clean the crankshaft pulley thread using an
air gun.
(2) Apply engine oil to the crankshaft pulley bolt
seat and thread.
(3) Tighten the bolts temporarily with tightening
torque of 44 Nom(4.5 kgf-m, 33 ft-lb).
(4) Tighten the crankshaft pulley bolts.
Tightening torque:
127 N-m (13 kgf-m, 94.0 ft-lb) 5) Install the A/C belt.

C: INSPECTION
1) Make sure the V-belt is not worn or otherwise
damaged.
2) Check the tension of the belt. <Ref. to
ME(D0HC TURBO)-45, INSPECTION, V-belt.>

ME(D0HC TURBO)-46
 BELT COVER
MECHANICAL

14.Belt Cover C: INSPECTION

Make sure the cover is not damaged.
A: REMOVAL
1) Remove the V-belt. <Ref. to ME(D0HC TUR-
BO)-44, REMOVAL, V-belt.>
2) Remove the crankshaft pulley. <Ref. to
ME(D0HC TURBO)-46, REMOVAL, Crankshaft
Pulley.>
3) Remove the left-hand belt cover (A).
4) Remove the right-hand belt cover (B).
5) Remove the front belt cover (C).

B: INSTALLATION
1) Install the front belt cover (C).
Tightening torque:
5 N-m (0.5 kgf-m, 3.6 ff-lb)
2) Install the right-hand belt cover (B).
Tightening torque:
5 N.m (0.5 kgf-m, 3.6 ff-lb)
3) Install the left-hand belt cover (A).
Tightening torque:
5 N-m (0.5 kgf-m, 3.6 ff-lb)

4) Install the crankshaft pulley. <Ref. to ME(D0HC

TURBO)-46, INSTALLATION, Crankshaft Pulley.>
5) Install the V-belt. <Ref. to ME(D0HC TURBO)-
44, INSTALLATION, V-belt.>

ME(D0HC TURBO)-47
 TIMING BELT ASSEMBLY
MECHANICAL

15Timing Belt Assembly

A: REMOVAL
1. TIMING BELT
1) Remove the V-belt. <Ref. to ME(D0HC TUR-
BO)-44, REMOVAL, V-belt.>
2) Remove the crankshaft pulley. <Ref. to
ME(D0HC TURBO)-46, REMOVAL, Crankshaft
Pulley.>
3) Remove the belt cover. <Ref. to ME(D0HC
TURBO)-47, REMOVAL, Belt Cover.>
4) Remove the timing belt guides. (MT vehicle)
5) If the alignment mark and/or arrow mark (which
indicates rotation direction) on timing belt fade
away, put new marks before removing the timing
belt as follows:
(1) Turn the crankshaft using ST, and align
alignment marks on crankshaft sprocket, left-
hand intake camshaft sprocket, left-hand ex-
haust camshaft sprocket, right-hand intake cam-
shaft sprocket and right hand exhaust camshaft
sprocket with notches of belt cover and cylinder
block.
ST 499987500 CRANKSHAFT SOCKET

EN0257

ME(D0HC TURBO)-48

(2) Using white paint, put alignment and/or ar-
row marks on the timing belts in relation to the
sprockets.
Z,: 54.5 tooth length
Z,: 51 tooth length
Z,: 28 tooth length
6) Remove the belt idler (A).
I I I I I I I I J
TIMING BELT ASSEMBLY
MECHANICAL
7 ) Remove the timing belt.
CAUTION:
After the timing belt has been removed, never
rotate the intake and exhaust, camshaft sprock-
et. If the camshaft sprocket is rotated, the in-
take and exhaust valve heads strike together
and valve stems are bent.
2. BELT IDLER AND AUTOMATIC BELT
TENSION ADJUSTER ASSEMBLY
1) Remove the belt idler (B) and (C).
S2M1226A
2) Remove the belt idler No. 2.
3) Remove the automatic belt tension adjuster as-
sembly.
S2M1223A
S2M1226A
ME(D0HC TURBO)-49
 TIMING BELT ASSEMBLY
MECHANICAL

B: INSTALLATION 2) Install the automatic belt tension adjuster as-

sembly.
1. AUTOMATIC BELT TENSION ADJUST-
ER ASSEMBLY AND BELT IDLER Tightening torque:
39 N-m (4.0 kgf-m, 28.9 ft-lb)
1) Preparation for installation of automatic belt ten-
sion adjuster assembly:
CAUTION:
Always use a vertical type pressing tool to
move the adjuster rod down.
Do not use a lateral type vise.
Push the adjuster rod vertically.
Be sure to slowly move the adjuster rod down
applying a pressure of 294 N (30kgf, 66 Ib).
Press-in the push adjuster rod gradually tak-
ing more than three minutes.
Do not allow press pressure to exceed 9,807 3) Install the belt idler No. 2.
N (1,000 kgf, 2,205 Ib).
Press the adjuster rod as far as the end sur- Tightening torque:
face of the cylinder. Do not press the adjuster 39 N.m (4.0 kgf-m, 28.9 ff-lb)
rod into the cylinder. Doing so may damage the
cylinder.
Do not release the press pressure until stop-
per pin is completely inserted.
(1) Attach the automatic belt tension adjuster
assembly to the vertical pressing tool.
(2) Slowly move the adjuster rod down with a
pressure of 294 N (30 kgf, 66 Ib) until the adjust-
er rod is aligned with the stopper pin hole in the
cy1inder.

4) Install the belt idler.

Tightening torque:
39 N.m (4.0 kgf-m, 28.9 ft-lb)

\ I 1 H2M23821

(3) With a 2 mm (0.08 in) dia. stopper pin or a 2

mm (0.08 in) (nominal) dia. hex bar wrench in-
serted into the stopper pin hole in the cylinder,
secure the adjuster rod.

ME(D0HC TURBO)-50
 TIMING BELT ASSEMBLY
MECHANICAL

2. TIMING BELT (4) Align single line mark (A) on left-hand ex-
haust camshaft sprocket with notch (B) on belt
1) Preparation for installation of automatic belt ten-
cover by turning the sprocket counterclockwise
sion adjuster assembly. <Ref. to ME(D0HC TUR-
s viewed from front of engine).
BO)-50, AUTOMATIC BELT TENSION
ADJUSTER ASSEMBLY AND BELT IDLER, Tim-
ing Belt Assembly.>
2) Crankshaft and camshaft sprocket alignment.
(1) Align mark (A) on the crankshaft sprocket
with mark on the oil pump cover at cylinder
block.

( 5 ) Align single line mark (A) on left-hand intake

camshaft sprocket with notch (B) on belt cover
by turning the sprocket clockwise (as viewed
from front of engine).
Ensure double lines (C) on intake and exhaust
camshaft sprockets are aligned.
(2) Align single line mark (A) on the right-hand
exhaust camshaft sprocket with notch (B) on
beIt cover.

(3) Align single line mark (A) on the right-hand

intake camshaft sprocket with notch (B) on belt
cover.
(Make sure double lines (C) on intake camshaft
and exhaust camshaft sprockets are aligned.)

ME(D0HC TURBO)-51
 TIMING BELT ASSEMBLY
MECHANICAL
(6) Ensure camshaft and crankshaft sprockets
are positioned properly.
CAUTION:
Intake and exhaust camshafts for this DOHC
engine can be independently rotated with the
timing belts removed. As can be seen from the
figure, if the intake and exhaust valves are lifted
simultaneously, their heads will interfere with
each other, resulting in bent valves.
(B) B2M1392B
(A) Intake camshaft
(B) Exhaust camshaft
ME(D0HC TURBO)-52
When the timing belts are not installed, four
camshafts are held at the “zero-lift” position,
where all cams on camshafts do not push the
intake and exhaust valves down. (Under this
condition, all valves remain unlifted.)
When the camshafts are rotated to install the
timing belts, #2 intake and #4 exhaust cam of
left-hand camshafts are held to push their cor-
responding valves down. (Under this condition,
these valves are held lifted.) Right-side cam-
shafts are held so that their cams do not push
valves down.
Left-hand camshafts must be rotated from
the “zero-lift” position to the position where the
timing belt is to be installed at as small an angle
as possible, in order to prevent mutual interfer-
ence of intake and exhaust valve heads.
Do not allow the camshafts to rotate in the di-
rection shown in the figure as this causes both
intake and exhaust valves to lift simultaneous-
ly, resulting in interference with their heads.
I Rotate direction
S2M1231A
 TIMING BELT ASSEMBLY
MECHANICAL

3) Installation of timing belt:

S2M0410

Align the alignment mark on the timing belt with marks on the sprockets in the alphabetical order shown in
the figure. While aligning marks, position the timing belt properly.
CAUTION:
Disengagement of more than three timing belt teeth may result in interference between the valve
and piston.
Ensure the belt’s rotating direction is correct.

Arrow mark Timing belt

I /

28 tooth
r
54.5 tooth length
--
51 tooth length
- -_ . 28 tooth
length ength

(E)
/
Install it in the end.
b !I

S2M1232P
I

ME(D0HC TURBO)-53
 ' TIMING BELT ASSEMBLY
MECHANICAL

4) Install the belt idlers.

Tightening torque:
39 N.m (4.0kgf-m, 28.9 ft-lb)
CAUTION:
Make sure that the marks on the timing belt and
sprockets are aligned.

5) After ensuring that the marks on the timing belt

and sprockets are aligned, remove the stopper pin
from tensioner adjuster.
6) Install the timing belt guide. (MT vehicle)
(1) Temporarily tighten the remaining bolts. (3) Tighten the remaining bolts.
(2) Check and adjust clearance between the
timing belt and timing belt guide. Tightening torque:
9.8 N.m (1.0kgf-m, 7.2 ft-lb)
Clearance:
1.020.5 mm (0.039M.020in)

EN0254

ME(D0HC TURBO)-54
 m
TIMING BELT ASSEMBLY
MECHANICAL

C: INSPECTION
1. TIMING BELT
1) Check the timing belt teeth for breaks, cracks,
and wear. If any fault is found, replace the belt.
2) Check the condition of back side of belt; if any
crack is found, replace the belt.
CAUTION:
Be careful not to let oil, grease or coolant
contact the belt. Remove quickly and thorough-
ly if this happens.
Do not bend the belt sharply.
Bending radius: h
60 mm (2.36 in) or more

7) Install the belt cover. <Ref. to ME(D0HC TUR-

BO)-47, INSTALLATION, Belt Cover.>
8) Install the crankshaft pulley. <Ref. to ME(D0HC
G2M0115
TURBO)-46, REMOVAL, Crankshaft Pulley.>
9) Install the V-belt. <Ref. to ME(D0HC TURBO)-
44, INSTALLATION, V-belt.>

ME(D0HC TURBO)-55
 TIMING BELT ASSEMBLY
MECHANICAL

2. AUTOMATIC BELT TENSION ADJUST- 3. BELT TENSION PULLEY

ER 1) Check the mating surfaces of timing belt and
1) Visually check the oil seals for leaks, and rod contact point of adjuster rod for abnormal wear or
ends for abnormal wear or scratches. If necessary, scratches. Replace the belt tension pulley if faulty.
replace the automatic belt tension adjuster assem- 2) Check the belt tension pulley for smooth rotation.
bly. Replace if noise or excessive play is noted.
CAUTION: 3) Check the belt tension pulley for grease leakage.
Slight traces of oil at rod's oil seal does not in- 4. BELTIDLER
dicate the a problem.
1) Check the idler for smooth rotation. Replace if
2) Check that the adjuster rod does not move when noise or excessive play is noted.
a pressure of 294 N (30 kgf, 66 Ib) is applied to it. 2) Check the outer contacting surfaces of idler pul-
This is to check adjuster rod stiffness. ley for abnormal wear and scratches.
3) If the adjuster rod is not stiff and moves freely 3) Check the idler for grease leakage.
when applying 294 N (30 kgf, 66 Ib), check it using
the following procedures:
(1) Slowly press the adjuster rod down to the
end surface of the cylinder. Repeat this motion 2
or 3 times.
(2) With the adjuster rod moved all the way up,
apply a pressure of 294 N (30 kgf, 66 Ib) to it.
Check the adjuster rod stiffness.
(3) If the the adjuster rod is not stiff and moves
down, replace the automatic belt tension adjust-
er assembly with a new one.
CAUTION:
Always use a vertical type pressing tool to
move the adjuster rod down.
Do not use a lateral type vise.
Push the adjuster rod vertically.
Press-in the push adjuster rod gradually tak-
ing more than three minutes.
Do not allow press pressure to exceed 9,807
N (1,000 kgf, 2,205 Ib).
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
5.7fo.5 mm (0.224fo.020in)

ME(D0HC TURBO)-56
 m
CAMSHAFT SPROCKET
MECHANICAL

16.Camshaft Sprocket B: INSTALLATION

1) Install the camshaft sprocket No. 1. and No. 2.
A: REMOVAL To lock camshaft, use ST.
1) Remove the V-belt. <Ref. to ME(D0HC TUR- ST 499207100 CAMSHAFT SPROCKET
BO)-44, REMOVAL, V-belt.> WRENCH
2) Remove the crankshaft pulley. <Ref. to
ME(D0HC TURBO)-46, REMOVAL, Crankshaft Tightening torque:
Pulley.> 98 N-m (IO kgf-m, 72.4 ft-lb)
3) Remove the belt cover. <Ref. to ME(D0HC CAUTION:
TURBO)-47, REMOVAL, Belt Cover.> Do not confuse left and right side camshaft
4) Remove the timing belt assembly. <Ref. to sprockets during installation. The camshaft
ME(D0HC TURBO)-48, REMOVAL, Timing Belt sprocket No. 2 is identified by a projection used
Assembly.> to monitor camshaft position sensor.
5) Remove the camshaft position sensor. <Ref. to
FU(D0HC TURBO)-31, REMOVAL, Camshaft Po-
sition Sensor.>
6) Remove the camshaft sprockets. To lock the
camshaft, use ST.
ST 499207400 CAMSHAFT SPROCKET
WRENCH

2M1879A

2) Install the camshaft position sensor. <Ref. to

FU(D0HC TURBO)-31, INSTALLATION, Cam-
shaft Position Sensor.>
3) Install the timing belt assembly. <Ref. to
ME(D0HC TURBO)-50, INSTALLATION, Timing
Belt Assembly.>
4) Install the belt cover. <Ref. to ME(D0HC TUR-
BO)-47, INSTALLATION, Belt Cover.>
5) Install the crankshaft pulley. <Ref. to ME(D0HC
TURBO)-46, INSTALLATION, Crankshaft Pulley.>
6) Install the V-belt. <Ref. to ME(D0HC TURBO)-
44, INSTALLATION, V-belt.>
C: INSPECTION
1) Check the sprocket teeth for abnormal wear and
scratches.
2) Make sure there is no free play between sprock-
et and key.
3) Check the crankshaft sprocket notch used for
sensor for damage and contamination of foreign
matter.

ME(D0HC TURBO)-57
 CRANKSHAFT SPROCKET
MECHANICAL

17.Crankshaft Sprocket B: INSTALLATION

1) Install the crankshaft sprocket.
A: REMOVAL
1) Remove the V-belt. <Ref. to ME(D0HC TUR-
BO)-44, REMOVAL, V-belt.>
2) Remove the crankshaft pulley. <Ref. to
ME(D0HC TURBO)-46, REMOVAL, Crankshaft
PuHey.>
3) Remove the belt cover. <Ref. to ME(D0HC
TURBO)-47, REMOVAL, Belt Cover.>
4) Remove the timing belt assembly. <Ref. to
ME(D0HC TURBO)-48, REMOVAL, Timing Belt
Assembly .> EN0263
5) Remove the camshaft sprocket. <Ref. to
2) Install the camshaft sprocket. <Ref. to
ME(D0HC TURBO)-57, REMOVAL, Camshaft
ME(D0HC TURBO)-57, INSTALLATION, Cam-
Sprocket.>
s haft Sprocket.>
6) Remove the crankshaft sprocket.
3) Install the timing belt assembly. <Ref. to
ME(D0HC TURBO)-50, INSTALLATION, Timing
Belt Assembly.>
4) Install the belt cover. <Ref. to ME(D0HC TUR-
BO)-47, INSTALLATION, Belt Cover.>
5) Install the crankshaft pulley. <Ref. to ME(D0HC
TURB0)-46, INSTALLATION, Crankshaft PuIley.>
6) Install the V-belt. <Ref. to ME(D0HC TURBO)-
44, INSTALLATION, V-belt.>
C: INSPECTION
1) Check the sprocket teeth for abnormal wear and
scratches.
2) Make sure there is no free play between sprock-
et and key.
3) Check the crankshaft sprocket notch used for
sensor for damage and contamination of foreign
matter.

ME(DOHC TU RBO)-58
I
CAMSHAFT
MECHANICAL

18.Camshaft
A: REMOVAL
I ) Remove the V-belt. <Ref. to ME(D0HC TUR-
BO)-44, INSTALLATION, V-belt.>
2) Remove the crankshaft pulley. <Ref. to
ME(D0HC TURBO)-46, REMOVAL, Crankshaft
Pulley.>
3) Remove the belt cover. <Ref. to ME(D0HC
TURBO)-47, REMOVAL, Belt Cover.>
4) Remove the timing belt assembly. <Ref. to
ME(D0HC TURBO)-48, REMOVAL, Timing Belt
Assembly.>
5 ) Remove the camshaft sprocket. <Ref. to
ME(D0HC TURBO)-57, REMOVAL, Camshaft
Sprocket.>
6) Remove the crankshaft sprocket. <Ref. to
ME(D0HC TURBO)-58, REMOVAL, Crankshaft
Sprocket.>
7) Remove the right-hand belt cover No.2.
10) Remove the oil level gauge guide. (LH side
only)
11) Remove the spark plug cord.
12) Remove the rocker cover and gasket.
13) Loosen the intake camshaft cap bolts equally, a
little at a time in alphabetical sequence shown in
the figure.
U
L U
S2M1233A
14) Remove the camshaft caps and intake cam-
shaft.
15) Loosen the exhaust camshaft cap bolts equally,
a little at a time in alphabetical sequence shown in
the figure.

8) Remove the tensioner bracket.

16) Remove the camshaft caps and exhaust cam-

shaft.
CAUTION:
Arrange camshaft caps in order so that they
can be installed in their original positions.
17) Similarly, remove the right-hand camshafts and
related parts.

9) Remove the left-hand belt cover No. 2.

S2M1162

ME(DOHC TU RBO)-59
I
CAMSHAFT
MECHANICAL

B: INSTALLATION 2) Camshaft cap installation:

1) Camshaft installation: (1) Apply fluid packing sparingly to the cap mat-
Apply engine oil to the cylinder head at camshaft ing surface.
bearing location before installing the camshaft. In- CAUTION:
stall the camshaft so that each valves is close to or Do not apply fluid packing excessively. Failure
in contact with “base circle” of cam lobe. to do so may cause excess packing to come out
CAUTION: and flow toward oil seal, resulting in oil leaks.
When the camshafts are positioned as shown Fluid packing:
in the figure, camshafts need to be rotated at a THREE BOND 1215 or equivalent
minimum to align with the timing belt during in-
stallation.
Right-hand camshaft need not be rotated
when set at the position shown in the figure.
Left-hand intake camshaft: Rotate 80” clock-
wise.
Left-hand exhaust camshaft: Rotate 45” coun-
terclockwise.

A
h

(2) Apply engine oil to cap bearing surface and

install the cap on camshaft as shown by identifi-
cation mark (A).
(3) Gradually tighten the cap in at least two
stages in alphabetical sequence shown in the
figure, and then tighten to specified torque.
Tightening torque:
20 N.m (2.0 kgf-m, 14.5 ft-16)

I U U S2M 1233A
A Left side cylinder head (4) Similarly, tighten the cap on exhaust side.
B Right side cylinder head After tightening the cap, ensure the camshaft ro-
(a) Intake camshaft tates only slightly while holding it at “base” circle.
(b) Exhaust camshaft
Tightening torque:
20 Nom(2.0 kgf-m, 14.5 ft-16)

ME(D0HC TURBO)-60
 CAMSHAFT
MECHANICAL

3) Camshaft oil seal installation: 7) Install the right-hand belt cover No. 2.
Apply grease to the new oil seal lips and press onto Tightening torque:
the front end of camshaft by using ST1 and ST2. 5 N-m (0.5 kgf-m, 3.6 ft-lb)
CAUTION:
Use a new oil seal.
ST1 499587600 OIL SEAL INSTALLER
ST2 499597200 OIL SEAL GUIDE

8) Install the tensioner bracket.

Tightening torque:
25 N-m (2.5 kgf-m, 18.1 fWb)
4) Rocker cover installation:
(1) Install the gasket on rocker cover.
Install the peripheral gasket and ignition coil
gasket.
(2) Apply fluid packing to four front open edges
of peripheral gasket.
Fluid packing:
THREE BOND 1215 or equivalent

9) Install the left-hand belt cover No. 2.

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

(3) Install the rocker cover on cylinder head.

Ensure the gasket is properly positioned during
installation.
5) Install the spark plug cord.
6) Similarly, install the parts on right-hand side. S2M1162

10) Install the crankshaft sprocket. <Ref. to

ME(D0HC TURBO)-58, INSTALLATION, Crank-
shaft Sprocket.>
11) Install the camshaft sprockets. <Ref. to
ME(D0HC TURBO)-57, INSTALLATION, Cam-
shaft Sprocket.>
12) Install the timing belt assembly. <Ref. to
ME(D0HC TURBO)-50, INSTALLATION, Timing
Belt Assembly.>
13) Install the belt cover. <Ref. to ME(D0HC TUR-
BO)-47, INSTALLATION, Belt Cover.>

ME(D0HC TURBO)-61
 CAMSHAFT
MECHANICAL

14) Install the crankshaft pulley. <Ref. to C: INSPECTION

ME(DOHC TURBO)-467 INSTALLATION, Crank- 1) Measure the bend, and repair or replace if nec-
shaft Pulley.> essary.
15) Install the V-belt. <Ref. to ME(D0HC TURBO)-
44, INSTALLATION, V-belt.> Limit:
0.020 mm (0.0008 in)

2) Check the journal for damage and wear. Re-

place if faulty.

Front Center, rear

I Standard I 37.946-37.9635 mm 29.946 - 29.963 mm

(1.4939- 1.4946 in) (1.1790- 1.1796 in) I
4) Measurement of the camshaft journal oil clear-
ance:
(1) Clean the bearing caps and camshaft jour-
nals.
(2) Place the camshafts on the cylinder head.
(Without installing the valve rocker.)
(3) Place a plastigauge across each of the cam-
shaft jounals.
(4) Gradually tighten the cap in at least two
stages in alphabetical sequence shown in the
figure, and then tighten to specified torque.
Tightening torque:
20 N-m (2.0 kgf-m, 14.5 ff-lb)

I U U S2M1233A I

CAUTION:
Do not turn the camshaft.

ME(DOHC TU R BO)-62
 CAMSHAFT
MECHANICAL

(5) Remove the bearing caps.
(6) Measure the widest point of the plastigauge
on each journal.
If the oil clearance exceeds the limit, replace the
camshaft. If necessary, replace the camshaft
caps and cylinder head as a set.
Standard:
0.037 - 0.072 mm (0.0015 - 0.0028 in)
Limit:
0.10 mm (0.0039 in)
6) Measure the thrust clearance of camshaft with
dial gauge. If the clearance exceeds the limit, re-
place the caps and cylinder head as a set. If neces-
sary replace the camshaft.
Standard:
0.015 - 0.070 mm (0.0006 - 0.0028 in)
Limit:
0.1 mm (0.004 in)

(7) Completely remove the plastigauge.

5) Check the cam face condition; remove the minor
faults by grinding with oil stone. Measure the cam
height H;replace if the limit has been exceeded.
Cam height: H
Standard:
Intake:
46.25 - 46.35 mm (1.821 - 1.825 in)
Exhaust:
-
46.15 46.25 mm (1.817 - 1.821 in)
Limit:
Intake:
46.15 mm (7.81 7 in)
Exhaust:
46.05 mm (1.813 in)
Cam base circle diameter A:
37.0 mm (1.457 in)

I t

A
B2M1209A

ME(D0HC TURBO)-63
 CYLINDER HEAD ASSEMBLY
MECHANICAL
19.Cylinder Head Assembly
A: REMOVAL
1) Remove the V-belt. <Ref. to ME(D0HC TUR-
BO)-44, REMOVAL, V- belt.>
2) Remove the crankshaft pulley. <Ref. to
ME(D0HC TURBO)-46, REMOVAL, Crankshaft
PuHey.>
3) Remove the belt cover. <Ref. to ME(D0HC
TURBO)-47, REMOVAL, Belt Cover.>
4) Remove the timing belt assembly. <Ref. to
ME(D0HC TURBO)-48, REMOVAL, Timing Belt
Assembly.>
5 ) Remove the camshaft sprocket. <Ref. to
ME(D0HC TURBO)-57, REMOVAL, Camshaft
Sprocket.>
6) Remove the intake manifold. <Ref. to FU(D0HC
TURBO)-15, REMOVAL, Intake Manifold.>
7) Remove the bolt which installs the A/C compres-
sor bracket on cylinder head.
8) Remove the camshaft. <Ref. to ME(D0HC TUR-
BO)-59, REMOVAL, Camshaft.>
9) Remove the cylinder head bolts in alphabetical
sequence shown in the figure.
CAUTION:
Leave bolts (A) and (D) engaged by three or
four threads to prevent the cylinder head from
falling.
U U B2M1397C
ME(DOHC TURB0)-64
10) While tapping the cylinder head with a plastic
hammer, separate it from cylinder block.
Remove the bolts (A) and (D) to remove the cylin-
der head.
I n n
B2M1397C
11) Remove the cylinder head gasket.
CAUTION:
Do not scratch the mating surface of cylinder
head and cylinder block.
12) Similarly, remove the right side cylinder head.
B: INSTALLATION
1) Install the cylinder head and gaskets on cylinder
block.
CAUTION:
Use new cylinder head gaskets.
Be careful not to scratch the mating surface
of cylinder head and cylinder block.
2) Tighten the cylinder head bolts.
(1) Apply a coat of engine oil to washers and
bolt threads.
(2) Tighten all bolts to 29 N.m (3.0 kgf-m, 22 ft-
Ib) in alphabetical sequence.
Then tighten all bolts to 69 N-m(7.0 kgf-m, 51 ft-
Ib) in alphabetical sequence.
(3) Back off all bolts by 180" first; back them off
by 180" again.
(4) Tighten the bolts (A) and (B) to 34 N-m (3.5
kgf-m, 25 ft-lb).
I n n
 CYLINDER HEAD ASSEMBLY

(5) Tighten the bolts (C), (D), (E) and (F) to 15 C: DISASSEMBLY
N-m (1.5 kgf-m, 11 ft-lb). 1) Remove the valve shims and valve lifters.
n n 2) Compress the valve spring and remove the valve
spring retainer key. Remove each valve and valve
spring.
ST1 498267600 CYLINDER HEAD TABLE
ST2 499718000 VALVE SPRING REMOVER
CAUTION:
Keep the removed parts in order for re-install-
ing in their original positions.
Mark each valve to prevent confusion.
Use extreme care not to damage the lips of
the intake valve oil seals and exhaust valve oil
(6) Tighten all bolts by 80 to 90" in alphabetical seals.
sequence.
CAUTION:
Do not tighten the bolts more than 90".
(7) Further tighten all bolts by 80 to 90" in al-
phabetical sequence.
CAUTION:
Ensure the total "re-tightening angle" [in the
two previous steps] do not exceed 180".
3) Install the camshaft. <Ref. to ME(D0HC TUR-
BO)-60, INSTALLATION, Camshaft.> SZM1881A
4) Install the A/C compressor bracket on cylinder
head.
5) Install the intake manifold. <Ref. to FU(D0HC
TURBO)-18, INSTALLATION, Intake Manifold.>
6) Install the camshaft sprocket. <Ref. to
ME(D0HC TURBO)-57, INSTALLATION, Cam-
shaft Sprocket.>
7) Install the timing belt assembly. <Ref. to
ME(D0HC TURBO)-50, INSTALLATION, Timing
Belt Assembly.>
8) Install the belt cover. <Ref. to ME(D0HC TUR-
BO)-47, INSTALLATION, Belt Cover.>
9) Install the crankshaft pulley. <Ref. to ME(D0HC
TU RBO)-46, INSTALLAT10N, Crankshaft PuIley.>
10) Install the V-belt. <Ref. to ME(D0HC TURBO)-
44, INSTALLATION, V-belt.>

ME(D0HC TURBO)-65
 CYLINDER HEAD ASSEMBLY
MECHANICAL

D: ASSEMBLY

S2M1197A

(1) Exhaust valve (6) Valve spring (1 1) Exhaust valve oil seal
(2) Intake valve (7) Retainer (1 2) Intake valve guide
(3) Cylinder head (8) Retainer key (13) Exhaust valve guide
(4) Valve spring seat (9) Valve lifter
(5) Intake valve oil seal (10) Shim

ME(D0HC TURBO)-66
 CYLINDER HEAD ASSEMBLY
1) Installation of valve spring and valve:
(1) Coat the stem of each valve with engine oil
and insert the valve into valve guide.
CAUTION:
When inserting the valve into valve guide, use
special care not to damage the oil seal lip.
(2) Set the cylinder head on STI,
(3) Install the valve spring and retainer using
ST2.
ST1 498267600 CYLINDER HEAD TABLE
ST2 499718000 VALVE SPRING REMOVER
CAUTION:
Be sure to install the valve springs with their
close-coiled end facing the seat on the cylinder
head.
(4) Compress the valve spring and fit the valve
spring retainer key.
(5) After installing, tap the valve spring retainers
lightly with wooden hammer for better seating.
2) Apply oil to the surface of the valve lifter and
valve shim.
3) Install the valve lifter and valve shim.
ME(D0HC TURBO)-67
m
E: INSPECTION
1. CYLINDER HEAD
1) Make sure that no crack or other damage exists.
In addition to visual inspection, inspect the impor-
tant areas by means of red check.
2) Measure the warping of the cylinder head sur-
face that mates with crankcase by using a straight
edge (A) and thickness gauge (B).
If the warping exceeds 0.05 mm (0.0020 in), re-
grind the surface with a surface grinder.
Warping limit:
0.05 mm (0.0020 in)
Grinding limit:
0.3 mm (0.012 in)
Standard height of cylinder head:
127.5 mm (5.02 in)
CAUTION:
Uneven torque for the cylinder head nuts can
cause warping. When reassembling, pay spe-
cial attention to the torque so as to tighten
evenly.
 CYLINDER HEAD ASSEMBLY
MECHANICAL

2. VALVESEAT 2) If the clearance between valve guide and stem

Inspect the intake and exhaust valve seats, and exceeds the limit, replace the valve guide or valve
correct the contact surfaces with valve seat cutter if itself whichever shows greater amount of wear.
they are defective or when valve guides are re- See the following procedure for valve guide re-
placed. placement.

Valve seat width: W Valve guide inner diameter:

Intake 6.000 - 6.012 mm (0.2362 - 0.2367 in)
Standard Valve stem outer diameters:
1.0 mm (0.039 in) Intake
Limit 5.950 - 5.965 mm (0.2343 - 0.2348 in)
1.7 mm (0.067 in) Exhaust
Exhaust 5.945 - 5.960 mm (0.2341 - 0.2346 in)
Standard (1) Place the cylinder head on STI with the
1.5 mm (0.059 in) combustion chamber upward so that valve
Limit guides enter the holes in ST1.
2.2 mm (0.087 in) (2) Insert the ST2 into valve guide and press it
down to remove the valve guide.
ST1 498267600 CYLINDER HEAD TABLE
ST2 499767200 VALVE GUIDE REMOVER

\ ,

G2M0761

3. VALVE GUIDE
1) Check the clearance between valve guide and
stem. The clearance can be checked by measuring
the outside diameter of valve stem and the inside (3) Turn the cylinder head upside down and
diameter of valve guide with outside and inside mi- place ST as shown in the figure.
crometers respectively. ST 498767700 VALVE GUIDE ADJUSTER
Clearance between the valve guide and valve

L
stem:
Standard
Intake
0.035 - 0.062 mm (0.0014 - 0.0024 in)
Exhaust
0.040 - 0.067 mm (0.0016 - 0.0026 in)
Limit
0.15 mm (0.0059 in)

(4) Before installing a new valve guide, make

sure that neither scratches nor damages exist
on the inside surface of the valve guide holes in
cylinder head.

ME(D0HC TURBO)-68
 CYLINDER HEAD ASSEMBLY m
MECHANICAL
(5) Put a new valve guide, coated with sufficient 4. INTAKE AND EXHAUST VALVE
oil, in cylinder, and insert ST1 into valve guide.
1) Inspect the flange and stem of valve, and re-
Press in until the valve guide upper end is flush
place if damaged, worn, or deformed, or if “H” is
with the upper surface of ST2.
less than the specified limit.
ST1 499767200 VALVE GUIDE REMOVER
ST2 498267700 VALVE GUIDE ADJUSTER H:
Intake
Standard
1.2 mm (0.047 in)
Limit
0.8 mm (0.031 in)
Exhaust
Standard
1.5 mm (0.059 in)
Limit
0.8 mm (0.031 in)
S2M1883A
Valve overall length:
(6) Check the valve guide protrusion. Intake
Valve guide protrusion: L 104.4 mm (4.110in)
-
12.0 - 12.4 mm (0.472 0.488 in) Exhaust
104.7 mm (4.122 in)
(7) Ream the inside of valve guide with 3T.
Gently rotate the reamer clockwise while press-
ing it lightly into the valve guide, and return it
also rotating clockwise. After reaming, clean the
valve guide to remove chips.
ST 499767400 VALVE GUIDE REAMER
CAUTION:
Apply engine oil to the reamer when reaming.
If the inner surface of the valve guide is torn,
the edge of the reamer should be slightly
ground with an oil stone.
If the inner surface of the valve guide be-
comes lustrous and the reamer does not chips,
use a new reamer or remedy the reamer.
(8) Recheck the contact condition between
valve and valve seat after replacing the valve
guide.

G2M0153

2) Put a small amount of grinding compound on the

seat surface and lap the valve and seat surface.
Install a new intake valve oil seal after lapping.

ME(D0HC TURBO)-69
I CYLINDER HEAD ASSEMBLY
MECHANICAL

5. VALVE SPRINGS 6. INTAKE AND EXHAUST VALVE OIL

1) Check the valve springs for damage, free length, SEAL
and tension. Replace the valve spring if it is not Replace the oil seal with a new one, if the lip is
within specifications presented in the table. damaged or spring out of place, or when the surfac-
2) To measure the squareness of the valve spring, es of intake valve and valve seat are reconditioned
stand the spring on a surface plate and measure its or intake valve guide is replaced.
deflection at the top using a try square. 1) Place the cylinder head on ST1.
2) Press in the oil seal to the specified dimension
I 1 Valve spring I indicated in the figure by using ST2.
Free length 44.67 mm (1.7587 in)
ST1 498267600 CYLINDER HEAD TABLE
220.7t15.7 N
(22.5 f 1.6 kgf, 49.6f3.5 lb)/36.0 mm
ST2 498857100 VALVE GUIDE REMOVER
Tensiontspring (1.417 in) CAUTION:
height 510.9f25.5 N Apply engine oil to oil seal before force-fit-
(52.1f2.6 kgf, 114.9f5.7 lb)/26.6 mm ting.
(1.047 in) Differentiate between the intake valve oil seal
I Squareness I 2.5", 2.0 mm (0.079 in) I and exhaust valve oil seal by noting their differ-
ence in color.
Color of rubber part:
Intake [Black]
Exhaust [Brown]
Color of spring part:
Intake [Silver]
Exhaust [Silver]

S2M1924A

ME(D0HC TURBO)-70
 CYLINDER HEAD ASSEMBLY
MECHANICAL

7. VALVE LIFTER
1) Check the valve lifter visually.
2) Measure the outer diameter of valve lifter.
Outer diameter:
34.959 - 34.975 mm (1.3763 - 1.3770 in)

02M122;

3) Measure the inner diameter of valve lifter mating

part on cylinder head.
Inner diameter:
34.994 - 35.016 mm (1.3777 - 1.3786 in)

1400

CAUTION:
If difference between outer diameter of valve
lifter and inner diameter of valve lifter mating
part is over the limit, replace the cylinder head.
Standard:
0.019 - 0.057 mm (0.0007 - 0.0022 in)
Limit:
0.100 mm (0.0039 in)

ME(D0HC TURBO)-71
 iia
CYLINDER BLOCK
MECHANICAL

2O.Cylinder Block 16) Remove the oil cooler.

A: REMOVAL
NOTE:
Before conducting this procedure, drain the engine
oil completely if applicable.
1) Remove the intake manifold. <Ref. to FU(D0HC
TURBO)-15, REMOVAL, Intake Manifold.>
2) Remove the V-belt. <Ref. to ME(D0HC TUR-
BO)-44, REMOVAL, V-belt.>
3) Remove the crankshaft pulley. <Ref. to
ME(D0HC TURBO)-46, REMOVAL, Crankshaft
Pulley.>
4) Remove the belt cover. <Ref. to ME(D0HC
TURBO)-47, REMOVAL, Belt Cover.>
5) Remove the timing belt assembly. <Ref. to
ME(D0HC TURBO)-48, REMOVAL, Timing Belt
Assembly .>
6) Remove the camshaft sprocket. <Ref. to
ME(D0HC TURBO)-57, REMOVAL, Camshaft
Sprocket.>
7) Remove the crankshaft sprocket. <Ref. to
ME(D0HC TURBO)-58, REMOVAL, Crankshaft
Sprocket.>
(a) Gasket
8) Remove the generator and A/C compressor with
their brackets. (b) Oil cooler
9) Remove the cylinder head assembly. <Ref. to (c) Connector
ME(D0HC TURBO)-64, REMOVAL, Cylinder 17) Removal of oil pan:
Head Assembly.> (1) Turn the cylinder block with #2 and #4 piston
10) Remove the clutch disc and cover. (MT vehi- sides facing upward.
cles) <Ref. to CL-11, REMOVAL, Clutch Disc and (2) Remove the bolts which secure oil pan to
Cover.> cylinder block.
11) Remove the flywheel. (MT vehicles) <Ref. to
(3) Insert a oil pan cutter blade between cylin-
CL-14, REMOVAL, Flywheel.>
der block-to-oil pan clearance and remove the
12) Remove the drive plate. (AT vehicles) oil pan.
Using the ST, lock crankshaft.
ST 498497100 CRANKSHAFT STOPPER CAUTION:
Do not use a screwdriver or similar tool in place
of oil pan cutter.

13) Remove the oil separator cover.

14) Remove the water by-pass pipe for heater.
15) Remove the oil filter.
18) Remove the oil strainer stay.
19) Remove the oil strainer.
20) Remove the baffle plate.
21) Remove the water pipes.
22) Remove the water pump.

ME(DOHC TUR BO)-72

 CYLINDER BLOCK
MECHANICAL

23) Remove the oil pump from cylinder block.

Use a flat-bladed screwdriver as shown in the fig-
ure when removing the oil pump.
CAUTION:
Be careful not to scratch the mating surface of
cylinder block and oil pump.

\\ \\

S2M1819 I

EN029r

(1) Service hole plug (3) Circlip (5) Service hole cover
(2)
~, Gasket (4) Piston pin (6) O-ring
24) Remove the service hole cover and service 25) Rotate the crankshaft to bring # 1 and #2 pis-
hole plugs using the hexagon wrench [14 mm (0.55 tons to bottom dead center position, then remove
in)]. the piston circlip through service hole of #1 and #2
cylinders.

ME(D0HC TURBO)-73
 CYLINDER BLOCK
MECHANICAL

26) Draw out the piston pin from #1 and #2 pistons 27) Similarly remove the piston pins from #3 and #4
using ST. pistons.
ST 499097700 PISTON PIN REMOVER 28) Remove the bolts which connect cylinder block
on the side of #2 and #4 cylinders.
CAUTION:
Be careful not to confuse the original combina- 29) Back off the bolts which connect cylinder block
tion of piston, piston pin and cylinder. on the side of #1 and #3 cylinders two or three
turns.
I I
30) Set up the cylinder block so that #1 and #3 cyl-
inders are on the upper side, then remove the cyl-
inder block connecting bolts.
31) Separate the left-hand and right-hand cylinder
blocks.
CAUTION:
When separating the cylinder block, do not al-
low the connecting rod to fall and damage the
cylinder block.
\ + G2M0166

B2M2408r

(1) Cylinder block (3) Crankshaft (5) Piston

(2) Rear oil seal
\ ,
(4)
. . Crankshaft bearing
32) Remove the rear oil seal. Press the bearing at the end opposite to locking
33) Remove the crankshaft together with connect- lip.
ing rod. 35) Draw out each piston from cylinder block using
34) Remove the crankshaft bearings from cylinder a wooden bar or hammer handle.
block using a hammer handle. CAUTION:
CAUTION: Do not confuse the combination of piston and
Do not confuse the combination of crankshaft cylinder.
bearings.

ME(D0HC TURBO)-74
 CYLINDER BLOCK
MECHANICAL

B: INSTALLATION

02M2407E

(1) Crankshaft bearing (4) Rear oil seal Tightening torque: N-m (kgf-m, ft-lb)
(2) Crankshaft T1: 25 (2.5, 78.1)
(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
1
coat of engine oil to crankshaft pins.
1) Position the 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:
Is !M 1826A
THREE BOND 1215 or equivalent
CAUTION:
Do not allow fluid packing to jut into O-ring
grooves, oil passages, bearing grooves, etc.

ME(D0HC TURBO)-75
I CYLINDER BLOCK
MECHANICAL

3) Temporarily tighten the 10 mm cylinder block 6) Install the rear oil seal using ST1 and ST2.
connecting bolts in alphabetical sequence shown in ST1 499597100 OIL SEAL GUIDE
the figure. ST2 499587200 OIL SEAL INSTALLER

I B2M0088D I ' ~ ' S2M1827A

4) Tighten the 10 mm cylinder block connecting

(A) Rear oil seal
bolts in alphabetical sequence.
(B) Flywheel attaching bolt
Tightening torque:
47 N.m (4.8 kgf-m, 34.7 ft-lb) 7) Position the top ring gap at (A) or (B) in the fig-
ure.
180"

(B)

B2M0088D
EN0304
5) Tighten the 8 mm and 6 mm cylinder block con-
necting bolts in alphabetical sequence shown in the 8) Position the second ring gap at 180" on the re-
figure. verse side for the top ring gap.
9) Position the upper rail gap at (C) or (D) in the fig-
Tightening torque: ure.
(A) - (G): 25 N-m (2.5 kgf-m, 18.1 ft-lb)
(H): 6.4 N-m (0.65 kgf-m, 4.7 ft-lb)

EN0305

B2M0089F
10) Position the expander gap at 180" of the re-
verse side for the upper rail gap.

ME(DOHC TURB0)-76
 CYLINDER BLOCK
MECHANICAL

11) Position the lower rail gap at (E) or (F)in the fig- CAUTION:
ure. Use new circlips.
CAUTION:
Ensure ring gaps do not face the same direc-
tion.
Ensure ring gaps are not within the piston
skirt area.

Front side #2
B2M1403A

CAUTION:
Piston front mark faces towards the front of the
engine.
EN0305

12) Installing the circlip:

Install the circlips in piston holes located opposite
of the service holes in cylinder block, when posi-
tioning all pistons in the corresponding cylinders.

(A) Front mark

(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

ME(D0HC TURBO)-77
 CYLINDER BLOCK
MECHANICAL

13) Installing the piston: (3) Install the circlip.

(1) Turn the cylinder block so that #1 and #2 cyl- CAUTION:
inders face upward. Use new circlips.
(2) Using ST1, turn the crankshaft so that #1
and #2 connecting rods are set at bottom dead
center.
ST1 499987500 CRANKSHAFT SOCKET
(3) Apply a coat of engine oil to the pistons and
cylinders and insert pistons in their cylinders us-
ing ST2.
ST2 498744300 PISTON GUIDE

S2M 1828

(4) Apply fluid packing around the service hole

Plug.
Fluid packing:
THREE BOND 1215 or equivalent

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.
ST3 499017100 PISTON PIN GUIDE B2M2625

( 5 ) Install the service hole plug and gasket.

CAUTION:
Use a new gasket.

(2) Apply a coat of engine oil to the piston pin

and insert piston pin into piston and connecting
rod through service hole.

ME(D0HC TURBO)-78
 a
CYLINDER BLOCK
MECHANICAL

(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 the cylinder block so that #3 and #4 cyl- 19) Apply fluid packing to matching surfaces and
inders face upward. Using the same procedures install the oil pan.
as used for #1 and #2 cylinders, install the pis- Fluid packing:
tons and piston pins. THREE BOND 1215 or equivalent
15) Install the water pipe.
16) Install the baffle plate.
Tightening torque:
6.4 N.m (0.65 kgf-m, 4.7 ff-lb)
17) Install the oil strainer and O-ring
Tightening torque:
10 N-m (1.0 kgf-m, 7 ff-lb)
18) Install the oil strainer stay.

S2M 1833A

ME(DOHC TURBO)-79
 CYLINDER BLOCK
MECHANICAL

20) Apply fluid packing to matching surfaces and (2) Apply fluid packing to the matching surface
install the oil separator cover. of oil pump.
Fluid packing: Fluid packing:
THREE BOND 1215 or equivalent THREE BOND 1215 or equivalent

S2M1R34A LJLJ B2M03908

21) Install the drive plate. (AT vehicles)

(A) O-ring
To lock the crankshaft, use ST.
ST 498497100 CRANKSHAFT STOPPER (3) Apply a coat of engine oil to the inside of the
Tightening torque: oil seal.
72 N.m (7.3 kgf-m, 52.8 ft-lb) I .I
1

W &
S2M0118B

(4) Install the oil pump on cylinder block. Be

22) Install the flywheel. (MT vehicles) <Ref. to CL-
14, INSTALLATION, Flywheel.>
23) Install the clutch disc and cover. (MT vehicles)
<Ref. to CL-11, INSTALLATION, Clutch Disc and
Cover.>
24) Installation of oil pump:
(1) Discard the front oil seal after removal. Re-
place with a new one using ST.
ST 499587100 OIL SEAL INSTALLER
careful not to damage the oil seal during instal-
lation.
Tightening torque:
6.4 N.m (0.65 kgf-m, 4.7 ft-lb)
CAUTION:
Do not forget to install the O-ring and seal
when installing the oil pump.
Align the flat surface of oil pump's inner rotor
with crankshaft before installation.

M0235

ME(D0HC TURBO)-80

CYLINDER BLOCK
25) Install the water pump and gasket.
Tightening torque:
First; 12 N-m (1.2 kgf-m, 8.7 ft-16)
Second; 12 N.m (1.2 kgf-m, 8.7 ff-16)
CAUTION:
Be sure to use a new gasket.
When installing the water pump, tighten bolts
in two stages in alphabetical sequence as
shown in the figure.
H2M1846D
26) Install the water by-pass pipe for heater.
27) Install the oil cooler.
Tightening torque:
T I : 55 N-m (5.5 kgf-m, 40 ft-16)
T2: 69 N-m (7.0 kgf-m, 50.6 ff-16)
(A) O-ring
(B) Oil cooler
(C) Connector
28) Install the oil filter using ST.
ST 498547000 OIL FILTER WRENCH
ME(D0HC TURBO)-81
II
MECHANICAL
29) Install the water by-pass pipe between oil cool-
er and water pump.
30) Install the water pipe.
NOTE:
Always use a new O-ring.
31) Install the cylinder head assembly. <Ref. to
ME(D0HC TURBO)-64, INSTALLATION, Cylinder
Head Assembly.>
32) Install the oil level gauge guide and tighten the
attaching bolt (left side only).
33) Install the rocker cover.
34) Install the crankshaft sprocket. <Ref. to
ME(D0HC TURBO)-58, INSTALLATION, Crank-
shaft Sprocket.>
35) Install the camshaft sprocket. <Ref. to
ME(DOHC TU RBO)-57, INSTALLATION, Cam-
shaft Sprocket.>
36) Install the timing belt assembly. <Ref. to
ME(D0HC TURBO)-50, INSTALLATION, Timing
Belt Assembly.>
37) Install the belt cover. <Ref. to ME(D0HC TUR-
BO)-47, INSTALLATION, Belt Cover.>
38) Install the crankshaft pulley. <Ref. to
ME(D0HC TURBO)-46, INSTALLATION, Crank-
shaft Pulley.>
39) Install the generator and A/C compressor
brackets on cylinder head.
40) Install the V-belt. <Ref. to ME(D0HC TURBO)-
44, INSTALLATION,V-belt.>
41) Install the intake manifold. <Ref. to FU(D0HC
TURBO)-15 , REMOVAL, Intake Manifold.>
 CYLINDER BLOCK
MECHANICAL

C: DISASSEMBLY
I

B2M13201

(1) Connecting rod cap (3) Top ring (5) Oil ring
(2) Connecting rod bearing (4) Second ring (6) Circlip
1) Remove the connecting rod cap.
2) Remove the connecting rod bearing.
CAUTION:
Arrange the removed connecting rod, connect-
ing rod cap and bearing in order to prevent con-
fusion.
3) Remove the piston rings using the piston ring ex-
pander.
4) Remove the oil ring by hand.
CAUTION:
Arrange the removed piston rings in proper or-
der to prevent confusion.
5) Remove the circlip.

ME(D0HC TURBO)-82
 CYLINDER BLOCK
MECHANICAL

D: ASSEMBLY

~~

(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 the connecting rod bearings on connect- E: INSPECTION
ing rods and connecting rod caps.
1. CYLINDER BLOCK
CAUTION:
Apply oil to the surfaces of the connecting rod 1) Visually check for cracks and damage. Especial-
bearings. ly, inspect the important parts by means of red lead
2) Install the connecting rod on crankshaft. check.
2) Check the oil passages for clogging.
CAUTION: 3) Inspect the crankcase surface that mates with
Position each connecting rod with the side cylinder head for warping by using a straight edge,
marked facing forward. and correct by grinding if necessary.
3) Install the connecting rod cap with connecting
rod nut. Warping limit:
Ensure the arrow on connecting rod cap faces the 0.05 mm (0.0020 in)
front during installation. Grinding limit:
CAUTION: 0.1 mm (0.004 in)
Each the connecting rod has its own mating Standard height of cylinder block:
cap. Make sure that they are assembled cor- 201.0 mm (7.91 in)
rectly by checking their matching number.
When tightening the connecting rod nuts, ap-
ply oil on the threads.
4) Install the oil ring spacer, upper rail and lower rail
in this order by hand. Then install the second ring
and top ring with a piston ring expander.

ME(D0HC TURBO)-83
 CYLINDER BLOCK
MECHANICAL

2. CYLINDER AND PISTON 2) How to measure the inner diameter of each cyl-
inder:
1) The cylinder bore size is stamped on the cylinder Measure the inner diameter of each cylinder in both
block’s front upper surface. the thrust and piston pin directions at the heights
CAUTION: shown in the figure, using a cylinder bore gauge.
Measurement should be performed at a temper- CAUTION:
ature of 20°C (68°F). Measurement should be performed at a temper-
NOTE: ature of 20°C (68°F).
Standard sized pistons are classified into two
grades, “ A and “B”. These grades should be used Taper:
as a guide line in selecting a standard piston. Standard
0.015 mm (0.0006 in)
Standard diameter: Limit
A: 92.005 - 92.015 mm (3.6222 - 3.6226 0.050 mm (0.0020 in)
in)
B: 91.995 - 92.005 mm (3.6218 -3.6222 Out-of-roundness:
in) Standard
0.010 mm (0.0004 in)
Limit
0.050 mm (0.0020 in)

FO
l (0.39)
45 (1.77)

80 (3.15)

115 (4.53)
(E)
H2M1732C

W
(A) Main journal size mark
Unit: mm (in)
(B) Cylinder block RH-LH combination mark S2M1821A

(C) #1 cylinder bore size mark

(A) Piston pin direction
(D) #2 cylinder bore size mark
(B) Thrust direction
(E) #3 cylinder bore size mark
(F) #4 cylinder bore size mark 3) When the piston is to be replaced due to general
or cylinder wear, determine a suitable sized piston
by measuring the piston clearance.

ME(D0HC TURBO)-84
 CYLINDER BLOCK
MECHANICAL

4) How to measure the outer diameter of each pis- 6) Boring and honing:
ton: (1) If the value of taper, out-of-roundness, or
Measure the outer diameter of each piston at the cylinder-to-piston clearance measured exceeds
height shown in the figure. (Thrust direction) the specified limit or if there is any damage on
the cylinder wall, rebore it to use an oversize pis-
CAUTION:
Measurement should be performed at a temper- ton.
ature of 20°C (68°F). CAUTION:
When any of the cylinders needs reboring, all
Piston grade point H: other cylinders must be bored at the same time,
37.0 mm (1.457 in) and use oversize pistons. Do not perform bor-
Piston outer diameter: ing on one cylinder only, nor use an oversize
Standard piston for one cylinder only.
A: 91.985 - 91.995 mm (2) If the cylinder inner diameter exceeds the
(3.6214 -3.6218 in) limit after boring and honing, replace the crank-
B: 91.975 - 91.985 mm case.
(3.621 1 - 3.6214 in) CAUTION:
0.25 mm (0.0098 in) oversize Immediately after reboring, the cylinder diame-
92.225-92.235" ter may differ from its real diameter due to tem-
(3.6309 - 3.6313 in) perature rise. Thus, pay attention to this when
0.50 mm (0.0197 in) oversize measuring the cylinder diameter.
92.475-92.485"
Limit of cylinder enlarging (boring):
(3.6407 - 3.641 1 in)
0.5 mm (0.020 in)

IJ B2M1305A

5) Calculate the clearance between cylinder and

piston.
CAUTION:
Measurement should be performed at a temper-
ature of 20°C (68°F).
Cylinder to piston clearance at 20°C (68OF):
Standard
0.010 - 0.030 mm (0.0004 - 0.0012 in)
Limit
0.050 mm (0.0020 in)

ME(D0HC TURBO)-85
 CYLINDER BLOCK

3. PISTON AND PISTON PIN 4) Check the circlip installation groove on the piston
for burr (A). If necessary, remove burr from the
'1 Check the pistons and piston pins for damage, groove so that the piston pin can lightly move.
cracks, and wear and the piston ring grooves for
wear and damage. Replace if defective.
2) Measure the piston-to-cylinder clearance at
each cylinder. <Ref. to ME(D0HC TURBO)-84,
CYLINDER AND PISTON, INSPECTION, Cylinder
Block.> If any of the clearances is not within speci- (A),
fication, replace the piston or bore the cylinder to
use an oversize piston.
3) Make sure that the piston pin can be inserted into
the piston pin hole with a thumb at 20°C (68°F). Re-
place if defective.
I
B2M0420E
~~ ~

Standard clearance between piston pin and

hole in piston: 5) Check the piston pin circlip for distortion, cracks
and wear.
Standard
0.004 - 0.008 mm (0.0002 - 0.0003 in)
Limit
0.020 mm (0.0008 in)

B2M1401

I
Micrometer
B2M0084A

ME(D0HC TURBO)-86
I CYLINDER BLOCK
MECHANICAL

4. PISTON RING 2) Squarely place the piston ring and oil ring in cyl-
inder, and measure the piston ring gap with a thick-
1) If the piston ring is broken, damaged, or worn, or
ness gauge.
if its tension is insufficient, or when the piston is re-
placed, replace the piston ring with a new one of
the same size as the piston. Standard Limit
CAUTION: 0.20 - 0.35
Top ring 1.O (0.039)
“N” is marked on the end of the top and sec-
ond rings. When installing the rings to the pis- 1.O (0.039)
ton, face this mark upward.

I
3 “N

EN0330

The oil ring is a combined ring consisting of

two rails and a spacer in between. When install-
ing, be careful to assemble correctly. 3) Measure the clearance between piston ring and
piston ring groove with a thickness gauge.
CAUTION:
Before measuring the clearance, clean the pis-
7“N”
ton ring groove and piston ring.
Unit: mm (in)
Standard Limit

between pis-
ton ring and

(A) Top ring groove ring

0.00281
(6) Second ring
(C) Oil ring
(a) Upper rail
(b) Spacer
(c) Lower rail

B2M1402

ME(D0HC TURBO)-87
 CYLINDER BLOCK
MECHANICAL

5. CONNECTING ROO 4) Inspect the connecting rod bearing for scar,

peeling, seizure, melting, wear, etc.
1) Replace the connecting rod, if the large or small
5) Measure the oil clearance on individual connect-
end thrust surface is damaged.
ing rod bearings by means of plastigauge. If any oil
2) Check for bend or twist using a connecting rod clearance is not within specification, replace the
aligner. Replace the connecting rod if the bend or defective bearing with a new one of standard size
twist exceeds the limit. or undersize as necessary. (See the table below.)
Limit of bend or twist per 100 mm (3.94 in) in Connecting rod oil clearance:
length:
0.10 mm (0.0039 in) Standard
-
0.020 0.046 mm (0.0008 - 0.0018 in)
Limit
0.05 mm (0.0020 in)
I Unit: mm (in)
I
Bearing size Outer diameter of
I Bearing
(Thickness at cen-
ter)
crank pin

I Standard
1.492 - 1.501 47.984 - 48.000

1.510-1.513 47.954 - 47.970

(0.0012)

n undersize

(0.0020)
undersize
1.520 - 1.523 47.934 - 47.950

1.620 - 1.623 47.734 - 47.750

(0.0098)
undersize

B2M1184B

(A) Thickness gauge

(B) Connecting rod

3) Install the connecting rod fitted with bearing to

crankshaft and measure the side clearance (thrust
clearance). Replace the connecting rod if the side
clearance exceeds the specified limit.
Connecting rod side clearance:
Standard
-
0.070 0.330 mm (0.0028 - 0.0130 in)
Limit
0.4 mm (0.016 in)

ME(DOHC TUR BO)-88

 CYLINDER BLOCK
6) Inspect the bushing at connecting rod small end,
and replace if worn or damaged. Also measure the
piston pin clearance at the connecting rod small
end.
Clearance between piston pin and bushing:
Standard
0 - 0.022 mm (0 - 0.0009 in)
Limit
0.030 mm (0.0012 in)
U place or recondition crankshaft as necessary.
B2M0084
7) Replacement procedure is as follows:
(1) Remove the bushing from connecting rod
with ST and press.
(2) Press the bushing with ST after applying oil
on the periphery of bushing.
ST 499037100 CONNECTING ROD BUSH-
ING REMOVER AND IN-
STALLER
(3) Make two 3 mm (0.12 in) holes in bushing.
Ream the inside of bushing.
(4) After completion of reaming, clean the bush-
ing to remove chips.
ME(D0HC TURBO)-89
MECHANICAL
6. CRANKSHAFT AND CRANKSHAFT
BEARING
1) Clean the crankshaft completely and check for
cracks by means of red lead check etc., and re-
place if defective.
2) Measure the crankshaft bend, and correct or re-
place if it exceeds the limit.
CAUTION:
If a suitable V-block is not available, install #1
and #5 crankshaft bearing on cylinder block,
position crankshaft on these bearings and mea-
sure the crankshaft bend using a dial gauge.
Crankshaft bend limit:
0.035 mm (0.0014 in)
3) Inspect the crank journal and crank pin for wear.
If they are not within the specifications, replace the
bearing with a suitable (undersize) one, and re-
When grinding the crank journal or crank pin, finish
them to the specified dimensions according to the
undersize bearing to be used.
Crank pin and crank journal:
Out-of-roundness
0.020 mm (0.0008 in) or less
Taper limit
0.07 mm (0.0028 in)
Grinding limit
0.250 mm (0.0098 in)
G2M0179
 CYLINDER BLOCK
MECHANICAL

Unit: mm (in)

#1, #3, #5 #2, #4

59.992 - 60.008 59.992 - 60.008 47.984 - 48.000
Journal O.D.
(2.3619 - 2.3625) (2.3619 - 2.3625) (1.8891 - 1.8898)
Standard Bearing size
1.998 - 2.01 1 2.000 - 2.013 1.492-1.510
(Thickness at cen-
(0.0787 - 0.0792) (0.0787 - 0.0793) (0.0587 - 0.0591)
ter)
59.962 - 59.978 59.962 - 59.978 47.954 - 47.970
Journal O.D.
(2.3607 - 2.361 3) (2.3607 - 2.361 3) (1.8879 - 1.8886)
0.03 (0.0012)
Bearing size
undersize 2.01 7 - 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 47.934 - 47.950
Journal O.D.
(2.3599 - 2.3605) (2.3599 - 2.3605) (1.8872 - 1.8878)
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)

I --
0.25 (0.0098)
Journal O.D.
59.742
(2.3520
59.758
2.3527)
59.742 - 59.758
(2.3520 - 2.3527)
47.734 - 47.750
(1.8793 - 1.8799)
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 the bearing. ment is not within the specification, replace the de-
fective bearing with an undersize one, and replace
Crankshaft thrust clearance:
or recondition the crankshaft as necessary.
Standard
0.030 - 0.115 mm (0.0012 - 0.0045 in) I Unit: mm fin) I
Limit
0.25 mm (0.0098 in) Standard 0.01 0 - 0.030 (0.0004 -
0.001 2)
I Limit I 0.040 (0.0016) I

EN0341 I
5) Inspect individual crankshaft bearings for signs
of flaking, seizure, melting, and wear.

ME(D0HC TURBO)-90
 ENGINE TROUBLE IN GENERAL
MECHANICAL

21 .Engine Trouble in General

A: INSPECTION
NOTE: A - Very often
“RANK’ shown in the chart refers to the possibility B - Sometimes
of reason for the trouble in order (“Very often” to C - Rarely
“Rarely”)
TROUBLE PROBLEM PARTS, ETC. I POSSIBLE CAUSE I RANK
1. Engine will not start.
1) Starter does not turn. Starter Defective battery-to-starter harness B
Defective starter switch C
Defective inhibitor switch or neutral switch C
1 Defective starter I B
Battery I Poor terminal connection I A
Run-down battery A
Defective charging system B
Friction Seizure of crankshaft and connecting rod bearing C
Seized camshaft C
I Seized or stuck piston and cylinder I C
~~

2) Initial combustion does Starter 1 Defective starter I C

not occur. Engine control system <Ref. to EN(D0HC TURBO)-2, Basic Diagnostic Procedure.> 1 A
Fuel line Defective fuel pump and relay I A
I
Lack of or insufficient fuel I
I
B
Belt I Defective I B
I Defective timina I B
Compression I Incorrect valve clearance I C
1 Loosened spark plugs or defective gasket I C
Loosened cylinder head bolts or defective gasket C
Improper valve seating C
Defective valve stem C
F W o r n G broken valve sprina I B
I Worn or stuck piston rings, cylinder and piston I C
I Incorrect valve timing I B
I Improper engine oil (low viscosity) B
3) Initial combustion occur. Engine control system <Ref. to EN(D0HC TURBO)-2, Basic Diagnostic Procedure.> A
Intake system Defective intake manifold gasket B
Defective throttle bodv aasket B
I Defective fuel pump and relay
~~

Fuel line I C
1 Clogged fuel line I C
I Lack of or insufficient fuel I B
Belt Defective I B
Defective timina
“ I B
Compression Incorrect valve clearance C
Loosened spark plugs or defective gasket C
Loosened cylinder head bolts or defective gasket C
I Improper valve seating I C
Defective valve stem C
Worn or broken valve spring B
Worn or stuck piston rinas. cvlinder and piston C
I.lncorrect v a G timina I B
I Improper engine oil (low viscosity) I B

ME(D0HC TURBO)-91
 ENGINE TROUBLE IN GENERAL
MECHANICAL

TROUBLE PROBLEM PARTS, ETC. I POSSIBLE CAUSE I

RANK
4) Engine stalls after initial Engine control system <Ref. to EN(D0HC TURBO)P, Basic Diagnostic Procedure.> I A
combustion. Intake system Loosened or cracked intake duct B
Loosened or cracked PCV hose C
Loosened or cracked vacuum hose C
I
I
Defective intake manifold aasket I B
I Defective throttle body gasket I B
Dirty air cleaner element C
Fuel line Clogged fuel line C
Lack of or insufficient fuel B
Belt Defective B
Defective timina B
Compression I Incorrect valve clearance I C
I Loosened spark plugs or defective gasket I C
I Loosened cylinder head bolts or defective gasket I C
Improper valve seating I C
Defective valve stem II C
I Worn or broken valve sprina I B
I Worn or stuck piston rings, cylinder and piston I C
I Incorrect valve timing I B
I Improper engine oil (low viscosity) B
2. Rough idle and engine Engine control system <Ref. to EN(D0HC TURBO)-2, Basic Diagnostic Procedure.> A
stall Intake system Loosened or cracked intake duct / A
Loosened or cracked PCV hose / A
I Loosened or cracked vacuum hose I A
I Defective intake manifold gasket I B
Defective throttle body gasket I B
Defective PCV valve I C
Loosened oil filler cap B
Dirty air cleaner element C
Fuel line Defective fuel Dump and relav C
I Clogged fuel line I C
I Lack of or insufficient fuel I B
Belt I Defective timing I C
Compression Incorrect valve clearance B
Loosened spark plugs or defective gasket B
Loosened cvlinder head bolts or defective aasket B
I Improper valve seatina I B
I Defective valve stem I C
1 Worn or broken valve spring I B
I Worn or stuck piston rings, cylinder and piston I B
Incorrect valve timing ] A
ImDroDer enaine oil (low viscositv) I B
Lubrication system I Incorrect oil pressure -1 --B
I Defective rocker cover gasket I C
Cooling system I Overheating I C
Others I Malfunction of evaporative emission control system I A
Stuck or damaged throttle valve B
Accelerator cable out of adjustment C

ME(D0HC TURBO)-92
 ENGINE TROUBLE IN GENERAL
MECHANICAL

PROBLEM PARTS, ETC. I POSSIBLE CAUSE RANK

Engine control system <Ref. to EN(D0HC TURBO)-2, Basic Diagnostic Procedure.> A
Intake system Loosened or cracked intake duct I A
Loosened or cracked PCV hose / A
FLoosened or cracked vacuum hose I B
I Defective intake manifold gasket I B
I Defective throttle body gasket I B
Defective PCV valve B
Loosened oil filler cap B
Dirty air cleaner element A
Fuel line Defective fuel Dump and relav B
1 Cloaaed fuel line I B
I Lack of or insufficient fuel I C
Belt Defective timing B
Compression Incorrect valve clearance B
Loosened spark plugs or defective gasket B
Loosened cvlinder head bolts or defective aasket B
I Improper valve seating I B
I Defective valve stem I C
Worn or broken valve spring B
Worn or stuck piston rings, cylinder and piston C
Incorrect valve timing A
Improper enaine oil (low viscositv) B
~~

~
Lubrication svstem Incorrect oil pressure I B
Cooling system Overheating I C
Over coolina I C
Others I Malfunction of evaporative emission control system A
Engine control system <Ref. to EN(D0HC TURBO)-2, Basic Diagnostic Procedure.> A
Intake system Loosened or cracked intake duct A
Loosened or cracked PCV hose A
I Loosened or cracked vacuum hose I A
I Defective intake manifold gasket I B
Defective throttle body gasket B
Defective PCV valve B
Loosened oil filler cap B
Dirty air cleaner element B
Fuel line Defective fuel pump and relav B
1 Clogged fuel line I B
Lack of or insufficient fuel C
Belt Defective timing B
Compression Incorrect valve clearance B
Loosened spark Dluas or defective aasket C
1 Loosened cylinder head bolts or defective gasket I C
I Improper valve seating I C
Defective valve stem
Worn or broken valve spring
Worn or stuck piston rings, cylinder and piston
Incorrect valve timing A
Improper enaine oil (low viscositv) B
I
~~

Coolina svstem Overheating

Others I Malfunction of evaporative emission control system I C

ME(D0HC TURB0)-93
 ENGINE TROUBLE IN GENERAL
MECHANICAL

TROUBLE I PROBLEM PARTS, ETC. I POSSIBLE CAUSE RANK I

5. Enaine does not return to I Enaine control svstem <Ref. to EN(D0HC TURBOb2. Basic Diaanostic Procedure.> II A
I idle.
*
Intake system I
, I

Loosened or cracked vacuum hose

*

I A
II II Others 1I Stuck or damaaed
- throttle valve \I A 1
I
I Accelerator cable out of adjustment I B
I
6. Dieseling (Run-on) I
1
Engine control system <Ref. to EN(D0HC TURBO)-2, Basic Diagnostic Procedure.> I A
I
I I Cooling system I Overheating I B I
I Others I1 Malfunction of evaoorative emission control svstem I B 1
7. After burning in exhaust Engine control system <Ref. to EN(D0HC TURBO)-2, Basic Diagnostic Procedure.> A
system Intake system I Loosened or cracked intake duct C
II II II Loosened or cracked PCV hose I
I
C 1I
II II II Loosened or cracked vacuum hose
I I Defective PCV valve
Loosened oil filler cap C
Defective timing B
Incorrect valve clearance B
II II II Loosened spark pluns -
. - or defective nasket I
I
C 1I
II II II Loosened cylinder head bolts or defective gasket I C I
I
II II II Improper valve seating I B 4
I
I I I Defective valve stem I C 1
Worn or broken valve spring C
Worn or stuck piston rings, cylinder and piston C
Incorrect valve timing A
II II Lubrication system I Incorrect oil pressure I C 1I
I I Cooling system I Over cooling I C 1
I
~~

Others Malfunction of evaporative emission control system C

8. Knocking Engine control system <Ref. to EN(D0HC TURBO)-2, Basic Diagnostic Procedure.> A
Intake system I Loosened oil filler cap B
II II Belt I
I
-
Defective timina I
I
B I
I
Compression Incorrect valve clearance I C
Incorrect valve timing I B
Cooling system Overheating A
9. Excessive engine oil con- Intake system Loosened or cracked PCV hose A
sumption Defective PCV valve B
Loosened oil filler cap I C
Compression Defective valve stem I A
Worn or stuck piston rings, cylinder and piston I A
Lubrication system Loosened oil pump attaching bolts and defective B
gasket
Defective oil filter o-rina B
Defective crankshaft oil seal I B
Defective rocker cover gasket I B
Loosened oil drain plug or defective gasket I B
Loosened oil pan fitting bolts or defective oil pan I B

ME(D0HC TURBO)-94
 ENGINE TROUBLE IN GENERAL
MECHANICAL

TROUBLE PROBLEM PARTS, ETC. 1 POSSIBLE CAUSE RANK

10. Excessive fuel consump- Engine control system <Ref. to EN(D0HC TURBO)-2, Basic Diagnostic Procedure.> A
I tion I Intake svstem I Dirtv air cleaner element I A I

-
Belt Defective timing B
Compression Incorrect valve clearance B
Loosened spark plugs or defective gasket C
Loosened cylinder head bolts or defective gasket C
Improper valve seating B
Defective valve stem C
Worn or broken valve spring C
Worn or stuck piston rings, cylinder and piston B
Incorrect valve timing 6
Lubrication system Incorrect oil pressure C
Cooling system Over cooling C
Others Accelerator cable out of adjustment B

ME(D0HC TURBO)-95
 ENGINE NOISE
MECHANICAL

22.Engine Noise
A: INSPECTION
Type of sound Condition Possible cause
Valve mechanism is defective.
Incorrect valve clearance
Sound increases as engine
Regular clicking sound Worn valve rocker
speed increases.
Worn camshaft
Broken valve sDrina
Worn crankshaft main bearing
Oil pressure is low.
Worn connecting rod bearing (big end)
Heavy and dull clank
Loose flywheel mounting bolts
Oil pressure is normal.
Damaaed enaine mountina ~
~~ ~~

Ignition timing advanced

High-pitchedclank (Spark
knock)
Clank when engine speed is
medium (1,000 to 2,000 rpm).
Knocking sound when engine
is operating under idling speed
and engine is warm
Squeaky sound
Rubbing sound
Gear scream when starting
engine
Sound like polishing glass with
a dry cloth
Hissing sound
~
Sound is noticeable when Accumulation of carbon inside combustion chamber
accelerating with an overload. Wrong spark plug
Improper gasoline
Sound is reduced when fuel Worn crankshaft main bearing
injector connector of noisy cyl- Worn bearing at crankshaft end of connecting rod
inder is disconnected.
(NOTE9
Sound is reduced when fuel Worn cylinder liner and piston ring
injector connector of noisy cyl- Broken or stuck piston ring
inder is disconnected. Worn piston pin and hole at piston end of connecting rod
(NOTE*)
Sound is not reduced if each Unusually worn valve lifter
fuel injector connector is dis- Worn cam gear
connected in turn. (NOTE*) Worn camshaft journal bore in crankcase
I - Insufficient generator lubrication
I - Defective generator brush and rotor contact
- Defective ignition starter switch
Worn pear and starter pinion
- Loose drive belt
Defective water pump shaft
Loss of compression
Air leakage in air intake system, hoses, connections or mani-
folds

Timing belt noise - Loose timing belt

Belt contacting case/adjacent part
Valve tappet noise Incorrect valve clearance
NOTE*:
When disconnectingthe 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(D0HC TURBO)-49, OPERATION, Clear Memory Mode.> and
INSPECTION MODE <Ref. to EN(D0HC TURBO)-46, OPERATION, Inspection Mode.> after connecting the fuel injector con-
nector.

ME(D0HC TURBO)-96
EXHAUST

EX(D0HC TURBO)
Page
1. General Description .................................................................................... 2
2. Front Exhaust Pipe...................................................................................... 6
3. Center Exhaust Pipe ................................................................................... 8
4. Joint Pipe .................................................................................................. 12
3 -

5. Rear Exhaust Pipe .................................................................................... 13

6. Muffler ....................................................................................................... 14
 GENERAL DESCRIPTION
EXHAUST

1 General Description
A: COMPONENT
1. FRONT EXHAUST PIPE

EN1183

EX(D0HC TURBO)-2
 GENERAL DESCRIPTION
EXHAUST

Gasket Front exhaust pipe lower insulator (21) Turbocharger joint pipe
Upper exhaust manifold cover (RH) (22) Gasket
(RH) Front exhaust pipe lower insulator (23) Front oxygen (NF) sensor
Exhaust manifold (RH) (LH) (24) Precatalytic converter
Lower exhaust manifold cover Front exhaust pipe lower cover (25) Exhaust temperature sensor
(RH) Front exhaust pipe lower clamp
Front exhaust pipe upper clamp Gasket
Front exhaust pipe upper cover Gasket
Front exhaust pipe upper insulator Upper exhaust manifold cover Tightening torque: N.m (kgf-m, ft-lb)
(RH) (LH) T1: 19 (1.9, 13.7)
Front exhaust pipe upper insulator Exhaust manifold (LH) T2: 25 (2.5, 18.1)
(LH) Lower exhaust manifold cover T3: 35 (3.6, 26.0)
Gasket (LH) T4: 40 (4, 28.9)
Front exhaust pipe Gasket

EX(D0HC TURB0)S
 GENERAL DESCRIPTION
EXHAUST

2. CENTER AND REAR EXHAUST PIPE, AND MUFFLER

L4
I \

EN1113

Gasket Rear catalytic converter (25) Upper rear exhaust pipe cover
Front catalytic converter Upper clamp (Rear)
Upper center pipe cover (Front) Gasket (26) Gasket
Center exhaust pipe (Front) Rear exhaust pipe (27) Muffler
Lower center pipe cover (Front) Lower rear exhaust pipe cover (28) Cushion
Bracket (Front) (29) Muffler cutter
Gasket Chamber (30) Center exhaust pipe (Rear)
Upper center pipe cover (Rear) Lower rear exhaust pipe cover
Lower center pipe cover (Rear) (Rear) Tightening torque: N.m (kgf-m, ft-lb)
Upper rear catalytic converter Cushion T1: 13 (1.3, 9.6)
cover Spring T2: lS(1.8, 13.0)
Lower clamp Bolt T3: 30 (3.1, 22.4)
Lower rear catalytic converter Upper rear exhaust pipe cover T4: 35 (3.6, 26.0)
cover (Front) T5: 48 (4.9, 35.4)
Rear oxygen sensor

EX(D0HC TURBO)-4
 GENERAL DESCRIPTION
EXHAUST

B: CAUTION
Wear working clothing, including a cap, protec-
tive goggles, and protective shoes during opera-
tion.
Remove contamination including dirt and corro-
sion before removal, installation or disassembly.
Keep the disassembled parts in order and pro-
tect them from dust or dirt.
Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary re-
moval, installation, disassembly, and replacement.
Be careful not to burn your hands, because each
part on the vehicle is hot after running.
Be sure to tighten fasteners including bolts and
nuts to the specified torque.
Place shop jacks or safety stands at the specified
points.
Before disconnecting electrical connectors of
sensors or units, be sure to disconnect the negative
terminal from battery.

EX(D0HC TURBO)-5
~

FRONT EXHAUST PIPE

EXHAUST

2. Front Exhaust Pipe 10) Separate the front exhaust pipe from exhaust
manifolds.
A: REMOVAL
1) Disconnect the ground terminal from battery.

B: INSTALLATION
CAUTION:
2) Remove the front oxygen (NF) sensor. <Ref. to
Replace the gaskets with new ones.
FU(D0HC TURBO)-42, REMOVAL, Front Oxygen
(NF) Sensor.> 1) Assemble the front exhaust pipe and exhaust
3) Remove the under cover. manifolds.
4) Remove the lower exhaust manifold cover (RH). Tightening torque:
5) Remove the lower and upper exhaust manifold 35 N.m (3.6 kgf-m, 26.0 ff-lb)
covers (LH).

- G2M0854

2) Install the front exhaust pipe covers.

6) Remove the bolts and nuts which hold the front
exhaust pipe assembly to turbocharger joint pipe.
7) While holding the front exhaust pipe assembly
with one hand, remove the nuts which hold the front
exhaust pipe assembly to cylinder head exhaust
port.
0
0 0 0 0
Tightening torque:
25 N.m (2.5 kgf-m, 78.7 ff-lb)
3) Install the upper exhaust manifold cover (RH).
Tightening torque:
79 N-m (1.9 kgf-m, 73.7 ff-lb)
4) Install the front exhaust pipe assembly.
Tightening torque:
35 N-m (3.6 kgf-m, 26.0 ff-lb)

8) Remove the front exhaust pipe assembly.

9) Remove the covers from exhaust manifold and
front exhaust pipe.

EX(D0HC TURBO)-6
 lls
FRONT EXHAUST PIPE
EXHAUST

5) Connect the exhaust manifold (RH) to turbo-

charger joint pipe.
Tightening torque:
35 N-m (3.6 kgf-m, 26.0 ft-lb)

6) Install the upper and lower exhaust manifold

covers (LH).
Tightening torque:
79 N-m (7.9 kgf-m, 73.7 ff-lb)
7) Install the lower exhaust manifold cover (RH).
Tightening torque:
79 N*m (7.9 kgf-m, 73.7 ft-lb)

8) Install the front oxygen (NF)sensor. <Ref. to

FU(D0HC TURBO)-43, INSTALLATION, Front
Oxygen (NF)Sensor.>
9) Install the under cover.
10) Connect the battery ground terminal to battery.

EX(D0HC TURBO)-7
 CENTER EXHAUST PIPE
EXHAUST

3. Center Exhaust Pipe 10) Remove the bolts which install the lower upper
side of turbocharger upper cover, and remove it.
A: REMOVAL
1) Set the vehicle on the lift.
2) Disconnect the ground terminal from battery.
3) Remove the intercooler. <Ref. to IN(D0HC
TURBO)-10, REMOVAL, Intercooler.>
4) Remove the intercooler bracket.

11) Separate the center exhaust pipe from turbo-

charger.

5) Lift-up the vehicle.

6 ) Remove the under cover.
7) Remove the bolts which install the lower side of
turbocharger upper cover.
CAUTION:
Be careful, the turbocharger and exhaust pipe
are hot.
12) Lift-up the vehicle.
13) Disconnect the connector from rear oxygen
sensor.

8) Lower the vehicle.

9) Remove the turbocharger upper cover.
14) Vertically draw out clip from crossmember.

I S2M2254

EX(D0HC TURBO)-8
 CENTER EXHAUST PIPE
m
EXHAUST

15) Separate the center exhaust pipe from rear ex- B: INSTALLATION
haust pipe.
CAUTION:
Replace the gaskets with new ones.
1) Install the center exhaust pipe and temporarily
tighten the bolt which holds center exhaust pipe to
hanger bracket.
2) Temporarily tighten the bolt which holds the cen-
ter pipe to transmission.
3) Connect the center exhaust pipe to turbocharg-
er.
Tightening torque:
'I \ I G2M085E
35 N-m (3.6 kgf-m, 26.0 ft-lb)
16) Remove the bolt which holds center exhaust
pipe bracket to transmission.

4) Install the center exhaust pipe to rear exhaust

pipe.
17) Remove the intercooler bracket. Tightening torque:
18) Remove the bolt which holds center exhaust
18 N-m (1.8 kgf-m, 13.0 ft-lb)
pipe to hanger bracket.
CAUTION:
Be careful not to pull down the center exhaust
pipe.

I' I G2M0855 I

5 ) Connect the connector to rear oxygen sensor.

19) Remove the center exhaust pipe.

EX(D0HC TURBO)-9
 CENTER EXHAUST PIPE
EXHAUST

6) Secure clip on the crossmember. 11) Place the turbocharger lower cover, and tighten
the bolts which install the upper side of lower cover.
Tightening torque:
7.4 N.m (0.75 kgf-m, 5.4 ff-lb)

I I S2M2254

7) Tighten the bolt which holds the center exhaust

pipe bracket to transmission.
Tightening torque:
30 N-m (3.1 kgf-m, 22.4 ff-lb)
12) Place the turbocharger upper cover, and tight-
en the bolts which install the upper side of upper
cover.
Tightening torque:
7.4 Nom(0.75 kgf-m, 5.4 ff-lb)

8) Tighten the bolt which holds the center exhaust

pipe to hanger bracket.
Tightening torque:
35 N-m (3.6 kgf-m, 26.0 ff-lb)
13) Lift-up the vehicle.
14) Tighten the bolts which install the under side of
turbocharger upper cover.
Tightening torque:
7.4 N-m (0.75 kgf-m, 5.4 ff-lb)

9) Tighten the bolts which hold the intercooler

bracket.
Tightening torque:
35 N-m (3.6 kgf-m, 26.0 ff-lb)
10) Lower the vehicle.
15) Install the under cover.
16) Lower the vehicle.

EX(D0HC TURBO)-I 0
 CENTER EXHAUST PIPE
EXHAUST

17) Install the intercooler bracket.

18) Install the intercooler. <Ref. to IN(D0HC TUR-

BO)-11, INSTALLATION, Intercooler.>

EX(D0HC TURBO)-1 1
I
JOINT PIPE
EXHAUST

4. Joint Pipe 6) Remove the lower exhaust manifold cover (RH).

A: REMOVAL
1) Disconnect the ground terminal from battery

7) Remove the nuts which hold the front exhaust

manifold to joint pipe.

2) Remove the solenoid valve cover.

8) Remove the center exhaust pipe. <Ref. to

3) Disconnect the exhaust temperature sensor con-
nector.
EX(D0HC TURBO)-8, REMOVAL, Center Exhaust
Pipe.>
9) Remove the turbocharger. <Ref. to IN(D0HC
TURBO)-12, REMOVAL, Turbocharger.>
10) Take off the joint pipe in the upward direction.
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
T: 35 N-m (3.6 kgf-m, 26.0 ff-lb)

4) Remove the front oxygen (NF) sensor. <Ref. to

FU(D0HC TURBO)-42, REMOVAL, Front Oxygen
(NF) Sensor.>
5) Remove the under cover.

EX(D0HC TURBO)-12
 REAR EXHAUST PIPE
EXHAUST

5. Rear Exhaust Pipe B: INSTALLATION

A: REMOVAL
1) Disconnect the ground terminal from battery.
CAUTION:
Replace the gaskets with new ones.
1) Install the rear exhaust pipe to muffler.
Tightening torque:
48 N.m (4.9 kgf-m, 35.4 ft-lb)

2) Lift up the vehicle.

3) Separate the rear exhaust pipe from center ex-
haust pipe.
CAUTION: 2) Install the rear exhaust pipe to center exhaust
Be careful, the exhaust pipe is hot. pipe.
Tightening torque:
18 N-m (1.8 kgf-m, 13.0 ft-lb)

4) Separate the rear exhaust pipe from muffler.

CAUTION:
Be careful not to pull down the rear exhaust 3) Lower the vehicle.
pipe. 4) Connect the battery ground terminal to battery.

~~

5) Remove the rear exhaust pipe. C: INSPECTION

1) Make sure there are no exhaust leaks from con-
nections and welds.
2) Make sure there are no holes or rusting.
3) Make sure the cushion rubber is not worn or
cracked.

EX(D0HC TURBO)-13
 MUFFLER
EXHAUST

6. Muffler B: INSTALLATION
1) Install in the reverse order of removal.
A: REMOVAL CAUTION:
1) Separate the muffler from rear exhaust pipe. Replace the gasket with a new one.
CAUTION:
Tightening torque:
Be careful, the exhaust pipe is hot.
48 N.m (4.9 kgf-m, 35.4 ft-lb)

2) Remove the rubber cushions, and detach muf-

fler. C: INSPECTION
1) Make sure there are no exhaust leaks from con-
CAUTION: nections and welds.
Be careful not to drop the muffler during remov-
2) Make sure there are no holes or rusting.
al.
3) Make sure the cushion rubber is not worn or
NOTE: cracked.
To facilitate removal, apply a coat of SUBARU
CRC to the mating area of rubber cushions in ad-
vance.
SUBARU CRC (Part No. 00430 1003)

II EN089

EX(D0HC TURBO)-14
IGNITION

IG(D0HC TURBO)
Page
1. General Description .................................................................................... 2
2. Spark Plug................................................................................................... 4
3. Ignition Coil and Ignitor Assembly ............................................................... 8
 GENERAL DESCRIPTION
IGNITION

1. General Description
A: SPECIFICATIONS
I / ~ Item I Designation I

I and ignitor
assemblv I Manufacturer DIAMOND

1 TvDe and manufacturer I PFRGG: NGK I

Spark plug Thread size mm 14, P = 1.25
Spark gap mm (in) 0.7 - 0.8 (0.028 - 0.031)

IG(D0HC TURBO)-2
 GENERAL DESCRIPTION
B: COMPONENT
(1) Spark plug
(2) Ignition coil and ignitor ASSY
C: CAUTION
Wear working clothing, including a cap, protec-
tive goggles, and protective shoes during opera-
tion.
Remove contamination including dirt and corro-
sion before removal, installation or disassembly.
Keep the disassembled parts in order and pro-
tect them from dust or dirt.
Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary re-
moval, installation, disassembly, and replacement.
IG(D0HC TURBO)-3
IGNITION
El
EN085:
Tightening torque: N-m (kgf-m, ft-lb)
T l : 21 (2.1, 15)
T2: 16 (1.6, 11.7)
Be careful not to burn your hands, because each
part on the vehicle is hot after running.
Be sure to tighten fasteners including bolts and
nuts to the specified torque.
Place shop jacks or safety stands at the specified
points.
Before disconnecting electrical connectors of
sensors or units, be sure to disconnect the negative
terminal from battery.
I SPARK PLUG
IGNITION

2. Sparkplug 5) Remove the spark plugs with the spark plug

sockets.
A: REMOVAL
CAUTION:
All spark plugs installed on an engine, must be
of the same heat range.
Spark plug:
NGK: PFRGG
1. RH SIDE
1) Disconnect the ground terminal from battery.

2. LH SIDE
1) Disconnect the battery terminals, and then re-
move the battery and battery carrier.

2) Remove the air cleaner lower case. <Ref. to

IN(D0HC TURBO)-7, REMOVAL, Air Cleaner.>
3) Disconnect the connector from ignition coil.

2) Disconnect the washer motor connector

EN0854

4) Remove the ignition coil.

3) Disconnect the rear window glass washer hose

from washer motor, then plug connection with a
suitable cap.

EN0855I

IG(D0HC TURBO)-4
 SPARK PLUG
4) Remove the two bolts which hold the washer
tank, then take the tank away from the working ar-
ea.
5) Disconnect the connector from ignition coil.
6) Remove the ignition coil.
7) Remove the spark plug with the spark plug sock-
ets.
.
EN0859
IG(D0HC TURBO)+
IGNITION
B: INSTALLATION
1. RH SIDE
1) Install in the reverse order of removal.
Tightening torque (Spark plug):
21 N-m (2.1 kgf-m, 15 ft-lb)
Tightening torque (Ignition coil):
16 N.m (1.63 kgf-m, 11.8 fi-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
1) Install in the reverse order of removal.
Tightening torque (Spark plug):
21 N.m (2.1 kgf-m, 15 ft-lb)
Tightening torque (Ignition coil):
16 N-m (1.63 kgf-m, 11.8 ft-lb)
CAUTION:
The above torque should be only applied to
new spark plugs without oil on their threads.
In case their threads are lubricated, the torque
should be reduced by approximately 1/3 of the
specified torque in order to avoid over-stress-
ing.
 SPARK PLUG
IGNITION

C: INSPECTION 3) Oil fouled:

Check the electrodes and inner and outer porcelain
of plugs, noting the type of deposits and the degree
of electrode erosion.
Wet black deposits show excessive oil entrance
into combustion chamber through worn rings and
pistons or excessive clearance between valve
guides and stems. If the same condition remains
after repair, use a hotter plug.

(E,
S6M0420A

(A) Electrode gap G6M0089

(B) Carbon accumulation or wear 4) Overheating:

(C) Cracks White or light gray insulator with black or gray
(D) Damage brown spots and bluish burnt electrodes indicate
(E) Damaged gasket engine overheating. Moreover, the appearance re-
sults from incorrect ignition timing, loose spark
1) Normal: plugs, wrong selection of fuel, hotter range plug,
Brown to grayish-tan deposits and slight electrode etc. It is advisable to replace with plugs having
wear indicate correct spark plug heat range. colder heat range.

3M0087 G6M009C

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.
It is advisable to replace with plugs having hotter
heat range.

IG(D0HC TURBO)-6
 SPARK PLUG
IGNITION

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

S6M0412A

NOTE:
Replace with a new spark plug if this area is worn to
“ball” shape.

IG(D0HC TURBOJ-7
 IGNITION COIL AND IGNITOR ASSEMBLY
IGNITION

3. Ignition Coil and Ignitor As- C: INSPECTION

sembly Ignitor is integrated with the coil. Therefore resis-
tance cannot be measured.
A: REMOVAL
Direct ignition type has been adopted.
Refer to the “Spark Plug Removal” for removal pro-
cedure. <Ref. to IG(D0HC TURBO)-4, REMOV-
AL, Spark Plug.>
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
76 N-m (7.63 kgf-m, 7 7.8 ft-lb)

IG(D0HC TURBO)-8
ENGINE (DIAGNOSTICS)

EN(D0HC TURBO)
Page
1. Basic Diagnostic Procedure ........................................................................ 2
2. Check List for Interview............................................................................... 4
3. General Description .................................................................................... 6
4. Electrical Components Location.................................................................. 9
5. Engine Control Module (ECM) I/O Signal ................................................. 26
6. Engine Condition Data .............................................................................. 30
7. Transmission Control Module (TCM) I/O Signal ....................................... 32
8. Data Link Connector ................................................................................. 35
9. OBD-ll General Scan Tool ........................................................................ 36
10. Subaru Select Monitor............................................................................... 38
11. Read Diagnostic Trouble Code ................................................................. 45
12. Inspection Mode ........................................................................................ 46
13. Clear Memory Mode.................................................................................. 49
14. Compulsory Valve Operation Check Mode ............................................... 50
15. Engine Malfunction Indicator Lamp (MIL) ................................................. 52
16. Diagnostics for Engine Starting Failure..................................................... 63
17. List of Diagnostic Trouble Code (DTC) ..................................................... 80
18. Diagnostic Procedure with Diagnostic Trouble Code (DTC) ..................... 88
19. General Diagnostic Table ........................................................................ 372
I
BASIC DIAGNOSTIC PROCEDURE
ENGINE (DIAGNOSTICS)

1. Basic Diagnostic Procedure

A: PROCEDURE
1. ENGINE
~

Step Check Yes No

CHECK ENGINE START FAILURE. )oes the engine start? Go to step 2. Inspection using
1)Ask the customer when and how the trouble “Diagnostics for
occurred using the interview check list. <Ref. to Engine Start Fail-
EN(D0HC TURBO)-4, CHECK, Check List for ure”. <Ref. to
Interview.> EN(D0HC
2)Start the engine. TURBO)-63, Diag-
nostics for Engine
Starting Failure.>
I
CHECK ILLUMINATION OF CHECK ENGINE )oes CHECK ENGINE mal- Go to step 3. Inspection using
MALFUNCTION INDICATOR LAMP (MIL). Jnction indicator lamp illumi- “General Diagnos-
late? tics Table”. <Ref.
to EN(D0HC
TURBO)-372,
General Diagnos-
tic Table.>
I CHECK INDICATION OF DTC ON DISPLAY. )oes the Subaru Select Moni- Record the diag- Repair the related
1)Turn the ignition switch to OFF. 3r or OBD-II general scan tool nostic trouble parts.
2)Connect the Subaru Select Monitor or the idicate DTC? code. Repair the NOTE:
OBD-ll general scan tool to data link connec- trouble cause. If DTC is no
tor. <Ref. to EN(D0HC shown on displa!
3)Turn the ignition switch to ON and the Sub- TURBO)-80, List although the MIL il
aru Select Monitor or OBD-I1 general scan tool of Diagnostic Trou- luminates, per
switch to ON. ble Code (DTC).r form diagnostics o
4)Read the DTC on the Subaru Select Monitor Go to step 4. MIL (CHECK EN
or OBD-ll general scan tool. GINE malfunctior
indicator lamp) cir
cuit or combinatior
meter. <Ref. tc
EN(D0HC TUR
BO)-52, Engint
Malfunction Indica
tor Lamp (MIL).>
I PERFORM THE DIAGNOSIS. Ioes the Subaru Select Moni- Inspect using Complete the
1)Perform the clear memory mode. <Ref. to or or OBD-ll general scan tool “Diagnostics Pro- diagnosis.
EN(D0HC TURBO)-49, Clear Memory Mode.: ndicate DTC? cedure with Diag-
2)Perform the inspection mode. <Ref. to nostic Trouble
EN(D0HC TURBO)-46, Inspection Mode.> Code (DTC)”.
<Ref. to EN(D0HC
TURBO)-88, Diag-
nostic Procedure
with Diagnostic
Trouble Code
IDTCb

EN(D0HC TURBO)-2
 BASIC DIAGNOSTIC PROCEDURE
ENGINE (DIAGNOSTICS)
~ ~

2. AUTOMATIC TRANSMISSION
When the trouble code about automatic transmis-
sion is shown on display, carry out the following ba-
sic 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-11,
Differential Gear Oil.>
3) ATF leak check <Ref. to AT-9, Automatic Trans-
mission Fluid.>
4) Differential gear oil leak check <Ref. to AT-1 1,
Differential Gear Oil.>
5) Stall test <Ref. to AT-13, Stall Test.>
6) Line pressure test <Ref. to AT-16, Line Pressure
Test.>
7) Transfer clutch pressure test <Ref. to AT-18,
Transfer Clutch Pressure Test.>
8) Time lag test <Ref. to AT-15, Time Lag Test.>
9) Road test <Ref. to AT-12, Road Test.>
10) Shift characteristics <Ref. to AT-18, Transfer
Clutch Pressure Test.>

EN(D0HC TURBO)-3
 CHECK LIST FOR INTERVIEW
ENGINE (DIAGNOSTICS)

2. Check List for Interview Check the following items when problem has oc-
curred.
A: CHECK NOTE:
1. CHECK LIST NO. 1 Use copies of this page for interviewing customers.

I Customer's name Engine no.

I Date of sale Fuel brand
Odometer reading km
miles
Weather U Fine
0 Cloudy
U Rainy
U Snowy
U Various/Others:
Outdoor temperature
0 Hot
U Warm
0 Cool
U Cold
U Highway
U Suburbs
U Inner city
U Uphill
U Downhill
0 Rough road
U Others:
U Cold
U Warming-up
U After warming-up
0 Any temperature
U Others:
Engine speed
Vehicle speed MPH I
Driving conditions

I Headlight U ON/U OFF Rear defogger U O N D OFF

I Blower Cl ON/U OFF Radio U O N D OFF
U ON/U OFF CD/Cassette U ON/U OFF
U ON/U OFF Car phone CI O N D OFF
Front wiper U ON/R OFF I CB I U O N D OFF
I Rear wiper CI ON/U OFF

EN(D0HC TURBO)-4
 CHECK LIST FOR INTERVIEW
ENGINE (DIAGNOSTICSI

2. CHECK LIST NO. 2 NOTE:

Check the following items about the vehicle's state Use copies of this page for interviewing customers.
when MIL turns on,
a) Other warning lights or indicators turn on. CI YesD No
2 Low fuel warning light
;ICharge indicator light
2 AT diagnostics indicator light
3 ABS warning light
3 Engine oil pressure warning light
b) Fuel level
Lack of gasoline: CI YesD No
Indicator Dosition of fuel aauae:
nntentional connectina or disconnectinq of harness connectors or spark plug cords: CI YesD No
What:
d) Intentional connecting or disconnecting of hoses: D YesD No
What:
e) Installing of parts other than genuine parts: CI Yes/CI No
What:
Where:
f) Occurrence of noise: D YesD No
From where:
What kind:
a) Occurrence of smell: CI YesD No
* F r o m where:
What kind:
h) Intrusion of water into engine compartment or passenger compartment: CI YesD No
i) Troubles occurred
Q Engine does not start.
D Engine stalls during idling.
CI Engine stalls while driving.
Q Engine speed decreases.
Q Engine speed does not decrease.
CI Rough idling
0 Poor acceleration
CI Back fire
Q After fire
No shift
CI Excessive shift shock

EN(D0HC TURB0)d
 GENERAL DESCRIPTION
ENGINE (DIAGNOSTICS)

3. General Description 8) Use ECM mounting stud bolts at the body head
grounding point when measuring voltage and resis-
A: CAUTION tance inside the passenger compartment.
1) Airbag system wiring harness is routed near the
engine control module (ECM), main relay and fuel
pump relay.
CAUTION:
All Airbag system wiring harness and con-
nectors are colored yellow. Do not use electri-
cal test equipment on these circuit.
Be careful not to damage the Airbag system
wiring harness when servicing the engine con-
trol module (ECM), transmission control mod-
ule (TCM), main relay and fuel pump relay.
2) Never connect the battery in reverse polarity. 9) Use engine grounding terminal or engine proper
The ECM will be destroyed instantly. as the grounding point to the body when measuring
The fuel injector and other part will be damaged voltage and resistance in the engine compartment.
in just a few minutes more.
3) Do not disconnect the battery terminals while the
engine is running.
A large counter electromotiveforce will be gener-
ated in the generator, and this voltage may damage
electronic parts such as ECM, etc.
4) Before disconnecting the connectors of each
sensor and the ECM, be sure to turn OFF the igni-
tion switch.
5) Poor contact has been identified as a primary
cause of this problem. To measure the voltage and/
or resistance of individual sensors or all electrical 10) Use TCM mounting stud bolts at the body head
control modules at the harness side connector, use grounding point when measuring voltage and resis-
a tapered pin with a diameter of less than 0.64 mm tance inside the passenger compartment.
(0.025 in). Do not insert the pin more than 5 mm
(0.20 in) into the part.
6) Before removing the ECM from the located posi-
tion, disconnect two cables on battery.
Otherwise, the the ECM may be damaged.
CAUTION:
When replacing the 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
1666F
compartment and the harness connectors on the.
engine side and body side are all designed to be 11) Every MFI-related part is a precision part. Do
waterproof. However, it is still necessary to take not drop them.
care not to allow water to get into the connectors
when washing the vehicle, or when servicing the
vehicle on a rainy day.

EN(D0HC TURBO)-6
 GENERAL DESCRIPTION
12) Observe the following cautions when installing
a radio in MFI equipped models.
CAUTION:
The antenna must be kept as far apart as pos-
sible from the control unit.
(The ECM is located under the steering column,
inside of the instrument panel lower trim panel.)
The antenna feeder must be placed as far
apart as possible from the ECM and MFI har-
ness.
Carefully adjust the antenna for correct
matching.
When mounting a large power type radio, pay
special attention to the three items above men-
tioned.
Incorrect installation of the radio may affect
the operation of the ECM.
13) Before disconnecting the fuel hose, disconnect
the fuel pump connector and crank the engine for
more than five seconds to release pressure in the
fuel system. If engine starts during this operation,
run it until it stops.
14) Problems in the electronic-controlledautomatic
transmission may be caused by failure of the en-
gine, the electronic control system, the transmis-
sion proper, or by a combination of these. These
three causes must be distinguished clearly when
performing diagnostics.
15) Diagnostics should be conducted by rotating
with simple, easy operations and proceeding to
complicated, difficult operations. The most impor-
tant thing in diagnostics is to understand the cus-
tomer's complaint, and distinguish between the
three causes.
16) On ABS vehicle, when performing driving test
in jacked-up or lifted-up position, sometimes the
warning light may be lit, but this is not a malfunction
of the system. The reason for this is the speed dif-
ference between the front and rear wheels. After di-
agnosis of engine control system, perform the ABS
memory clearance procedure of self-diagnosis sys-
tem.
B: INSPECTION
Before performing diagnostics, check the following
items which might affect engine problems:
1. BATTERY
1) Measure battery voltage and specific gravity of
electrolyte.
Standard voltage: 12 V
Specific gravity: Above 1.260
2) Check the condition of the main and other fuses,
and harnesses and connectors. Also check for
proper grounding.
EN(D0HC TURBO)-7
ENGINE (DIAGNOSTICS)
2. ENGINE GROUNDING
Make sure the engine grounding terminal is proper-
ly connected to the engine.
145
C: NOTE
1. DESCRIPTION
The on-board diagnostics (OBD) system detects
and indicates a fault in various inputs and outputs
of the complex electronic control. CHECK ENGINE
malfunction indicator lamp (MIL) in the combination
meter indicates occurrence of a fault or trouble.
Further, against such a failure or sensors as may
disable the drive, the fail-safe function is provided
to ensure the minimal driveability.
The OBD system incorporated with the vehicles
within this engine family complies with Section
1968.1, California Code of Regulations (OBD-ll
regulation). The OBD system monitors the compo-
nents and the system malfunction listed in Engine
Section which affects on emissions.
When the system decides that a malfunction oc-
curs, MIL illuminates. At the same time of the MIL il-
lumination or blinking, a diagnostic trouble code
(DTC) and a freeze frame engine conditions are
stored into on-board computer.
The OBD system stores freeze frame engine
condition data (engine load, engine coolant tem-
perature, fuel trim, engine speed and vehicle
speed, etc.) into on-board computer when it detects
a malfunction first.
If the OBD system detects the various malfunc-
tions including the fault of fuel trim or misfire, the
OBD system first stores freeze frame engine condi-
tions about the fuel trim or misfire.
When the malfunction does not occur again for
three consecutive driving cycles, MIL is turned off,
but DTC remains at on-board computer.
The OBD-ll system is capable of communication
with a general scan tool (OBD-I1 general scan tool)
formed by IS0 9141 CARB.
I GENERAL DESCRIPTION
ENGINE (DIAGNOSTICS)
The OBD-II diagnostics procedure is different
from the usual diagnostics procedure. When trou-
bleshooting OBD-ll vehicles, connect Subaru Se-
lect Monitor or the OBD-ll general scan tool to the
vehicle.
2. ENGINE AND EMISSION CONTROL SYS-
TEM
The Multipoint Fuel Injection (MFI) system is a
system that supplies the optimum air-fuel mixture
to the engine for all the various operating condi-
tions through the use of the latest electronic tech-
nology.
With this system fuel, which is pressurized at a con-
stant pressure, is injected into the intake air pas-
sage of the cylinder head. The injection quantity of
fuel is controlled by an intermittent injection system
where the electro-magnetic injection valve (fuel in-
jector) opens only for a short period of time, de-
D: PREPARATION TOOL
ILLUSTRATION TOOL NUMBER
24082AA150
(Newly adopted tool)
82M3876
22771AA030
82M3877
EN(D0HC TURBO)-8
pending on the quantity of air required for one cycle
of operation. In actual operation, the injection quan-
tity is determined by the duration of an electric
pulse applied to the fuel injector and this permits
simple, yet highly precise metering of the fuel.
Further, all the operating conditions of the engine
are converted into electric signals, and this results
in additional features of the system, such as large
improved adaptability, easier addition of compen-
sating element, etc.
The MFI system also has the following features:
Reduced emission of harmful exhaust gases.
Reduced in fuel consumption.
Increased engine output.
Superior acceleration and deceleration.
Superior startability and warm-up perfor-
mance in cold weather since compensation is
made for coolant and intake air temperature.
DESCRIPTION REMARKS
SARTRIDGE Troubleshooting for electrical
systems.
SELECT MONITOR KIT Troubleshooting for electrical
systems.
English: 22771AA030 (With-
out printer)
German: 22771AA070
(Without printer)
French: 22771AA080
(Without printer)
Spanish: 22771AA090
(Without printer)
 ELECTRICAL COMPONENTS LOCATION
ENGINE (DIAGNOSTICS)

4. Electrical Components Location

A: LOCATION
1. ENGINE
MODULE

(1) Engine control module (ECM) (3) Test mode connector

(2) CHECK ENGINE malfunction indi- (4) Data link connector
cator lamp (MIL)

EN1065
B3M1575A

I
EN(D0HC TURBO)-9
 ELECTRICAL COMPONENTS LOCATION
ENGINE (DIAGNOSTICS)
SENSOR

(1) Pressure sensor (4) Knock sensor (8) Tumble generator valve position
(2) Engine coolant temperature sen- (5) Camshaft position sensor sensor
sor (6) Crankshaft position sensor
(3) Throttle position sensor (7) Mass air flow and intake air tem-
perature sensor

EN(D0HC TURBO)-IO
ELECTRICAL COMPONENTS LOCATION
ENGINE (DIAGNOSTICS)

\
EN1012

n
EN1015

EN(D0HC TURBO)-I 1
 ELECTRICAL COMPONENTS LOCATION
ENGINE (DIAGNOSTICS)

EN0948

(1) Front oxygen (NF) sensor (3) Exhaust temperature sensor (5) Rear oxygen sensor
(2) Precatalytic converter (4) Front catalytic converter (6) Rear catalytic converter

EN(D0HC TURBO)-12
ELECTRICAL COMPONENTS LOCATION
ENGINE (DIAGNOSTICS)

EN1017

EN(D0HC TURBO)-13
 ELECTRICAL COMPONENTS LOCATION
ENGINE (DIAGNOSTICS)

(3) (4)
EN1067

(1) Fuel level sensor (3) Fuel tank pressure sensor

(2) Fuel temperature sensor (4) Fuel sub level sensor

H2M3207A B2M1807A

EN(D0HC TURBO)-14
ELECTRICAL COMPONENTS LOCATION
ENGINE (DIAGNOSTICS)

EN(D0HC TURBO)-15
 ELECTRICAL COMPONENTS LOCATION
~

ENGINE (DIAGNOSTICS)

SOLENOID VALVE, ACTUATOR, EMISSION CONTROL SYSTEM PARTS AND IGNITION SYSTEM
PARTS

EN0951

(1) Wastegate control solenoid valve (3) Purge control solenoid valve (5) Tumble generator valve actuator
(2) Idle air control solenoid valve (4) Ignition coil

EN(D0HC TURBO)-16
ELECTRICAL COMPONENTS LOCATION
m
ENGINE (DIAGNOSTICS)

(4) EN1024

EN(D0HC TURBO)-17
 ELECTRICAL COMPONENTS LOCATION
ENGINE (DIAGNOSTICS)

EN1068

(1) Pressure control solenoid valve (3) Drain valve

(2) Canister (4) Drain filter

SUBARU

-
H2M2444A

EN(D0HC TURBO)-18
ELECTRICAL COMPONENTS LOCATION
ENGINE (DIAGNOSTICS)

EN(D0HC TURBO)-19
 ELECTRICAL COMPONENTS LOCATION
ENGINE (DIAGNOSTICS)

(1) Fuel pump (4) Fuel pump controller (7) Radiator sub fan relay 1
(2) Main relay (5) Radiator main fan relay 1 (8) Radiator sub fan relay 2
(3) Fuel pump relay (6) Radiator main fan relay 2 (9) Starter

EN(D0HC TURBO)-20
 ELECTRICAL COMPONENTS LOCATION
ENGINE (DIAG NOSTlCS)

EN1191

-(9)

EN1030

EN(D0HC TURBO)-21
 ELECTRICAL COMPONENTS LOCATION
3
ENGINE (DIAGNOSTICS)

2. TRANSMISSION
Module

(1) Transmission Control Module (2) AT diagnostic indicator light (for AT

(TCM) (for AT vehicles) vehicles)

EN(DOHC TURB0)-22
 ELECTRICAL COMPONENTS LOCATION
a
ENGINE (DIAGNOSTICS)

Sensor

(2) Vehicle speed sensor 2 (for MT vehicles)

(3) Vehicle speed sensor 2 (for AT vehicles)
(4) Torque converter turbine speed sensor (for AT vehicles)
(5) ATF temperature sensor (for AT vehicles)
(6) Brake light switch

EN(D0HC TURBO)-23
 ELECTRICAL COMPONENTS LOCATION
ENGINE (DIAGNOSTICS)
Solenoid Valve And Switch (AT Vehicles)

(8) (1’0) 02M2263A 2264A

(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

Solenoid Valve And Switch (MT Vehicles)

(1) Neutral position switch

EN(DOHC TURB0)-24
ELECTRICAL COMPONENTS LOCATION
ENGINE (DIAGNOSTICS)

EN(D0HC TURBO)-25
 ENGINE CONTROL MODULE (ECM) I/O SIGNAL
ENGINE (DIAGNOSTICS)

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

A: ELECTRICAL SPECIFICATION
r

To @ To @ To @

To @ To a

EN0955

I
Signal (V)
Content nector Ignition SW ON Note
nal No. Engine ON (Idling)
Con-
No. Termi- lEnaine OFF)
Crank- Signal (+) 0 -7 - +7 Sensor output waveform
shaft posi- Signal (-) 0 I 0 I -
tion sensor Shield n I 0 I -
Camshaft Signal (+) 0 -7 - +7 Sensor output waveform
position Signal (-) 0 0 -
sensor Shield 0 0 -
Signal B135
Throttle
Power
position B135 5 5
sensor supply
GND(sen-
0 0
sor)
Signal 0 0 - 0.9 -
Rear oxy- n I 0 I -
Shield
gen sen- 1

sor GND(sen-
61 35 19 0 0
sor)
Front oxy- Signal 1 0-1.0 0-1.0

+-
gen (W
sensor Signal 2 B137 5 0- 1.0 0- 1.0
heater
Rear oxygen sensor -
0-1.0 0- 1.0
heater signal
Engine 1.0- 1.4 1.o - 1.4 I After warm-up the engine.
coolant
B135 19 0 0 After warm-up the engine.

“5” and “ 0are repeatedly dis-

Vehicle speed signal Oor5 0 or 5
Dlaved when vehicle is driven.

EN(D0HC TURBO)-26
 ENGINE CONTROL MODULE (ECM) I/O SIGNAL
ENGINE (DIAGNOSTICS)

Signal (V)
‘On- Termi- -
Content nector Ignition SW ON Note
nal No. Engine ON (Idling)
No. (Engine OFF)
Mass air Signal 684 13 - 0.3 - 4.5 -
flow sen- Shield 684 8 0 0 -
sor GND 684 7 0 0 -

#I B136 24 0 13-14 Waveform

Ignition #2 B136 23 0 13-14 Waveform
control #3 6136 22 0 13-14 Waveform
#4 6136 21 0 13-14 Waveform

EN(D0HC TURBO)-27
 ENGINE CONTROL MODULE (ECM) I/O SIGNAL
ENGINE (DIAGNOSTICS)

Con- Signal (V)

Termi-
Content nector Ignition SW ON Note
nal No. Engine ON (Idling)
No. (Engine OFF)
#1 B137 1 10-13 1-14 Waveform
Fuel injec- #2 B136 6 10- 13 1-14 Waveform
I I
~

tor #3 B136 5 10- 13 1-14 Wavef o i

#4 B136 4 10- 13 I 1-14 I Waveform
Idle air
control
Signal B136 10 0 or 13- 14 0 or 13 - 14 Waveform
solenoid
valve
Fuel pump Signal 1 B134 13
controller Signal 2 B136 15
ON: 0.5, or less ON: 0.5, or less -
A/C relay control 8137 27
OFF: 10- 13 OFF: 13- 14
Radiator fan relay 1 ON: 0.5, or less ON: 0.5, or less -
B137 17
control OFF: 10- 13 OFF: 13- 14
Radiator fan relay 2
control
B137 28
ON: 0.5, or less
OFF: 10 - 13
1 ON: 0.5, or less
OFF: 13 - 14
1 With A/C vehicles only

Malfunction indicator - - Light “ON”: 1, or less

B137 15
lamp Liaht “OFF: 10 - 14
Engine speed output B136 9 - I 0- 13, or more I Waveform
Purge control solenoid ON: 1, or less ON: 1, or less -
B137 16
valve OFF: 10 - 13 OFF: 13 - 14
Toraue control 1 sianal B134 19 5 5 -
Toraue control 2 sianal B134 18 5 1 - 5
Torque control cut sig-
nal
Fuel temperature sen-
B136 14 8
I 8

Ambient temperature: 25°C

B135 6 2.5 - 3.8 2.5 - 3.8
sor (75°F)
The value obtained after the
Fuel tank Signal 15 2.3 - 2.7 2.3 - 2.7 fuel filler cap was removed
pressure
sensor - 1I
sor)
B134 19 0 0
once and recapped.

Fuel tank pressure con-

trol solenoid valve
B137 22
ON: 1, or less
OFF: 10 - 13 1 ON: 1, or less
OFF: 13-14 I -

Drain valve

AT diagnosis input sig-

B137 11
ON: 1, or less
OFF: 10- 13
Less than 1 +-+More
I ON: 1, or less
OFF:13-14
Less than 1 ++ More
I -

B135 20 Waveform
nal than 4 than 4
AT load signal B135 28 4.3 - 4.4 I 0.9 - 1.4 I -
Signal B135 8 1.7 - 2.4 I 1.1 -1.6 I
Pressure
sensor
Power
B135 9 5
I
I
5
~
I
I
-

B135 19 0 0

Fuel level sensor B135 25 0.12 - 4.75 0.12 - 4.75 -

ON: 0 ON: 0 -
Small light switch B134 17
OFF: 10 - 13 OFF: 13 - 14
ON: 0 ON: 0 -
Blower fan switch B134 9
OFF: 10- 13 OFF: 13- 14

Rear defogger switch

Power steering oil pres-

B134 3
ON: 0
OFF: 10- 13 I ON: 0
OFF:13-14
ON: 0
I
B135 24 10- 13 -
sure switch OFF: 13 - 14

EN(D0HC TURBO)-28
 ENGINE CONTROL MODULE (ECM) I/O SIGNAL
ENGINE (DIAGNOSTICS1

GND (ignition system) 6136 18 0 0 -

6136 17 0 0 -
GND (power supply) -
6134 22 0 0
6134 7 0 0 -
GND (control systems) -
6134 15 0 0
GND (oxygen sensor -
B137 9 0 0
heater 1)
GND (oxygen sensor -
B137 8 0 0
heater 2)

EN(D0HC TURBO)-29
 ENGINE CONDITION DATA
ENGINE (DIAGNOSTICS)

6. Engine Condition Data

A: ELECTRICAL SPECIFICATION
Content Specified data
1.6 - 2.9 (%): Idling
Engine load
6.4 - 12.8 (%): 2,500 rpm racing
Measuring condition:
After engine is warmed-up.
Gear position is in neutral position. (MT vehicle)
Gear position is in “N” or “P” position. (AT vehi-
cle)
A/C is turned OFF.
All accessory switches are turned OFF.

EN(D0HC TURBO)-30
ENGINE CONDITION DATA
ENGINE (DIAGNOSTICS)

EN(D0HC TURBO)-31
 TRANSMISSION CONTROL MODULE (TCM) I/O SIGNAL
ENGINE (DIAGNOSTICS)

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

A: ELECTRICAL SPECIFICATION

S2M2131

NOTE:
Check with ignition switch ON.
Resistanceto
Content nector Measuring conditions Voltage (V)
nal No. body (ohms)
I

Back-up power supply 856 I 1 lanition switch OFF I 10-13 I -

Ignition power supply
B54 24
Ignition switch ON (with
-
enaine OFF)
Select lever in “ Prange
10-13

Less than 1
l -
“P” range -
855 1 Select lever in any other than
switch More than 8
“P” ranae (exceDt “N” ranae)
Select lever in “N” range I Less than 1 I
“N” range
switch
855 14 Select lever in any other than
“N” ranae
- * - (exceDt “P” ranael
\ - I . , I (
1 Morethan8
I
I
-

Select lever in ‘W ranae“ I Less than 1

“R” range -
855 3 Select lever in any other than
switch More than 8
“ R ranae
Select lever in “D” range I Less than 1 I
Inhibitor
switch
“D” range
switch
B55 4 Select lever in any other than
“D” ranae
.,
I Morethan 8
I
-

I I

Select lever in “ 3ranae

I
I Less than 1
“3” range -
B55 5 Select lever in any other than
switch More than 8
“ 3 range
Select lever in “2” range I Less than 1
“2” range
switch
Select lever in any other than
“2” ranae
“
I
I
Morethan 8
I
-

Select lever in “1” ranae I Less than 1

“1” range ~

-
switch
Select lever in any other than
. ranae
“1” .a -
More than 8
I
Brake switch B55 I 12
Brake pedal depressed.
Brake pedal released.
More than 10.5
Less than 1
-

AT OIL TEMP warning light B56 1 11

Light ON
Liaht OFF
Less than 1
More than 9
-

EN(D0HC TURBO)-32
 TRANSMISSION CONTROL MODULE (TCM) I/O SIGNAL
ENGINE (DIAGNOSTlCS)

Termi- Resistance to
Content nector Measuring conditions Voltage (V)
nal No. body (ohms)

Throttle position sensor I 854 3

Throttle fully closed.
Throttle fully open.
Approx. 0.5
Approx. 4.3
-

- lanition switch ON (With

Approx . 5.0 -
supply 2 1 - engine OFF) I
ATF temperature 20°C
2.9 - 4.0 2.1 -2.9 k

I 11
\ I

ATF temperature sensor

ATF temperature 80°C
0.5 - 0.8 275 - 375
854
Vehicle stopped.
.. 0
I

Rear vehicle speed sensor 24 Vehicle speed at least 20 More than (AC 450 - 650

I
km/h (12 MPH)
Vehicle stopped. 0
Front vehicle speed sensor 855 18 Vehicle speed at least 20 More than (AC range) 450 - 650
km/h (12 MPH)
Engine idling after warm-up. n
v
Torque converter turbine (D range)
450 - 650
speedsensor - Engine idling after warm-up.
More than 1 (AC range)
(N ranoe) - I

Vehicle speed at most 10 Less than I t

Vehicle speed output signal 17
km/h (6 MPH) +More than 5
Ignition switch ON (with
0
engine OFF)
Engine speed signal 855 l7
Ignition switch ON (with
8-11
1
engine
- ON) I
When cruise control is set
Less than 1
fSET lamD ON) -
Cruise set signal 22
When cruise control is not
More than 6.5
set (SET lamD OFF)
Ignition switch ON (with -
Torque control signal 1 5 More than 4.8

Ignition switch ON (with -

Torque control signal 2 14 More than 4.8
engine ON)
Torque control cut signal 10 Ignition switch ON 8 -
1st or 4th gear More than 9
Shift solenoid 1 854 22 - 10-16
2nd or 3rd gear Less than 1

I
~

1st or 2nd gear More than 9

Shift solenoid 2 854 5 ~

10-16
3rd or 4th gear Less than 1
Throttle fully closed (with
1.5 - 5.0
engine OFF) after warm-up.
Line pressure duty solenoid 854 9 2.0 - 4.5
Throttle fully open (with
Less than 0.5

-c
engine OFF) after warm-up.
When lock up occurs. More than 8.5
Lock-up duty solenoid 7 10-17
When lock up is released. Less than 0.5
Fuse on FWD switch More than 8.5
Fuse removed from FWD

I
Transfer duty solenoid 6 switch (with throttle fully 10-17
Less than 0.5
open and with select lever in
854 1st gear).
Throttle fully closed (with
1.5 - 5.0
engine OFF) after warm-up.
2-4 brake duty solenoid
I 2.0-4.5
'

Throttle fully open (with

Less than 0.5
854 engine OFF) after warm-up.

EN(D0HC TURBO)-33
I TRANSMISSION CONTROL MODULE (TCM) I/O SIGNAL
ENGINE (DIAGNOSTICS)

Con-
Termi- Resistance to
Content nector Measuring conditions Voltage (V)
nal No. body (ohms)
No.
Throttle fully closed (with
More than 8.5
engine OFF) after warm-up. a- IIEW;
"I YVT I , w
Throttle fully open (with
Less than 0.5
engine OFF) after warm-up.
1st gear Less than 1
I
3rd clear
" More than 9
2nd gear Less than 1
Low clutch timing solenoid 854 15 10- 16
4th Clear More than 9
Sensor ground line 1 1 854 1 19 I - 0 I Lessthan 1
Sensor ground line 2 I 855 I 9 1 - 0 I Lessthan 1
856 19
System ground line - 0 Less than 1
854 20
Less than 1 t -
AT diagnosis signal 856 21 Ignition switch ON
+ More than 4
Data link signal (Subaru 15 I - -

EN(D0HC TURBO)-34
 DATA LINK CONNECTOR
ENGINE (DIAGNOSTICS)

8. Data Link Connector

A: NOTE
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-ll general scan tools and the Subaru Select Mon-
itor, 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 I S 0 9141 CARB
3 Blank 11 Blank
4 Blank 12 Ground
5 I Blank 13 I Ground
6 I Line end check signal 1 14 I Blank
7 Blank 15 Blank
8 Line end check signal 2 16 Blank

EN(D0HC TURBO)-35
 OBD-II GENERAL SCAN TOOL
ENGINE (DIAGNOSTICS)

9. OBD-Il General Scan Tool
A: OPERATION
1. HOW TO USE OBD-II GENERAL SCAN
TOOL
1) Prepare a general scan tool (OBD-II general
scan tool) required by SAE J1978.
2) Open the cover and connect the OBD-II general
scan tool to the data link connector located in the
lower portion of the instrument panel (on the driv-
er's side).
3) Using the OBD-II general scan tool, call up diag-
nostic trouble code(s) and freeze frame data.
OBD-II general scan tool functions consist of:
(1) MODE $01: Current powertrain diagnostic
data
(2) MODE $02: Powertrain freeze frame data
(3) MODE $03: Emission-related powertrain di-
agnostic trouble codes
(4) MODE $04: Clear/Reset emission-related
diagnostic information
Read out data according to repair procedures. (For
detailed operation procedures, refer to the OBD-II
General Scan Tool Operation Manual.)
NOTE:
For details concerning diagnostic trouble codes, re-
fer to the List of Diagnostic Trouble Code (DTC).
<Ref. to EN(D0HC TURBO)-80, List of Diagnostic
Trouble Code (DTC).>

2. MODE $01 (CURRENT POWERTRAIN DIAGNOSTIC DATA)

01 I Number of emission-relatedDowertraintrouble codes and MIL status ONIOFF

I 03 I Fuel svstem control status I - I
04 I Calculated engine load value YO

05 I Engine coolant temperature "C

I 06 I Short term fuel trim I % I
07 I Long term fuel trim %
OB I Intake manifold absolute Dressure kPa
I OC I Enaine revolution I rDm I
I OD I Vehicle speed I kmlh I
OE Ignition timing advance 0

OF Intake air temperature "C

10 Air flow rate from pressure sensor glsec
11 Throttle valve opening angle %
13 Check whether oxvaen sensor is installed. -
Oxygen sensor output voltage and short term fuel trim associated with oxygen sensor-bank
l5 V and Yo
2
24 A/F sensor 1 output voltage and short term fuel trim associated with A/F sensor 1 V and Yo
1C I On-board diagnosis system -

NOTE:
Refer to OBD-II general scan tool manufacturer's instruction manual to access generic OBD-II PlDs (MODE
$01).

EN(D0HC TURBO)-36
 OBD-II GENERAL SCAN TOOL
ENGINE (DIAGNOSTICS)

3. MODE $02 (POWERTRAIN FREEZE FRAME DATA)

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.
I PID I Data I Unit of measure I
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 O/O

r-07 I Long term fuel trim I Yo I

OB Intake manifold absolute pressure kPa
OC Engine revolution rPm
OD 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)
Refer to Read Diagnostic Trouble Code for information about data denoting emission-related powertrain di-
agnostic trouble codes. <Ref. to EN(D0HC TURBO)-45, Read Diagnostic Trouble Code.>
5. MODE $04 (CLEAR/RESET EMISSION-RELATED DIAGNOSTIC INFORMATION)
Refers to the mode used to clear or reset emission-related diagnostic information (OBD-II trouble diagnostic
information).
NOTE:
Refer to OBD-II general scan tool manufacturer's instruction manual to clear or reset emission-related diag-
nostic information (MODE $04).

EN(D0HC TURBO)-37
 SUBARU SELECT MONITOR
ENGINE (DIAGNOSTICS)
1O.Subaru Select Monitor
A: OPERATION
1. HOW TO USE SUBARU SELECT MONI-
TOR
1) Prepare the Subaru Select Monitor kit. <Ref. to
EN(D0HC TURBO)-8, PREPARATION TOOL,
General Description.>
2) Connect the diagnosis cable to Subaru Select
Monitor.
3) Insert the cartridge into Subaru Select Monitor.
<Ref. to EN(D0HC TURBO)-8. PREPARATION
TOOL, General Description.>
4) Connect the 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).
EN(DOHC TURB0)-38
(2) Connect the diagnosis cable to data link
connector.
CAUTION:
Do not connect scan tools except for Subaru
Select Monitor and OBD-ll general scan tool.
5) Turn the ignition switch to ON (engine OFF) and
Subaru Select Monitor switch to ON.
I 52M0288 I
6) Using the Subaru Select Monitor, call up diag-
nostic trouble code(s) and various data, then
record them.
2. READ DIAGNOSTIC TROUBLE CODE
(DTC) FOR ENGINE. (NORMAL MODE)
Refer to Read Diagnostic Trouble Code for infor-
mation about how to indicate DTC. <Ref. to
EN(D0HC TURBO)-45, Read Diagnostic Trouble
Code.>
3. READ DIAGNOSTIC TROUBLE CODE
(DTC) FOR ENGINE. (OBD MODE)
Refer to Read Diagnostic Trouble Code for infor-
mation about how to indicate DTC. <Ref. to
EN(D0HC TURBO)-45, Read Diagnostic Trouble
Code.>
 SUBARU SELECT MONITOR
ENGINE (DIAGNOSTICS)

4. READ CURRENT DATA FOR ENGINE. (NORMAL MODE)

1) On the <<Main Menu,, display screen, select the {Each System Check} and press the [YES] key.
2) On the &ystem Selection Menu), display screen, select the {Engine Control System} and press the [YES]
key.
3) Press the [YES] key after displayed the information of engine type.
4) On the <<Engine Diagnosis), display screen, select the, {Current Data Display & Save} and press the [YES]
key.
5) On the <<Data Display Menu,, display screen, select the {Data Display} and press the [YES] key.
6) Using the scroll key, move the display screen up or down until the desired data is shown.
A list of the support data is shown in the following table.

Contents Display Unit of measure

Battery voltage Battery Voltage V
Vehicle speed Sianal
~~
Vehicle Speed km/h or MPH
Enaine speed sianal 1 Engine Speed I rpm
Engine coolant temperature signal I Coolant Temp. I "C or OF
Ignition timing signal Ignition Timing deg
Throttle position signal Throttle Opening Angle %
Throttle position signal Throttle Sensor Voltage V
Injection pulse width Fuel Injection #I Pulse ms
Idle air control sianal ISC Valve Dutv Ratio %
Fuel pump duty control signal Fuel Pump Duty YO
A/F sensor current A/F Sensor #I Current mA
N F sensor resistance N F Sensor #I Resistance R
Front oxygen (NF) sensor output signal A/F Sensor #I -
Rear oxygen sensor output signal Rear 0 2 Sensor V
Short term fuel trim A/F Correction #I %
1 Knocking Correction I
Knock sensor signal
Atmospheric absolute pressure signal 1 Atmosphere Pressure
1 deg
mmHg or kPa or inHg or
Dsi
mmHg or kPa or inHg or
Intake manifold relative pressure signal Mani. Relative Pressure
psi

Intake manifold absolute pressure signal 1 Mani. Absolute Pressure 1 mmHg or kPa or inHg or
Dsi
8- ~

A/F correction (short term fuel trim) by rear oxygen sensor A/F Correction #3 YO

Long term whole fuel trim N F Learning #I %

Front oxygen (A/F) sensor heater current A/F Heater Current 1 A
Rear oxvaen sensor heater voltaae Rear 0 2 Heater Voltage V
Canister purge control solenoid valve duty ratio 1 CPC Valve Duty Ratio I %
Primary supercharged pressure control signal 1 Primary Control I Oh
Tumble generator valve position sensor signal (right side) TGV Position Sensor R V
Tumble generator valve position sensor signal (left side) TGV Position Sensor L V
Tumble aenerator valve drive sianal TGV Drive OPEN or CLOSE
I Fuel Level I V
Intake air temperature signal Intake Air Temp. "C or OF
Learned ignition timing Learned Ignition Timing deg
Mass air flow sensor signal Mass Air Flow gls
Mass air flow sensor signal Air Flow Sensor Voltage V
mmHg or kPa or inHg or
Fuel tank pressure signal Fuel Tank Pressure
psi
Fuel temperature signal Fuel Temp "C or OF
Exhaust gas temperature signal Exhaust Gas Temperature OC or OF
MTIAT identification signal AT Vehicle ID Signal ON or OFF
Fuel Dressure control solenoid valve sianal PCV Solenoid Valve ON or OFF

EN(D0HC TURBO)-39
 SUBARU SELECT MONITOR
ENGINE (DIAGNOSTICS)

Contents Display Unit of measure

Drain valve sianal 1 Vent. Solenoid Valve ON or OFF
I Ignition switch signal I Ignition Switch I ON or OFF I
I Test mode connector signal I Test Mode Signal I ON or OFF I
Neutral position switch signal Neutral Position Switch ON or OFF
Air conditioning switch signal N C Switch ON or OFF
Air conditioning signal N C Compressor Signal ON or OFF
Radiator main fan relav sianal Radiator Fan Relav #I ON or OFF
I Fuel pump relay signal I Fuel Pump Relay I ON or OFF I
Knocking signal Knocking Signal ON or OFF
Radiator sub fan relay signal Radiator Fan Relay #2 ON or OFF
Power steering switch signal PIS Switch ON or OFF
Engine torque control signal #I Torque Control Signal #I ON or OFF
Enaine toraue control sianal #2 Toraue Control Sianal #2 ON or OFF
Engine torque control permission signal Torque Permission Signal ON or OFF
Rear oxygen sensor rich signal Rear 0 2 Rich Signal ON or OFF
Starter switch signal Starter Switch ON or OFF
Idle switch signal Idle Switch 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 SW ON or OFF
Blower fan switch signal Blower Fan SW ON or OFF
Small light switch signal Light Switch ON or OFF
Tumble generator valve output signal TGV Output ON or OFF

EN(D0HC TURBO)-40
 SUBARU SELECT MONITOR
ENGINE IDIAGNOSTICSI

5. READ CURRENT DATA FOR ENGINE. (OBD MODE)

1) On the ((MainMenu)) display screen, select the {Each System Check} and press the [YES] key.
2) On the ((SystemSelection Menu), display screen, select the {Engine Control System} and press the YES]
key.
3) Press the [YES] key after displayed the information of engine type.
4) On the ((Engine Diagnosis), display screen, select the {OSD System} and press the [YES] key.
5) On the <<OBD Menu))display screen, select the {Current Data Display & Save} and press the [YES key.
6) On the ((DataDisplay Menu,, display screen, select the {Data Display} and press the [YES] key.
7) Using the scroll key, move the display screen up or down until the desired data is shown.
A list of the support data is shown in the following table.

Contents Display Unit of measure

Number of diagnosis code Number of Diagnosis Code -
Malfunction indicator lamp status MI (MIL) ON or OFF
Monitorina test of misfire Misfire monitoring Complete or incomplete
Monitoring test of fuel system Fuel system monitoring Complete or incomplete
Monitoring test of comprehensive component Component monitoring Complete or incomplete
Test of catalyst Catalyst Diagnosis Complete or incomplete
Test of heated catalyst Heated catalyst No support
Test of evaporative emission purge control system Evaporative purge system Complete or incomplete
Test of secondary air system Secondary air system No support
Test of air conditioning system refrigerant 1 A/C system refrigerant No support
Test of oxygen sensor Oxygen sensor Complete or incomplete
Test of oxygen sensor heater 0 2 Heater Diagnosis Complete or incomplete
Test of EGR system EGR system No support
Air fuel ratio control system for bank 1 Fuel System for Bank 1 -
Engine load data Calculated load value YO

Engine coolant temperature signal Coolant Temp. "C or O F

Short term fuel trim by front oxygen (NF) sensor Short term fuel trim B1 O/O

Long term fuel trim by front oxygen ( N F ) sensor Long term fuel trim B1 YO

Intake manifold absolute pressure signal I

I
Mani. Absolute Pressure
mmHg or kPa or inHg or
psi I
Enaine meed sianal I Engine Speed rPm
Vehicle speed signal I Vehicle Speed km/h or MPH
Ignition timing advance for #1 cylinder Ignition timing adv. #I 0

Intake air temperature signal Intake Air Temp. "C or OF

Intake air amount Mass Air Flow g/s
Throttle position signal Throttle Opening Angle O/O

A/F sensor sianal NF sensor #11 V

Rear oxvaen sensor outDut sianal I Oxygen Sensor #I 2 V
Air fuel ratio correction by rear oxygen sensor Short term fuel trim #12 YO
On-board diagnostic system OBD System -
NOTE:
For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL.

EN(D0HC TURBO)-41
 SUBARU SELECT MONITOR
ENGINE (DIAGNOSTICS)

6. READ FREEZE FRAME DATA FOR ENGINE. (OBD MODE)

1) On the ((MainMenu,, display screen, select the {Each System Check} and press the [YES] key.
2) On the ((SystemSelection Menu>> display screen, select the {Engine Control System} and press the [YES]
key.
3) Press the [YES] key after displayed the information of engine type.
4) On the ((EngineDiagnosis,, display screen, select the {OBD System} and press the [YES] key.
5) On the <<OBD Menu>)display screen, select the {Freeze Frame Data} and press the [YES] key.
A list of the support data is shown in the following table.

I Diagnostic trouble code (DTC) for freeze frame data I Freeze frame data I DTC I
I Air fuel ratio control system for bank 1 I Fuel system for Bank1 I ON or OFF I
Engine load data Calculated load valve %
Engine coolant temperature signal Coolant Temp. "C or OF
Short term fuel trim bv front oxvaen (NF) sensor Short term fuel trim B1 %
I Lonq term fuel trim bv front oxvqen (NF) sensor I I
~~

Lona term fuel trim 81 % I

1
~~

Intake manifold absolute pressure signal 1 Mani. Absolute Pressure I mmHg or kPa or inHg or
mi I
Engine speed signal Engine Speed rPm
Vehicle speed signal Vehicle Speed km/h or MPH

EN(D0HC TURBO)-42
 SUBARU SELECT MONITOR
ENGINE (DIAGNOSTICS)

7. LED OPERATION MODE FOR ENGINE

1) On the ((Main Menu,, display screen, select the {Each System Check} and press the [YES] key.
2) On the ((SystemSelection Menu)) display screen, select the {Engine Control System} and press the [YES]
key.
3) Press the [YES] key after displayed the information of engine type.
4) On the ((EngineDiagnosis), display screen, select the {Current Data Display & Save} and press the [YES]
key.
5) On the <<DataDisplay Menu))display screen, select the {Data & LED Display} and press the [YES] key.
6) Using the scroll key, move the display screen up or down until the desired data is shown.
A list of the support data is shown in the following table.
Contents Display
. - I Message 1 LED "ON" requirements
lanition 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 sianal
" I
N C Switch orOFF When air conditioning switch is turned ON.
W.l"., ni-...-.l A /P Cinn-l When air conditioning compressor is in func-
Prrmnrrrr.r.nv
ON or OFF tion,
..

Radiator main fan relay signal Radiator Fan Relay #1 ON or OFF When radiator main fan 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.
..-.-I u4 T-r-. .- P..-+..nl CL-.nnl u.4
ON Or OFF
When engine torque control signal 1 is
entered.

Engine torque control signal #2

Engine torque control permission

Torque Control Signal #2
1 1
When engine torque control signal 2 is
ON Or OFF entered.
When engine torque control permission sig-
Torque Control Permission ON Or OFF
sianal nal is entered.
When rear oxygen sensor mixture ratio is
Rear oxygen sensor rich signal Rear 0 2 Rich Signal ON or OFF
rich,
Starter switch signal Starter Switch 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 Signal ON or OFF entered,

Camshaft position sensor signal 1 Camshaft Position Signal 1 ON or OFF I When camshaft position sensor signal is
entered.
Power steering switch signal PIS Switch ON or OFF When power steering switch is entered.
Rear defogger switch signal Rear Defogger Switch ON or OFF When rear defogger switch is turned ON.
Blower fan switch sianal - I
Blower Fan Switch I
ON or OFF I
When blower fan switch is turned ON.
Liaht switch sianal
~
I LiQht Switch 1 ON or OFF I When small light switch is turned ON.
Tumble generator valve actuator
TGV Output ON or OFF When TGV actuator signal is entered.
signal
Tumble generator valve drive sig- OPEN Or
TGV Drive When TGV moves and valve opens.
nal CLOSE
Fuel pressure control solenoid When fuel pressure control solenoid valve is
valve signal
pcv Solenoid Valve ON Or OFF in function.
Drain valve signal Vent. Solenoid Valve ON or OFF When drain valve is in function.
NOTE:
For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL.

EN(D0HC TURBO)-43
 SUBARU SELECT MONITOR
ENGINE (DIAGNOSTICS)
~

8. READ CURRENT DATA FOR AT

1) On the ((Main Menu)) display screen, select the {Each System Check} and press the [YES] key.
2) On the ((SystemSelection Menu))display screen, select the {Transmission Control System} and press the
[YES] key.
3) Press the [YES] key after displayed the information of transmission type.
4) On the ((TransmissionDiagnosis), display screen, select the {Current-Data Display & Save} and press the
[YES] key.
5) On the ((DataDisplay Menu))display screen, select the {Data Display} and press the [YES] key.
6) Using the scroll key, move the display screen up or down until the desired data is shown.
A list of the support data is shown in the following table.
I Contents I Display I Unit of measure
Battery voltage Battery Voltage V
Rear vehicle speed sensor signal Rear Wheel Speed km/h or MPH
Front vehicle speed sensor sianal - Front Wheel Speed km/h or MPH
Engine speed signal Engine Speed rPm
Automatic transmission fluid temperature signal ATF Temp. "C or OF
I
Mass air flow sensor signal Air Flow Sensor Voltage V
Throttle position signal Throttle Sensor Voltage V
Gear position Gear Position -
Line pressure control dutv ratio Line Pressure Dutv Ratio YO

Transfer clutch control duty ratio Transfer Duty Ratio YO

Power supply for throttle position sensor Throttle Sensor Power V
Torque converter turbine speed signal Turbine Revolution Speed rPm
2-4 brake timing pressure control duty ratio Brake Clutch Duty Ratio YO
Stop lamp switch signal Stop Light Switch ON or OFF
Anti lock brake system sianal ABS Sianal ON or OFF
I Cruise control system signal I Cruise Control Signal I ON or OFF I
NeutraVParking 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 Timina Sol. ON or OFF
I Low clutch timing control solenoid valve I Low Clutch Timing Sol. I ON or OFF I

EN(D0HC TURBO)-44
I READ DIAGNOSTIC TROUBLE CODE
ENGI NE (DIAGNOSTICS)

11.Read Diagnostic Trouble 3. OBD-ll GENERAL SCAN TOOL

Code Refers to data denoting emission-related power-
train diagnostic trouble codes.
A: OPERATION For details concerning diagnostic trouble codes, re-
fer to the List of Diagnostic Trouble Code (DTC).
1. SUBARU SELECT MONITOR (NORMAL <Ref. to EN(D0HC TURBO)-80, List of Diagnostic
MODE) Trouble Code (DTC).>
1) On the ((Main Menu,, display screen, select the NOTE:
{Each System Check} and press the [YES] key. Refer to OBD-II general scan tool manufacturer's
2) On the <<System Selection Menu)) display instruction manual to access emission-related
screen, select the {Engine Control System} and powertrain diagnostic trouble codes (MODE $03).
press the [YES] key.
3) Press the [YES] key after displayed the informa-
tion of engine type.
4) On the <<EngineDiagnosis,) display screen, se-
lect the {Diagnostic Code@)Display} and press the
[YES] key.
5) On the <<DiagnosticCode(s) Display)) display
screen, select the {Current Diagnostic Code(s)} or
{History Diagnostic Code@)}and press the [YES]
key.
NOTE:
For detailed operation procedure, refer to the
SUBARU SELECT MONITOR OPERATION MAN-
UAL.
For detailed concerning diagnostic trouble
codes, refer to the List of Diagnostic Trouble Code
(DTC). <Ref. to EN(D0HC TURBO)-80, List of Di-
agnostic Trouble Code (DTC).>
2. SUBARU SELECT MONITOR (OBD
MODE)
1) On the <<MainMenu)) display screen, select the
(2. Each System Check} and press the [YES] key.
2) On the <<SystemSelection Menu,, display
screen, select the {Engine Control System} and
press the [YES] key.
3) Press the [YES] key after displayed the informa-
tion of engine type.
4) On the <<EngineDiagnosis,, display screen, se-
lect the {OBD System} and press the [YES] key.
5) On the <<OBDMenu)) display screen, select the
{Diagnosis Code(s) Display} and press the [YES]
key.
6) Make sure that a diagnostic trouble code (DTC)
is shown on the display screen.
NOTE:
For detailed operation procedure, refer to the
SUBARU SELECT MONITOR OPERATION MAN-
UAL.
For detailed concerning diagnostic trouble
codes, refer to the List of Diagnostic Trouble Code
(DTC). <Ref. to EN(D0HC TURBO)-80, List of Di-
agnostic Trouble Code (DTC).>

EN(D0HC TURBO)-45
 INSPECTION MODE
ENGINE (DIAGNOSTICS)

12.lnspection Mode 2. SUBARU SELECT MONITOR

After performing diagnostics and clearing the mem-
A: OPERATION ory, check for any remaining unresolved trouble da-
1. PREPARATION FOR THE INSPECTION ta.
MODE 1) Prepare the Subaru Select Monitor kit. <Ref. to
EN(D0HC TURBO)-8, PREPARATION TOOL,
Raise the vehicle using a garage jack and place on General Description.>
safety stands or drive the vehicle onto free rollers.
WARNING:
Before raising the vehicle, ensure parking
brakes are applied.
Do not use a pantograph jack in place of a
safety stand.
Secure a rope or wire t o the front and rear
towing or tie-down hooks to prevent the lateral
runout of front wheels.
Do not abruptly depresshelease the clutch
pedal or accelerator pedal during works even S2M0285
when engine is operating at low speeds since 2) Connect the diagnosis cable to Subaru Select
this may cause the vehicle t o jump off free roll- Monitor.
ers. 3) Insert the cartridge into Subaru Select Monitor.
In order to prevent the vehicle from slipping <Ref. to EN(D0HC TURBO)-8, PREPARATION
due to vibration, do not place any wooden TOOL, General Description.>
blocks or similar items between the safety
stands and the vehicle.
Since the rear wheels will also rotate, do not
place anything near them. Also, make sure that
nobody goes in front of the vehicle.

4) Connect the test mode connector at the lower

portion of instrument panel (on the driver's side), to
the side of the center console box.
Safeystand

02M2969P

EN(D0HC TURBO)-46
 INSPECTION MODE
am
ENGINE (DIAGNOSTICS)

5) Connect the Subaru Select Monitor to data link
connector.
(1) Connect the Subaru Select Monitor to data
link connector located in the lower portion of the
instrument panel (on the driver’s side).
I
. .
I I
(2) Connect the diagnosis cable to data link
connector.
CAUTION:
Do not connect scan tools except for Subaru
Select Monitor and OBD-II general scan tool.
6) Turn the ignition switch to ON (engine OFF) and
Subaru Select Monitor switch to ON.
12) Perform subsequent procedures as instructed
on the display screen.
If trouble still remains in the memory, the corre-
sponding diagnostic trouble code (DTC) appears
on the display screen.
NOTE:
For detailed operation procedure, refer to the
SUBARU SELECT MONITOR OPERATION MAN-
UAL.
For detailed concerning diagnostic trouble
codes, refer to the List of Diagnostic Trouble Code
(DTC). <Ref. to EN(D0HC TURBO)-80, List of Di-
agnostic Trouble Code (DTC).>
Release the parking brake.
The speed difference between front and rear
wheels may light either the ABS warning light, but
this indicates no malfunctions. When engine con-
trol diagnosis is finished, perform the ABS memory
clearance procedure of self-diagnosis system.
3. OBD-II GENERAL SCAN TOOL
After performing the diagnostics and clearing the
memory, check for any remaining unresolved trou-
ble data:
1) Connect the test mode connector (A) at the low-
er side of the instrument panel (on the driver’s
side), to the side of the center console box.

. -
S2M0288 I
7) On the ((Main Menu,, display screen, select the
{2. Each System Check} and press the [YES] key.
8) On the ((System Selection Menu,) display
screen, select the {Engine Control System} and
press the [YES] key.
9) Press the [YES] key after displayed the informa-
tion of engine type.
10) On the ((EngineDiagnosis,, display screen, se-
lect the {Dealer Check Mode Procedure} and press
the [YES] key.
11) When the “Perform Inspection (Dealer Check)
Mode?” is shown on the display screen, press the
[YES] key.

EN(D0HC TURBO)-47
 INSPECTION MODE
ENGINE (DIAGNOSTICS)

2) Connect the OBD-II general scan tool to its data

link connector in the lower portion of the instrument
panel (on the driver’s side).
CAUTION:
Do not connect scan tools except for Subaru
Select Monitor and OBD-II general scan tool.

3) Start the engine.

NOTE:
Depress the clutch pedal when starting the engine.
4) Using the shift lever, turn the “N” position switch
to ON.
5) Keep the engine speed in the 2,500 - 3,000
rpm range for 40 seconds.
6) Place the shift lever in the “1st” gear and drive
the vehicle at 5 to 10 km/h (3 to 6 MPH).
NOTE:
The speed difference between front and rear
wheels may light the ABS warning light, but this in-
dicates no malfunctions.When engine control diag-
nosis is finished, perform the ABS memory
clearance procedure of self-diagnosis system.
7) Using the OBD-II general scan tool, check for di-
agnostic trouble code(s) and record the result(s).
NOTE:
For detailed operation procedures, refer to the
OBD-ll General Scan Tool Instruction Manual.
For detailed concerning diagnostic trouble
codes, refer to the List of Diagnostic Trouble Code
(DTC). <Ref. to EN(D0HC TURBO)-80, List of Di-
agnostic Trouble Code (DTC).>

EN(D0HC TURB0)-48
 CLEAR MEMORY MODE
ENGINE (DIAGNOSTICS)

13.Clear Memory Mode

A: OPERATION
1. SUBARU SELECT MONITOR (NORMAL
MODE)
1) On the ((Main Menu)) display screen, select the
(2. Each System Check} and press the [YES] key.
2) On the ((System Selection Menu)) display
screen, select the {Engine Control System} and
press the [YES] key.
3) Press the [YES] key after displayed the informa-
tion of engine type.
4) On the ((Engine Diagnosis,) display screen, se-
lect the {Clear Memory} and press the [YES] key.
5) When the 'Done' and 'Turn Ignition Switch OFF'
are shown on the display screen, turn the Subaru
Select Monitor and ignition switch to OFF.
NOTE:
For detailed operation procedure, refer to the
SUBARU SELECT MONITOR OPERATION MAN-
UAL.
2. SUBARU SELECT MONITOR (OBD
MODE)
1) On the ((Main Menu,) display screen, select the
(2. Each System Check} and press the [YES] key.
2) On the &ystem Selection Menu), display
screen, select the {Engine Control System} and
press the [YES] key.
3) Press the [YES] key after displayed the informa-
tion of engine type.
4) On the (<EngineDiagnosis,, display screen, se-
lect the {OBD System} and press the [YES] key.
5) On the (<OBDMenu)) 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 the Subaru Select Monitor and ignition
switch to OFF.
NOTE:
For detailed operation procedure, refer to the
SUBARU SELECT MONITOR OPERATION MAN-
UAL.
3. OBD-II GENERAL SCAN TOOL
For clear memory procedures using the OBD-II
general scan tool, refer to the OBD-II General Scan
Tool Instruction Manual.

EN(D0HC TURBO)-49
 COMPULSORY VALVE OPERATION CHECK MODE
ENGINE (DIAGNOSTICS)

14.Compulsory Valve Operation 5) Connect the Subaru Select Monitor to data link
connector.
Check Mode (1) Connect the Subaru Select Monitor to data
link connector located in the lower portion of the
A: OPERATION instrument panel (on the driver's side).
1) Prepare the Subaru Select Monitor kit. <Ref. to
EN(D0HC TURBO)-8, PREPARATION TOOL,
General Description.>

I I

(2) Connect the diagnosis cable to data link

~
S2M0285 connector.
2) Connect the diagnosis cable to Subaru Select CAUTION:
Monitor. Do not connect scan tools except for Subaru
3) Insert the cartridge into Subaru Select Monitor. Select Monitor and OBD-ll general scan tool.
<Ref. to EN(D0HC TURBO)-8, PREPARATION 6) Turn the ignition switch to ON (engine OFF) and
TOOL, General Description.> Subaru Select Monitor switch to ON.

S2M0286A I S2M0288 I

4) Connect the test mode connector (A) at the low-
er portion of instrument panel (on the driver's side),
to the side of the center console box.
7) On the ((Main Menu)) display screen, select the
(2.Each System Check} and press the [YES] key.
8) On the ((System Selection Menu)) display
screen, select the {Engine Control System} and
press the [YES] key.
9) Press the [YES] key after displayed the informa-
tion of engine type.
10) On the ((EngineDiagnosis))display screen, se-
lect the {System Operation Check Mode} and press
the [YES] key.
11) On the ((System Operation Check Mode)) dis-
play screen, select the {Actuator ON/OFF Opera-
tion} and press the [YES] key.
12) Select the desired compulsory actuator on the
((ActuatorON/OFF Operation)) display screen and
press the [YES] key.
13) Pressing the [NO] key completes the compul-
sory operation check mode. The display will then
return to the ((Actuator ON/OFF Operation))
screen.

EN(D0HC TURBO)-50
 COMPULSORY VALVE OPERATION CHECK MODE
ENGINE (DIAGNOSTICS)

Contents Display
Compulsory fuel pump relay operation check Fuel Pump Relay
ComDulsorv radiator fan relay oDeration check Radiator Fan Relay
Compulsory air conditioning relay operation check I A/C Compressor Relay I
Compulsory purge control solenoid valve operation check CPC Solenoid Valve
Compulsory fuel pressure control solenoid valve operation check PCV Solenoid Valve
Compulsory drain valve operation check Vent Control Solenoid Valve
Compulsory fuel tank pressure sensor control valve operation check Fuel Tank Sensor Control Valve

Display
EGR Solenoid Valve
ASV Solenoid Valve
m C D Solenoid I
I Pressure Switching Sol. 1 I
I Pressure Switching Sol. 2 I
I AAI Solenoid Valve
For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL.

EN(D0HC TURBO)-51
 ENGINE MALFUNCTION INDICATOR LAMP (MIL)
ENGINE (DIAGNOSTICS)

15.Engine Malfunction Indicator Lamp (MIL)

A: PROCEDURE
1. Activation of check engine malfunction indicator lamp (MIL). <Ref. to EN(D0HC TURBO)-53, ACTIVATION OF CHECK
ENGINE MALFUNCTION INDICATOR LAMP (MIL), Engine Malfunction Indicator Lamp (MIL).>
1
2. Check engine malfunction indicator lamp (MIL) does not come on. <Ref. to EN(D0HC TURBO)-54, CHECK ENGINE MAL-
FUNCTION INDICATOR LAMP (MIL) DOES NOT COME ON., Enaine Malfunction Indicator Lamp (MIL).>
1
3. Check engine malfunction indicator lamp (MIL) does not go off. <Ref. to EN(D0HC TURBO)-56, CHECK ENGINE MAL-
FUNCTION INDICATOR LAMP (MIL) DOES NOT GO OFF., Engine Malfunction Indicator Lamp (MIL).>
1
4. Check engine malfunction indicator lamp (MIL) does not blink at a cycle of 3 Hz. <Ref. to EN(D0HC TURBO)-57, CHECK
ENGINE MALFUNCTION INDICATOR LAMP (MIL) DOES NOT BLINK AT A CYCLE OF 3 HZ., Engine Malfunction Indicator
Lamp (MIL).>
1
5. Check engine malfunction indicator lamp (MIL) remains blinking at a cycle of 3 Hz. <Ref. to EN(D0HC TURBO)-60, CHECK
ENGINE MALFUNCTION INDICATOR LAMP (MIL) REMAINS BLINKING AT A CYCLE OF 3 HZ., Engine Malfunction Indicator
Lamp (MIL).>

EN(D0HC TURBO)-52
 ENGINE MALFUNCTION INDICATOR LAMP (MIL)
m
ENGINE (DIAGNOSTICS)

B: ACTIVATION OF CHECK ENGINE 4) When the ignition switch is turned to ON (engine

MALFUNCTION INDICATOR off) or to “START” with the test mode connector
connected, the MIL blinks at a cycle of 3 Hz.
LAMP (MIL)
1) When the ignition switch is turned to ON (engine
off), the CHECK ENGINE malfunction indicator
lamp (MIL) in the combination meter illuminates. MIL ON
OFF ,
NOTE:
If the MIL does not illuminate, perform diagnostics
of the CHECK ENGINE light circuit or the combina- r4
1 sec. *
tion meter circuit. <Ref. to EN(D0HC TURBO)-54, Ignition
CHECK ENG INE MALFUNCTlON INDC A T 0R switch
LAMP (MIL) DOES NOT COME ON., Engine Mal- ON
function Indicator Lamp (MIL).> OBD0055P

I FNln74

2) After starting the engine, the MIL goes out. If it

does not, either the engine or the emission control
system is malfunctioning.

b) Trouble occurs.

ON
MIL
OFF Igniiion 1
switch En&e
ON Start OBD0053A

3) If the diagnosis system senses a misfire which

could damage the catalyzer, the MIL will blink at a
cycle of 1 Hz.

ON
MIL
OFF

Ignition
switch ~~g~~~
ON start ~ 1 sec. i
Misfire
start
OBD0054P

EN(D0HC TURBO)-53
 ENGINE MALFUNCTION INDICATOR LAMP (MIL)
ENGINE (DIAGNOSTICS)

C: CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) DOES NOT COME

ON.
DIAGNOSIS:
The CHECK ENGINE malfunction indicator lamp (MIL) circuit is open or shorted.
TROUBLE SYMPTOM:
When the ignition switch is turned ON (engine OFF), MIL does not come on.
WIRING DIAGRAM:

BATTERY

COMBINATION
METER

C:@ @ ECM

r 1 n i ~n
112 3 1 W 1 4 516 1 1 12131415161718191101
718 9 110111112 13114
L J

Pl?EwEa
10 11 12 13 14 15 16 17 18 19 20
1121314151 16171819110111
12~13~14~15[16~17~18~19~20~21~22~23~24

EN1137

Step Check Yes No

1 CHECK OUTPUT SIGNAL FROM ECM. Is the voltage less than 1 V? Go to step 4. Go to step 2.
1)Turnthe ignition switch to ON.
2)Measure the voltage between ECM connec-
tor and chassis ground.
Connector & terminal
(8137) No. 15 (+) - Chassis ground (-):

EN(DOHC TURB0)-54
 ENGINE MALFUNCTION INDICATOR LAMP (MIL)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK POOR CONTACT. ,oes the MIL come on when Tepair poor con- 30 to step 3.
haking or pulling ECM con- x t in ECM con-
ector and harness? lector.
CHECK ECM CONNECTOR. ;the ECM connector correctly leplace the ECM. Repair connection
onnected? :Ref. to FU(D0HC sf ECM connector,
'URB0)-47,
lngine Control
nodule.>
CHECK HARNESS BETWEEN COMBINA- ;the resistance less than 1 ;o to step 5. Repair harness
TION METER AND ECM CONNECTOR. 2? and connector.
1)Turn the ignition switch to OFF. NOTE:
2)Remove the combination meter. <Ref. to In this case, repai
IDI-11, Combination Meter Assembly.> the following:
3)Disconnectthe connector from ECM and Open circuit in
combination meter. harness between
4)Measure the resistance of harness between ECM and combi-
ECM and combination meter connector. nation meter con-
Connector & terminal nector
(8137) No. 15 - (i12) No. 6: 8 Poor contact in

couplingconnect0
CHECK POOR CONTACT. lepair poor con-
;there poor contact in combi- Go to step 6.
Check poor contact in combination meter con- iation meter connector? act in combination
nector. neter connector.
CHECK HARNESS BETWEEN COMBINA- s the voltage more than 10 V? So to step 7. Check the follow-
TION METER AND IGNITION SWITCH CON- ing and repair if
NECTOR. necessary.
1)Turn the ignition switch to ON. NOTE:
2)Measure the voltage between combination * Brokendown
meter connector and chassis ground. ignition relay.
Connector & terminal Blown out fuse
(i10) No. 7 (+) - Chassis ground (-): (No. 5).
If replaced fuse
(No. 5) blows eas-
ily, check the har-
ness for short
circuit of harness
between fuse (No.
5) and ignition
relay connector.
Open or short
circuit in harness
between fuse (No.
5) and battery ter-
minal
Open circuit in
harness between
fuse (No. 5) and
ignition relay con-
nector
Poor contact in
ignition relay con-
nector
Poor contact in
ignition switch cor
nector
I
CHECK LAMP BULB. s the lamp bulb condition OK; 3epair combina- Replace the lamp
Remove the engine malfunction indicator lamp :ion meter connec. bulb.
bulb. :or.

EN(D0HC TURBO)-55
 ENGINE MALFUNCTION INDICATOR LAMP (MIL)
ENGINE (DIAGNOSTICS)
~

D: CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) DOES NOT GO

OFF.
DIAGNOSIS:
The CHECK ENGINE malfunction indicator lamp (MIL) circuit is shorted.
TROUBLE SYMPTOM:
Although MIL comes on when the engine runs, trouble code is not shown on the Subaru select monitor
or OBD-ll general scan tool display.
WIRING DIAGRAM:

BATTERY

IGNITION

1
ql
OMBINATION
ETER

A:@
I
C:@

U @ ECM

EN1137

t
Step Check
1 CHECK HARNESS BETWEEN COMBINA- Does the MIL come on?
TlON METER AND ECM CONNECTOR. in harness <Ref. to FU(D0HC
1)Turnthe ignition switch to OFF.
2)Disconnect the connector from ECM.
3)Turn the ignition switch to ON.

EN(D0HC TURBO)-56
 ENGINE MALFUNCTION INDICATOR LAMP (MIL)
ENGINE (DIAGNOSTICS)

E: CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) DOES NOT BLINK

AT A CYCLE OF 3 HZ.
DIAGNOSIS:
The CHECK ENGINE malfunction indicator lamp (MIL) circuit is open or shorted.
Test mode connector circuit is in open.
TROUBLE SYMPTOM:
When in inspection mode, MIL does not blink at a cycle of 3 Hz.

EN(D0HC TURB0)-57
 ENGINE MALFUNCTION INDICATOR LAMP (MIL)
ENGINE (DIAGNOSTICS)

WIRING DIAGRAM:

IGNITION BATTERY
SBF-4 SBF-1
3 c

COMBINATION
METER

A:@

C:@

EN1138

EN(D0HC TURBO)-58
 ENGINE MALFUNCTION INDICATOR LAMP (MIL)
ENGINE (DIAGNOSTICS)
_____~

Step Check Yes No

CHECK STATUS OF CHECK ENGINE MAL- loes the MIL come on? io to step 2. Repair the MIL cir-
FUNCTION INDICATOR LAMP (MIL). cuit. <Ref. to
1)Turnthe ignition switch to OFF. EN(D0HC
2)Disconnectthe test mode connector. TURBO)-54,
3)Turn the ignition switch to ON. (engine OFF) CHECK ENGINE
MALFUNCTION
INDICATOR
LAMP (MIL)
DOES NOT
COME ON.,
Engine Malfunc-
tion Indicator
Lamp (MIL).>
! CHECK HARNESS BETWEEN COMBINA- loes the MIL come on? 3epair ground Go to step 3.
TlON METER AND ECM CONNECTOR. ;hort circuit in har-
1)Turnthe ignition switch to OFF. less between
2)Disconnectthe connector from ECM. :ombination meter
3)Turn the ignition switch to ON. ind ECM connec-
or.
I CHECK HARNESS BETWEEN TEST MODE s the resistance less than 1 i o to step 4. Repair harness
CONNECTOR AND CHASSIS GROUND. n? and connector.
1)Turn the ignition switch to OFF. NOTE:
2)Disconnect the connector from ECM. In this case, repaii
3)Measure the resistance of harness between the following:
test mode connector and chassis ground. Open circuit in
Connector & terminal harness between
(876) No. 1 - Chassis ground: test mode connec-
tor and chassis
ground
I CHECK POOR CONTACT. s there poor contact in ECM 3epair poor con- Go to step 5.
Check poor contact in ECM connector. :onnector? act in ECM con-
lector.
i CHECK HARNESS BETWEEN ECM AND s the resistance less than 1 i o to step 6. Repair open circuit
TEST MODE CONNECTOR. R? in harness
1)Connect the test mode connector. between ECM and
2)Measure the resistance of harness between test mode connec-
ECM and chassis ground. tor.
Connector & terminal
(8134) No. 14 - Chassis ground:
i CHECK POOR CONTACT. s there poor contact in ECM
Check poor contact in ECM connector. :onnector?
lector. TURBO)-47,
Engine Control
Module.>

EN(D0HC TURBO)-59
 ENGINE MALFUNCTION INDICATOR LAMP (MIL)
ENGINE (DIAGNOSTICS)

F: CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) REMAINS BLINK-

ING AT A CYCLE OF 3 HZ.
DIAGNOSIS:
Test mode connector circuit is shorted.
TROUBLE SYMPTOM:
MIL blinks at a cycle of 3 Hz when the ignition switch is turned to ON.
WIRING DIAGRAM:

IGNITION BATTERY
SBF-4 SBF-1
3 c

METER -1.- r

1121314151 r - l 16171819110111
12~13~14~15~16~17~18~19~20~21~22~23~24
112131415161 171819110111
12~13]14]15~16]17~18~19~20]21]22]23~24

m
EN1138

EN(D0HC TURBO)-60
 ENGINE MALFUNCTION INDICATOR LAMP (MIL)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK TEST MODE CONNECTOR. Does the MIL flash on and off? Go to step 2. System is in good
1)Disconnectthe test mode connector. order.
2)Turn the ignition switch to ON. NOTE:
MIL blinks at a c)
cle of 3 Hz whe
test mode connec
tor is connected.
CHECK HARNESS BETWEEN ECM CON- Is the resistance less than 5 Repair short circuit Replace the ECM.
NECTOR AND ENGINE GROUNDING TER- R? in harness <Ref. to FU(D0HC
MINAL. between ECM and TURBO)-47,
1)Turnthe ignition switch to OFF. test mode connec- Engine Control
2)Disconnectthe connector from ECM. tor. Module.>
3)Measure the resistance of harness between
ECM connector and chassis ground.
Connector & terminal
(8734) No. 74 - Chassis ground:

EN(D0HC TURBO)-61
 ENGINE MALFUNCTION INDICATOR LAMP (MIL)
ENGINE (DIAGNOSTICS)

EN(D0HC TURBO)-62
 DIAGNOSTICS FOR ENGINE STARTING FAILURE
ENGINE (DIAGNOSTICS)

16.Diagnostics for Engine Starting Failure

A: PROCEDURE
1. Inspection of starter motor circuit. <Ref. to EN(D0HC TURBO)-64, STARTER MOTOR CIRCUIT, Diagnostics for Engine
Startina Failure.>
L
2. Inspection of ECM power supply and ground line. <Ref. to EN(D0HC TURBO)-68, CONTROL MODULE POWER SUPPLY
AND GROUND LINE, Diagnostics for Engine Starting Failure.>
L
3. Inspection of ignition control system. <Ref. to EN(D0HC TURBO)-72, IGNITION CONTROL SYSTEM, Diagnostics for
Engine Starting Failure.>
-L
4. Inspection of fuel pump circuit. <Ref. to EN(D0HC TURBO)-76, FUEL PUMP CIRCUIT, Diagnostics for Engine Starting Fail-
ure.>
-1
5. Inspection of fuel injector circuit. <Ref. to EN(D0HC TURBO)-78, FUEL INJECTOR CIRCUIT, Diagnostics for Engine Start-
ing Failure.>

EN(D0HC TURBO)-63
 DIAGNOSTICS FOR ENGINE STARTING FAILURE
ENGINE (DIAGNOSTICS)

B: STARTER MOTOR CIRCUIT

CAUTION:
After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to EN(D0HC TUR-
BO)-49,'Clear Memory Mode.> and-INSPECTION MODE <Ref. to EN(D0HC TURBO)-46, Inspection
Mode.>.
WIRING DIAGRAM:

IGNITION

INTERRUPT
RELAY

I ITO SECURITY SYSTEM I

STARTER
INTER LOCK
RELAY (MT)

STARTER

SWITCH
(MT)

M @ ECM
-
-

7 8 9101112

EN1139

EN(D0HC TURBO)-64
 DIAGNOSTICS FOR ENGINE STARTING FAILURE
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK OPERATION OF STARTER MOTOR Ioes the starter motor operate 30 to step 2. Go to step 3.
vhen the switch starts?
CHECK DTC. s the trouble code stored in 3ecord the DTC. Go to step 3.
<Ref. to EN(D0HC TURBO)-45, OPERATION, nemory? <Ref. to EN(D0HC 3epair the trouble
Read Diagnostic Trouble Code.> -URBO)-80, LIST, List of Diag. :ase. <Ref. to
iostic Trouble Code (DTC).> !N(DOHC
rURBO)-88, Diag-
iostic Procedure
Nith Diagnostic
rrouble Code
DTC).>
CHECK INPUT SIGNAL FOR STARTER MO- s the voltage more than 10 V? 30 to step 4. Go to step 5.
TOR.
1)Turnthe ignition switch to OFF.
2)Disconnectthe connector from starter motor
3)Turn the ignition switch to ST.
4)Measure the power supply voltage between
starter motor connector terminal and engine
ground.
Connector & terminal
(814) No. 1 (+) - Engine ground (-):
CHECK GROUND CIRCUIT OF STARTER s the resistance less than 5 )heck the starter Repair open circuil
MOTOR. a? notor. <Ref. to of ground cable.
1)Turn the ignition switch to OFF. X - 6 , Starter.>
2)Disconnect the terminal from starter motor.
3)Measure the resistance of ground cable
between ground cable terminal and engine
ground. . I

CHECK HARNESS BETWEEN ECM AND s the resistance less than 1 qepair ground Go to step 6.
STARTER MOTOR CIRCUIT. 2? short circuit.
1)Turnthe ignition switch to OFF.
2)Measure the resistance between starter
motor and ECM.
Connector & terminal
(814) No. 1 - Engine ground:
CHECK HARNESS BETWEEN ECM AND s the resistance less than 1
STARTER MOTOR CIRCUIT. 3? short circuit.
1)Turnthe ignition switch to START.
2)Measure the resistance of fuse.
Connector & terminal
(6 14) No. 1 - Engine ground:
CHECK HARNESS BETWEEN BATTERY s the voltage more than 10 V? 30 to step 8. Repair open circuii
AND IGNITION SWITCH CONNECTOR. in harness
1)Turnthe ignition switch to OFF. between ignition
2)Disconnect the connector from ignition switch and battery,
switch.
3)Measure the power supply voltage between
ignition switch the connector and chassis

I
ground.
Connector & terminal
(872) No. 1 (+) - Chassis ground (-):
CHECK HARNESS BETWEEN BATTERY s the voltage more than 10 V? 3epair open circuit Go to step 9.
AND IGNITION SWITCH CONNECTOR. 3etween ignition
1)Connect the connector to ignition switch. ;witch and starter
2)Turn the ignition switch to START. notor circuit.
3)Measure the voltage between ignition switch
and chassis ground.
Connector & terminal
(872) No. 3 (+) - Chassis ground (-):

EN(D0HC TURBO)-65
 DIAGNOSTICS FOR ENGINE STARTING FAILURE
ENGINE (DIAGNOSTICS)

Step Check Yes No

9 CHECK POOR CONTACT. Is there poor contact in ignition Repair poor con- Replace the igni-
Check poor contact in ignition switch connec- switch connector? tact in ignition tion switch.
tor. switch connector.

EN(D0HC TURBO)-66
DIAGNOSTICS FOR ENGINE STARTING FAILURE
ENGINE (DIAGNOSTICS)

EN(D0HC TURBO)-67
 DIAGNOSTICS FOR ENGINE STARTING FAILURE
ENGINE (DIAGNOSTICS)

C: CONTROL MODULE POWER SUPPLY AND GROUND LINE

CAUTION:
After repair or replacement of faulty parts, conduct CLEAR MEMORY MODEeRef. to EN(D0HC TUR-
BO)-49, Clear Memory Mode.> and INSPECTION MODE. <Ref. to EN(D0HC TURBO)-46, Inspection
Mode.>
WIRING DIAGRAM:

MAIN RELAY

BATTERY

A:@

c:@ ECM

D:@

r 1

EN1171

EN(D0HC TURBO)-68
 DIAGNOSTICS FOR ENGINE STARTING FAILURE
ENGINE (DIAGNOSTICS)
_ _ _ _ _ ~

Step Check
CHECK MAIN RELAY. s the resistance less than 10
1)Turn the ignition switch to OFF. 2? relay.
2)Remove the main relay.
3)Connect the battery to main relay terminals
No. 1 and No. 2. I
4)Measure the resistance between main relay
terminals.
Terminals
NO. 3 - NO. 5:
NO. 4 - NO. 6:
CHECK GROUND CIRCUIT OF ECM. s the resistance less than 5 i o to step 3. Repair open circuit
1)Disconnect the connector from ECM. 2? in harness
2)Measure the resistance of harness between between ECM
ECM and chassis ground. connector and
Connector & terminal engine grounding
-
(6134) No. 7 Chassis ground: terminal.
-
( 6 134) No. 15 Chassis ground:
(6134) No. 22 - Chassis ground:
(6136) No,8 - Chassis ground:
-
(6136) No. 17 Chassis ground:
(6136) No. 18 - Chassis ground:
(8137) No. 8 - Chassis ground:
(8137) No. 9 - Chassis ground:
(684) No, 1 - Chassis ground: (MT vehi-
cle)
CHECK INPUT VOLTAGE OF ECM. s the voltage more than 10 V? io to step 4. Repair open or
Measure the voltage between ECM connector ground short cir-
and chassis ground. cuit of power sup-
Connector & terminal ply circuit.
(8137) No. 10 (+) - Chassis ground (-):
(8134) No. 5 (+) - Chassis ground (-): I

CHECK HARNESS BETWEEN ECM AND s the resistance more than 1 i o to step 5. Repair ground
MAIN RELAY CONNECTOR. dnR? short circuit in har.
1)Turn the ignition switch to OFF. ness between
2)Disconnect the connector from ECM. ECM connector
3)Measure the resistance between ECM and and main relay
chassis ground. connector, then
Connector & terminal replace the ECM.
(6134) No. 6 -Chassis ground:
CHECK OUTPUT VOLTAGE FROM ECM. s the voltage more than 10 V? ;o to step 6. Replace the ECM.
1)Connectthe connector to ECM. <Ref. to FU(D0HC
2)Turn the ignition switch to ON. TURBO)-47,
3)Measure the voltage between ECM connec- Engine Control
tor and chassis ground. Module.>
Connector & terminal
i
(6134) No. 6 (+) - Chassis ground (-):
CHECK INPUT VOLTAGE OF MAIN RELAY. s the voltage more than 10 V? ;o to step 7. Repair open circuil
Check the voltage between main relay connec- in harness
tor and chassis ground. between ECM
Connector & terminal connector and
(647) No. 2 (+) - Chassis ground (-): main relay connec
tor.
. CHECK GROUND CIRCUIT OF MAIN RE- s the resistance less than 5 ;o to step 8. Repair open circuii
LAY. 2? between main
1)Turnthe ignition switch to OFF. relay and chassis
2)Measure the resistance between main relay ground.
connector and chassis ground.
Connector 81terminal
(847) No. 1 - Chassis ground:

EN(DOHC TURBO)-69
I
DIAGNOSTICS FOR ENGINE STARTING FAILURE
ENGINE (DIAGNOSTICS)

Check Yes No
Is the voltage more than 10 V? Go to step 9. Repair open or
Measure the voltage between main relay con- ground short cir-
nector and chassis ground. cuit in harness of
Connector & terminal power supply cir-
(847) No. 5 (+) - Chassis ground (-): cuit.
(847) No. 6 (+) - Chassis ground (-):
CHECK INPUT VOLTAGE OF ECM. Is the voltage more than 10 V? Check ignition Repair open or
1)Connect the main relay connector. control system. ground short cir-
2)Turn the ignition switch to ON. <Ref. to EN(D0HC cuit in harness
3)Measure the voltage between ECM connec- TURBO)-72, IGNI- between ECM
tor and chassis ground. TION CONTROL connector and
Connector & terminal SYSTEM, Diag- main relay connec.
(8137) No. 2 (+) - Chassis ground (-): nostics for Engine tor.
(8137) No. 3 (+) - Chassis ground (-): Starting Failure.>

EN(D0HC TURB0)-70
DIAGNOSTICS FOR ENGINE STARTING FAILURE
ENGINE (DIAGNOSTICS)

EN(D0HC TURB0)-71
 DIAGNOSTICS FOR ENGINE STARTING FAILURE
ENGINE (DIAGNOSTICS)

D: IGNITION CONTROL SYSTEM

CAUTION:
After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to EN(D0HC TUR-
BO)-49, Clear Memory Mode.> and INSPECTION MODE <Ref. to EN(D0HC TURBO)-46, Inspection
Mode.>.
WIRING DIAGRAM:

@ ECM

IGNITION COIL IGNITION COIL IGNITION COIL IGNtTION COIL

No.1 N0.2 N0.3 N0.4

EN1140

EN(D0HC TURBO)-72
 DIAGNOSTICS FOR ENGINE STARTING FAILURE
ENGINE (D IAGNOSTlCS)

Step Check Yes No

CHECK SPARK PLUG CONDITION. s the spark plug's status OK? Go to step 2. Replace the spark
1)Removethe spark plug. <Ref. to IG(D0HC 3lug.
TURBO)-5, INSTALLATION, Spark Plug.>
2)Check the spark plug condition. <Ref. to
IG(D0HC TURBO)-6, INSPECTION, Spark
Plug.>
! CHECK IGNITION SYSTEM FOR SPARKS. Ioes spark occur at each cyl- Check fuel pump So to step 3.
1)Connectthe spark plug to ignition coil. nder? system. <Ref. to
2)Release the fuel pressure. <Ref. to EN(D0HC
FU(D0HC TURBO)-51, RELEASING OF TURBO)-76,FUEL
FUEL PRESSURE, OPERATION, Fuel.> PUMP CIRCUIT,
3)Contact the spark plug's thread portion on Diagnostics for
engine. Engine Starting
4)While opening the throttle valve fully, crank Failure.>
the engine to check that spark occurs at each
cylinder.
1 CHECK POWER SUPPLY CIRCUIT FOR IG- s the voltage more than 10 V? Go to step 4. Repair harness
NlTlON COIL & IGNITOR ASSEMBLY. 2nd connector.
1)Turn the ignition switch to OFF. NOTE:
2)Disconnectthe connector from ignition coil i3 In this case, repai
ignitor assembly. the following:
?)Turn the ignition switch to ON. Open circuit in
4)Measure the power supply voltage between harness between
ignition coil & ignitor assembly connector and ignition coil & igni-
engine ground. tor assembly, and
Connector & terminal ignition switch con
(€31) No. 3 (+) - Engine ground (-): nector
(€32) No. 3 (+) - Engine ground (-): Poor contact in
(E33) No. 3 (+) - Engine groundI)-( coupling connec-
(E34) No. 3 (+) - Engine ground (-): tors
I CHECK HARNESS OF IGNITION COIL & IG. s the resistance between less ;o to step 5. Repair harness
NITOR ASSEMBLY GROUND CIRCUIT. han 5 12? and connector.
1)Turnthe ignition switch to OFF. NOTE:
2)Measure the resistance between ignition coi In this case, repai
& ignitor assembly connector and engine the following:
ground. Open circuit in
Connector & terminal harness between
(€31) No. 2 - Engine ground: ignition coil & igni-
(E32) No, 2 - Engine ground: tor assembly con-
(E33) No. 2 - Engine ground: nector and engine
(E34) No. 2 - Engine ground: grounding termina
b CHECK HARNESS BETWEEN ECM AND IG s the resistance less than 1 ;o to step 6. Repair harness
NlTlON COIL & IGNITOR ASSEMBLY CON- n? and connector.
NECTOR. NOTE:
1)Turn the ignition switch to OFF. In this case, repai
2)Disconnect the connector from ECM. the following:
3)Disconnectthe connector from ignition coil 8 Open circuit in
ignitor assembly. harness between
4)Measure the resistance of harness between ECM and ignition
ECM and ignition coil & ignitor assembly con- coil & ignitor
nector. assembly connec-
Connector & terminal tor
. (6136) NO. 2 1 - (E34) NO. 1: Poor contact in
(6136) NO. 22 - (€33) NO. 1: coupling connect0
(6136) NO. 23 - (€32) NO. 1:
(6136) NO. 24 - (€31) NO. 1:

EN(D0HC TURBO)-73
 DIAGNOSTICS FOR ENGINE STARTING FAILURE
ENGINE (DIAGNOSTICSI
~

Step Check Yes No

I CHECK HARNESS BETWEEN ECM AND IG-
NITION COIL & IGNITOR ASSEMBLY CON- Ma? short circuit in har-
NECTOR. nessbetween
Measure the resistance of harness between ECM and ignition
ECM and engine ground. coil i
3 ignitor
Connector a terminal: assembly connec-
(6136) No. 21- Engine ground: tor.
-
(8736) No. 22 Engine ground:
(6736) No. 23- Engine ground:
-
(6136) No. 24 Engine ground:
CHECK POOR CONTACT. Is there poor contact in ECM
Check poor contact in ECM connector. connector?
assembly.

EN(D0HC TURBOk74
I
DIAGNOSTICS FOR ENGINE STARTING FAILURE
-
ENGINE (DIAGNOSTICS)

EN(D0HC TURBO)-75
 DIAGNOSTICS FOR ENGINE STARTING FAILURE
ENGINE (DIAGNOSTICS)

E: FUEL PUMP CIRCUIT

CAUTION:
After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to EN(D0HC TUR-
BO)-49, Clear Memory Mode.> and INSPECTION MODE <Ref. to EN(D0HC TURBO)-46, Inspection
Mode.>.
WIRING DIAGRAM:

BATTERY
SBF-5
3 c
FUEL PUMP
I

FUEL PUMP
CONTROLLER

FUEL
PUMP

EN(DOHC TURB0)-76
 DIAGNOSTICS FOR ENGINE STARTING FAILURE
-
ENGINE (DIAG NOSTlCSl

Step Check Yes No

1 CHECK OPERATING SOUND OF FUEL Does the fuel pump produce Check the fuel Record the DTC.
PUMP. operating sound? injector circuit. Repair the trouble
Make sure that fuel pump is in operation for <Ref. to EN(D0HC case. <Ref. to
two seconds when turning the ignition switch to TURBO)-78,FUEL EN(D0HC
ON. INJECTOR CIR- TURBO)-88, Diag-
NOTE: CUIT, Diagnostics nostic Procedure
Fuel pump operation can also be executed us- for Engine Start- with Diagnostic
ing Subaru Select Monitor (Function mode: ing Failure.> Trouble Code
FDOI). (DTC).>
For the procedure, refer to “Compulsory Valve
Operation Check Mode”. <Ref. to EN(D0HC
TURBO)-50, Compulsory Valve Operation
Check Mode.>

EN(D0HC TURBO)-77
r
DIAGNOSTICS FOR ENGINE STARTING FAILURE
ENGINE (DIAGNOSTICS)

F: FUEL INJECTOR CIRCUIT

CAUTION:
Check or repair only faulty parts.
After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to EN(D0HC
TURBO)-49, Clear Memory Mode.> and INSPECTION MODE. <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>
WIRING DIAGRAM:

I I ' " IC

I .
I

-
FUEL INJECTORS

EN1 142

EN(D0HC TURBO)-78
 DIAGNOSTICS FOR ENGINE STARTING FAILURE
-
ENGINE (DIAGNOSTICS)
~~~ ~~

Step Check Yes No

CHECK OPERATIONOF EACH FUEL INJEC- ;the fuel injector emits “oper- ;heck the fuel 20 to step 2.
TOR. iting” sound? bressure. <Ref. to
While cranking the engine, check that each AE(D0HC
fuel injector emits “operating” sound. Use a -URBO)-27,
sound scope or attach a screwdriver to the NSPECTION,
injector for this check. -uel Pressure.>
CHECK POWER SUPPLY TO EACH FUEL s the voltage more than 10 V? 20 to step 3. 3epair harness
INJECTOR. ind connector.
1)Turn the ignition switch to OFF. qOTE:
2)Disconnect the connector from #I cylinder n this case, repaii
fuel injector. he following:
3)Turn the ignition switch to ON. 1 Open circuit in
4)Measure the power supply voltage between iarness between
the fuel injector terminal and engine ground. nain relay and fuel
Connector & terminal njector connector
#I (€5) No. 2 (+) - Engine ground (-): 1 Poor contact in

#2 (E 16) No. 2 (+) - Engine ground (-): nain relay connec,

#3 (E6) No. 2 (+) - Engine ground (-): :or
#4 (El 7) No. 2 (+) - Engine ground (-): 1 Poor contact in

:oupling connectol
1 Poor contact in

‘uel injector con-

lector
I CHECK HARNESS BETWEEN ECM AND s the resistance less than 1 30 to step 4. qepair harness
FUEL INJECTOR CONNECTOR. 2? and connector.
1)Disconnect the connector from ECM. MOTE:
2)Measure the resistance of harness between in this case, repai
ECM and fuel injector connector. the following:
Connector & terminal 1 Open circuit in

(8137) NO. 1 - (€5) NO. 1: iarness between

-
(8136) NO. 6 (€16) NO. 1: ECM and fuel
(8136) NO. 5 - (E6) NO. 1: njector connector
(8136) NO. 4 - (€6) NO. 1: 1 Poor contact in

:oupling connect0
I CHECK HARNESS BETWEEN ECM AND s the resistance less than 1 qepair ground So to step 5.
FUEL INJECTOR CONNECTOR. A? short circuit in har-
Measure the resistance of harness between less between
ECM and fuel injector connector. ECM and fuel
Connector & terminal njector connector.
(8137) No. 1 - Chassis ground:
(8136) No. 6 - Chassis ground:
(8136) No. 5 - Chassis ground:
(8136) No. 4 - Chassis ground:
P CHECK EACH FUEL INJECTOR. s the resistance between 5 So to step 6. Replace the faulty
1)Turn the ignition switch to OFF. ind 20 Q? fuel injector.
2)Measure the resistance between each fuel
injector terminals.
Terminals
NO. 1 -NO. 2:
i CHECK POOR CONTACT. s there poor contact in ECM Repair poor con- Inspection using
Check poor contact in ECM connector. :onnector? tact in ECM con- “General Diagnos-
nector. tic Table”. <Ref. to
EN(D0HC
TURBO)-372,
INSPECTION,
General Diagnos-
tic Table.>

EN(D0HC TURBO)-79
 LIST OF DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

17.List of Diagnostic Trouble Code (DTC)

A: LIST
DTC
Item Index
No.
PO031 Front oxygen (NF) sensor heater cir- <Ref. to EN(D0HC TURBO)-88, DTC PO031 - FRONT OXYGEN (NF)
cuit low input SENSOR HEATER CIRCUIT LOW INPUT -, Diagnostic Procedure with
Diagnostic Trouble Code (DTC).>
PO032 Front oxygen (NF)sensor heater cir- <Ref. to EN(D0HC TURBO)-92, DTC PO032 - FRONT OXYGEN (NF)
cuit high input SENSOR HEATER CIRCUIT HIGH INPUT -, Diagnostic Procedure with
Diagnostic Trouble Code (DTC).>
PO037 Rear oxygen sensor heater circuit <Ref. to EN(D0HC TURBO)-94, DTC PO037 - REAR OXYGEN SENSOR
malfunction HEATER CIRCUIT MALFUNCTION-, Diagnostic Procedure with Diagnos-
tic Trouble Code (DTC).>
PO038 Rear oxygen sensor heater circuit <Ref. to EN(D0HC TURBO)-98, DTC PO038 - REAR OXYGEN SENSOR
high input HEATER CIRCUIT HIGH INPUT -, Diagnostic Procedure with Diagnostic
Trouble Code (DTC).>
PO101 Mass air flow sensor circuit range/ <Ref. to EN(D0HC TURBO)-100, DTC PO101 - MASS AIR FLOW SEN-
performance problem (high input) SOR CIRCUIT RANGE/PERFORMANCEPROBLEM (HIGH INPUT) -,
Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
PO102 Mass air flow sensor circuit low input <Ref. to EN(D0HC TURBO)-102, DTC PO102 - MASS AIR FLOW SEN-
SOR CIRCUIT LOW INPUT -, Diagnostic Procedure with Diagnostic Trou-
ble Code (DTC).>
PO103 Mass air flow sensor circuit high <Ref. to EN(D0HC TURBO)-106, DTC PO103 - MASS AIR FLOW SEN-
input SOR CIRCUIT HIGH INPUT -, Diagnostic Procedure with Diagnostic Trou-
ble Code (DTC).>
PO106 Pressure sensor circuit range/pedor- <Ref. to EN(D0HC TURBO)-108, DTC PO106 - PRESSURE SENSOR
mance problem (low input) CIRCUIT RANGE/PERFORMANCEPROBLEM (LOW INPUT) -, Diagnos-
tic Procedure with Diagnostic Trouble Code (DTC).>
PO107 Pressure sensor circuit low input <Ref. to EN(D0HC TURBO)-110, DTC PO107 - PRESSURE SENSOR
CIRCUIT LOW INPUT -, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
PO108 Pressure sensor circuit high input <Ref. to EN(D0HC TURBO)-114, DTC PO108 - PRESSURE SENSOR
CIRCUIT HIGH INPUT -, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
PO111 Intake air temperature sensor circuit <Ref. to EN(D0HC TURBO)-118, DTC PO111 - INTAKE AIR TEMPERA-
range/performance problem TURE SENSOR CIRCUIT RANGE/PERFORMANCEPROBLEM -, Diag-
nostic Procedure with Diagnostic Trouble Code (DTC).>
PO112 Intake air temperature sensor circuit <Ref. to EN(D0HC TURBO)-120, DTC PO112 - INTAKE AIR TEMPERA-
low input TURE SENSOR CIRCUIT LOW INPUT -, Diagnostic Procedure with Diag-
nostic Trouble Code (DTC).>
PO113 Intake air temperature sensor circuit <Ref. to EN(D0HC TURBO)-122, DTC PO113 - INTAKE AIR TEMPERA-
high input TURE SENSOR CIRCUIT HIGH INPUT -, Diagnostic Procedure with Diag-
nostic Trouble Code (DTC).>
PO117 Engine coolant temperature Sensor <Ref. to EN(D0HC TURBO)-126, DTC PO117 - ENGINE COOLANT TEM-
circuit low input PERATURE SENSOR CIRCUIT LOW INPUT -, Diagnostic Procedure with
Diagnostic Trouble Code (DTC).>
PO118 Engine coolant temperature sensor <Ref. to EN(D0HC TURBO)-128, DTC PO118 - ENGINE COOLANT TEM-
circuit high input PERATURE SENSOR CIRCUIT HIGH INPUT -, Diagnostic Procedure with
Diaqnostic Trouble Code (DTC).>
PO121 Throttle position sensor circuit range/ <Ref. to EN(D0HC TURBO)-132, DTC PO121 - THROTTLE P O S I T I O F
performance problem (high input) SENSOR CIRCUIT RANGE/PERFORMANCEPROBLEM (HIGH INPUT) -
, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
POI22 Throttle position sensor circuitlow <Ref. to EN(D0HC TURBO)-134, DTC PO122 -THROTTLE POSITION
input SENSOR CIRCUIT LOW INPUT -, Diagnostic Procedure with Diagnostic
Trouble Code (DTC).>

EN(D0HC TURBO)-80
 LIST OF DIAGNOSTIC TROUBLE CODE (DTC)
-
ENGINE (DIAGNOSTICS)

No.
DTC
PO123
I Item

Throttle position sensor circuit high

Index

<Ref. to EN(D0HC TURBO)-138, DTC PO123 - THROTTLE POSITION

input
PO125 Insufficient coolant temperature for
closed loop fuel control
PO128 Thermostat malfunction
PO131 Front oxygen (NF) sensor circuit
range/performance problem (low
SENSOR CIRCUIT HIGH INPUT -, Diagnostic Procedure with Diagnostic
Trouble Code (DTC).>
<Ref. to EN(D0HC TURBO)-140, DTC PO125 - INSUFFICIENT COOLANT
TEMPERATURE FOR CLOSED LOOP FUEL CONTROL -, Diagnostic
Procedure with Diaanostic Trouble Code ( D T C b
<Ref. to EN(D0HC TURBO)-142, DTC PO128 - THERMOSTAT MAL-
FUNCTION -, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(D0HC TURBO)-143, DTC PO131 - FRONT OXYGEN (NF)
SENSOR CIRCUIT RANGE/PERFORMANCEPROBLEM (LOW INPUT) -,

i
inDut) Diaanostic Procedure with Diaanostic Trouble Code (DTC).>
PO132 Front oxygen (NF) sensor circuit <Ref. to EN(D0HC TURBO)-144, DTC PO132 - FRONT OXYGEN (NF)
range/performance problem (high SENSOR CIRCUIT RANGE/PERFORMANCEPROBLEM (HIGH INPUT) -
input) , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
PO133 Front oxygen (NF) sensor circuit <Ref. to EN(D0HC TURBO)-146, DTC PO133 - FRONT OXYGEN (NF)
slow response SENSOR CIRCUIT SLOW RESPONSE -, Diagnostic Procedure with Diag-
nostic Trouble Code (DTC).>
PO136 Rear oxygen sensor circuit malfunc- <Ref. to EN(D0HC TURBO)-148, DTC PO136 - REAR OXYGEN SENSOR
tion CIRCUIT MALFUNCTION -, Diagnostic Procedure with Diagnostic Trouble
Code ( D T C b
Rear oxygen sensor circuit slow <Ref. to EN(D0HC TURBO)-150, DTC PO139 - REAR OXYGEN SENSOR
response CIRCUIT SLOW RESPONSE -, Diagnostic Procedure with Diagnostic
Trouble Code (DTC).>

+------
PO171 Fuel trim malfunction ( N F too lean) <Ref. to EN(D0HC TURBO)-152, DTC PO171 - FUEL TRIM MALFUNC-
TION (NF TOO LEAN) -, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
PO172 Fuel trim malfunction ( N F too rich) <Ref. to EN(D0HC TURBO)-153, DTC PO172 - FUEL TRIM MALFUNC-
TION (NF TOO RICH) -, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
PO181 Fuel temperature sensor A circuit <Ref. to EN(D0HC TURBO)-156, DTC PO181 - FUEL TEMPERATURE
range/performance problem SENSOR A CIRCUIT RANGE/PERFORMANCEPROBLEM -, Diagnostic
Procedure with Diagnostic Trouble Code (DTC).>
PO182 Fuel temperature sensor A circuit low <Ref. to EN(D0HC TURBO)-158, DTC PO182 - FUEL TEMPERATURE
input SENSOR A CIRCUIT LOW INPUT -, Diagnostic Procedure with Diagnostic
Trouble Code (DTC).>

I Fuel temperature sensor A circuit

high input
<Ref. to EN(D0HC TURBO)-160, DTC PO183 - FUEL TEMPERATURE
SENSOR A CIRCUIT HIGH INPUT -, Diagnostic Procedure with Diagnostic
Trouble Code (DTC).>
PO244 Wastegate control solenoid valve <Ref. to EN(D0HC TURBO)-164, DTC PO244 - WASTEGATE CONTROL
malfunction (high input) SOLENOID VALVE MALFUNCTION (HIGH INPUT) -, Diagnostic Proce-
dure with Diagnostic Trouble Code (DTC).>
PO245 Wastegate control solenoid valve cir- <Ref. to EN(D0HC TURBO)-166, DTC PO245 - WASTEGATE CONTROL
cuit low input SOLENOID VALVE CIRCUIT LOW INPUT -, Diagnostic Procedure with
Diagnostic Trouble Code (DTC).>
PO246 Wastegate control solenoid valve cir- <Ref. to EN(D0HC TURBO)-170, DTC PO246 - WASTEGATE CONTROL
cuit high input SOLENOID VALVE CIRCUIT HIGH INPUT -, Diagnostic Procedure with
Diaanostic Trouble Code ( D T C b
PO301 Cylinder 1 misfire detected <Ref. to EN(D0HC TURBO)-172, DTC PO301 - CYLINDER 1 MISFIRE
DETECTED -, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(D0HC TURBO)-172, DTC PO302 - CYLINDER 2 MISFIRE
DETECTED -. Diaanostic Procedure with Diaanostic Trouble Code (DTC).>
PO303 Cylinder 3 misfire detected <Ref.EEN(DOHC TGRBO)T72, DTC PO303 - CYLINDER 3 MISFIRE
DETECTED -, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
PO304 Cylinder 4 misfire detected <Ref. to EN(D0HC TURBO)-173, DTC PO304 - CYLINDER 4 MISFIRE
I
DETECTED -, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>

EN(D0HC TURBO)-81
 LIST OF DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

DTC
Item Index
No.
PO327 Knock sensor circuit low input <Ref. to EN(D0HC TURBO)-182, DTC PO327 - KNOCK SENSOR CIR-
CUIT LOW INPUT -, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
PO328 Knock sensor circuit high input <Ref. to EN(D0HC TURBO)-184, DTC PO328 - KNOCK SENSOR CIR-
CUIT HIGH INPUT -, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
PO335 Crankshaft position sensor circuit <Ref. to EN(D0HC TURBO)-186, DTC PO335 - CRANKSHAFT POSITION
malfunction SENSOR CIRCUIT MALFUNCTION-, Diagnostic Procedure with Diagnos
tic Trouble Code (DTC).>
PO336 Crankshaft position sensor circuit <Ref. to EN(D0HC TURBO)-188, DTC PO336 -Crankshaft Position Sensor
range/performance problem Circuit Range/Performance Problem -, Diagnostic Procedure with Diagnos
tic Trouble Code (DTC).>
PO340 Camshaft position sensor circuit mal- <Ref. to EN(D0HC TURBO)-190, DTC PO340 - CAMSHAFT POSITION
function SENSOR CIRCUIT MALFUNCTION-, Diagnostic Procedure with Diagnos.
tic Trouble Code (DTC).>
PO341 Camshaft position sensor circuit <Ref. to EN(D0HC TURBO)-192, DTC PO341 - CAMSHAFT POSITION
range/performance problem SENSOR CIRCUIT RANGE/PERFORMANCEPROBLEM -, Diagnostic
Procedure with Diagnostic Trouble Code (DTC).>
PO420 Catalyst system efficiency below <Ref. to EN(D0HC TURBO)-196, DTC PO420 - CATALYST SYSTEM
threshold EFFICIENCY BELOW THRESHOLD -, Diagnostic Procedure with Diag-
nostic Trouble Code (DTC).>
PO442 Evaporative emission control system <Ref. to EN(D0HC TURBO)-199, DTC PO442 - EVAPORATIVE EMIS-
malfunction SION CONTROL SYSTEM MALFUNCTION -, Diagnostic Procedure with
Diagnostic Trouble Code (DTC).>
PO444 Evaporative emission control system <Ref. to EN(D0HC TURBO)-204, DTC PO444 - EVAPORATIVE EMIS-
purge control valve circuit low input SION CONTROL SYSTEM PURGE CONTROL VALVE CIRCUIT LOW
~____
INPUT -, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
PO445 Evaporative emission control system <Ref. to EN(D0HC TURBO)-208, DTC PO445 - EVAPORATIVE EMIS-
purge control valve circuit high input SION CONTROL SYSTEM PURGE CONTROL VALVE CIRCUIT HIGH
INPUT -, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
PO447 Evaporative emission control system <Ref. to EN(D0HC TURBO)-210, DTC PO447 - EVAPORATIVE EMIS-
vent control low input SION CONTROL SYSTEM VENT CONTROL LOW INPUT -, Diagnostic
Procedure with Diagnostic Trouble Code (DTC).>
PO448 Evaporative emission control system <Ref. to EN(D0HC TURBO)-214, DTC PO448 - EVAPORATIVE EMIS-
vent control high input SION CONTROL SYSTEM VENT CONTROL HIGH INPUT -, Diagnostic
Procedure with Diagnostic Trouble Code (DTC).>
PO451 Evaporative emission control system <Ref. to EN(D0HC TURBO)-216, DTC PO451 - EVAPORATIVE EMIS-
pressure sensor range/performance SION CONTROL SYSTEM PRESSURE SENSOR RANGE/PERFOR-
problem MANCE PROBLEM -, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
PO452 Evaporative emission control system <Ref. to EN(D0HC TURBO)-218, DTC PO452 - EVAPORATIVE EMIS-
pressure sensor low input SION CONTROL SYSTEM PRESSURE SENSOR LOW INPUT -, Diagnos-
tic Procedure with Diagnostic Trouble Code (DTC).>
'0453 Evaporative emission control system <Ref. to EN(D0HC TURBO)-222, DTC PO453 - EVAPORATIVE EMIS-
pressure sensor high input SION CONTROL SYSTEM PRESSURE SENSOR HIGH INPUT -, Diag-
nostic Procedure with Diagnostic Trouble Code (DTC).>
'0461 Fuel level sensor circuit range/perfor- <Ref. to EN(D0HC TURBO)-225, DTC PO461 - FUEL LEVEL SENSOR
mance problem CIRCUIT RANGE/PERFORMANCE PROBLEM -, Diagnostic Procedure
with Diagnostic Trouble Code (DTC).>
'0462 . Fuel level sensor circuit low input <Ref. to EN(D0HC TURBO)-228, DTC PO462 - FUEL LEVEL SENSOR
CIRCUIT LOW INPUT -, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
'0463 Fuel level sensor circuit high input <Ref. to EN(D0HC TURBO)-232, DTC PO463 - FUEL LEVEL SENSOR
CIRCUIT HIGH INPUT -, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>

EN(D0HC TURBO)-82
 LIST OF DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

DTC
Item Index
No.
PO464 Fuel level sensor intermittent input <Ref. to EN(D0HC TURBO)-236, DTC PO464 - FUEL LEVEL SENSOR
INTERMITTENT INPUT-, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
PO480 Cooling fan relay 1 circuit low input <Ref. to EN(D0HC TURBO)-239, DTC PO480 - COOLING FAN RELAY 1
CIRCUIT LOW INPUT -, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
PO483 Cooling fan function problem <Ref. to EN(D0HC TURBO)-243, DTC PO483 - COOLING FAN FUNC-
TlON PROBLEM -, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
PO500 Vehicle speed sensor malfunction <Ref. to EN(D0HC TURBO)-246, DTC PO500 -VEHICLE SPEED SEN-
SOR MALFUNCTION-, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
PO506 Idle control system RPM lower than <Ref. to EN(D0HC TURBO)-248, DTC PO506 - IDLE CONTROL SYSTEM
expected RPM LOWER THAN EXPECTED -, Diagnostic Procedure with Diagnostic
Trouble Code (DTC).>
PO507 Idle control system RPM higher than <Ref. to EN(D0HC TURBO)-250, DTC PO507 - IDLE CONTROL SYSTEM
expected RPM HIGHER THAN EXPECTED -, Diagnostic Procedure with Diagnostic
Trouble Code (DTC).>
PO508 Idle control system circuit low input <Ref. to EN(D0HC TURBO)-252, DTC PO508 - IDLE CONTROL SYSTEM
CIRCUIT LOW INPUT -, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
PO509 Idle control system circuit high input <Ref. to EN(D0HC TURBO)-254, DTC PO509 - IDLE CONTROL SYSTEM
CIRCUIT HIGH INPUT -, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
PO512 Starter switch circuit high input <Ref. to EN(D0HC TURBO)-257, DTC PO512 - STARTER SWITCH CIR-
CUlT HIGH INPUT -, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
PO545 Exhaust gas temperature sensor cir- <Ref. to EN(D0HC TURBO)-260, DTC PO545 - EXHAUST GAS TEMPER-
cuit low input ATURE SENSOR CIRCUIT LOW INPUT -, Diagnostic Procedure with
Diagnostic Trouble Code (DTC).>
PO546 Exhaust gas temperature sensor cir- <Ref. to EN(D0HC TURBO)-262, DTC PO546 - EXHAUST GAS TEMPER-
cuit high input ATURE SENSOR CIRCUIT HIGH INPUT -, Diagnostic Procedure with
Diagnostic Trouble Code (DTC).>
PO604 Internal control module memory <Ref. to EN(D0HC TURBO)-266, DTC PO604 - INTERNAL CONTROL
check sum error MODULE MEMORY CHECK SUM ERROR -, Diagnostic Procedure with
Diagnostic Trouble Code (DTC).>
PO703 Brake switch input malfunction <Ref. to EN(D0HC TURBO)-268, DTC PO703 - BRAKE SWITCH INPUT
MALFUNCTION-, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
PO705 Transmission range sensor circuit <Ref. to AT-115, CHECK INHIBITOR SWITCH., Diagnostic Procedure for
malfunction No-Diagnostic Trouble Code (DTC).>
PO710 Transmissionfluid temperature sen- <Ref. to AT-48, DTC 27 ATF TEMPERATURE SENSOR, Diagnostic Proce-
sor circuit malfunction dure with Diagnostic Trouble Code (DTC).>
PO715 Torque converter turbine speed sen- <Ref. to AT-62, DTC 36 TORQUE CONVERTER TURBINE SPEED SEN-
sor circuit malfunction SOR, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
PO720 Output speed sensor (vehicle speed <Ref. to AT-57, DTC 33 FRONT VEHICLE SPEED SENSOR, Diagnostic Pro-
sensor 2) circuit malfunction cedure with Diagnostic Trouble Code (DTC).>
PO725 Engine speed input circuit malfunc- <Ref. to AT-44, DTC 11 ENGINE SPEED SIGNAL, Diagnostic Procedure
tion with Diagnostic Trouble Code (DTC).>
PO731 -. Gear 1 incorrect ratio <Ref. to EN(D0HC TURBO)-270, DTC PO731 - GEAR 1 INCORRECT
RATIO -, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
PO732 Gear 2 incorrect ratio <Ref. to EN(D0HC TURBO)-270, DTC PO732 -GEAR 2 INCORRECT
RATIO -, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
PO733 Gear 3 incorrect ratio <Ref. to EN(D0HC TURBO)-270, DTC PO733 - GEAR 3 INCORRECT
RATIO -, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>

EN(D0HC TURBO)-83
 LIST OF DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

DTC
Item Index
No.
PO734 Gear 4 incorrect ratio <Ref. to EN(D0HC TURBO)-270, DTC PO734 - GEAR 4 INCORRECT
RATIO -, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
PO741 Torque converter clutch system mal- <Ref. to EN(D0HC TURBO)-272, DTC PO741 -TORQUE CONVERTER
function CLUTCH SYSTEM MALFUNCTION-, Diagnostic Procedure with Diagnos-
tic Trouble Code (DTC).>
PO743 Torque converter clutch system <Ref. to AT-94, DTC 77 LOCK-UP DUTY SOLENOID, Diagnostic Procedure
(Lock-up duty solenoid) electrical with Diagnostic Trouble Code (DTC).>
PO748 Pressure control solenoid (Line pres- <Ref. to AT-86, DTC 75 LINE PRESSURE DUTY SOLENOID, Diagnostic
sure duty solenoid) electrical Procedure with Diaanostic Trouble Code [ D T C b
PO753 Shift solenoid A (Shift solenoid 1) <Ref. to AT-70, DTC 71 SHIFT SOLENOID 1, Diagnostic Procedure with
electrical Diagnostic Trouble Code (DTC).>
PO758 Shift solenoid B (Shift solenoid 2) <Ref. to AT-74, DTC 72 SHIFT SOLENOID 2, Diagnostic Procedure with
electrical Diagnostic Trouble Code (DTC).>
PO778 2-4 brake pressure control solenoid <Ref. to AT-90, DTC 76 2-4 BRAKE DUTY SOLENOID, Diagnostic Proce-
valve (2-4 brake duty solenoid) circuit dure with Diagnostic Trouble Code (DTC).>
malfunction
PO785 2-4 brake timing control solenoid <Ref. to AT-82, DTC 74 2-4 BRAKE TIMING SOLENOID, Diagnostic Proce-
valve (2-4 brake timing solenoid) cir- dure with Diagnostic Trouble Code (DTC).>
cuit malfunction
P i 086 Tumble generator valve #2 (LH) posi- <Ref. to EN(D0HC TURBO)-274, DTC Pi086 -TUMBLE GENERATOR
tion sensor circuit low input VALVE #2 (LH) POSITION SENSOR CIRCUIT LOW INPUT -, Diagnostic
Procedure with Diagnostic Trouble Code (DTC).>
P1087 Tumble generator valve #2 (LH) posi- <Ref. to EN(D0HC TURBO)-278, DTC Pi087 -TUMBLE GENERATOR
tion sensor circuit high input VALVE #2 (LH) POSITION SENSOR CIRCUIT HIGH INPUT -, Diagnostic
Procedure with Diagnostic Trouble Code (DTC).>
P i 088 Tumble generator valve #I (RH) posi- <Ref. to EN(D0HC TURBO)-280, DTC P1088 - TUMBLE GENERATOR
tion sensor circuit low input VALVE #I (RH) POSITION SENSOR CIRCUIT LOW INPUT -, Diagnostic
Procedure with Diagnostic Trouble Code (DTC).>
P i 089 Tumble generator valve #I (RH) posi- <Ref. to EN(D0HC TURBO)-284, DTC P i 089 - TUMBLE GENERATOR
tion sensor circuit high input VALVE #I (RH) POSITION SENSOR CIRCUIT HIGH INPUT -, Diagnostic
Procedure with Diagnostic Trouble Code (DTC).>
P i 090 Tumble generator valve #I (RH) mal- <Ref. to EN(D0HC TURBO)-286, DTC Pi090 -TUMBLE GENERATOR
function (stuck open) VALVE SYSTEM #I (RH) MALFUNCTION (STUCK OPEN) -, Diagnostic
Procedure with Diagnostic Trouble Code (DTC).>
Pi091 Tumble generator valve #I (RH) mal- <Ref. to EN(D0HC TURBO)-287, DTC Pi091 -TUMBLE GENERATOR
function (stuck close) VALVE SYSTEM #I (RH) MALFUNCTION (STUCK CLOSE) -, Diagnostic
Procedure with Diagnostic Trouble Code (DTC).>
P i 092 Tumble generator valve #2(LH) mal- <Ref. to EN(D0HC TURBO)-288, DTC Pi092 - TUMBLE GENERATOR
function (stuck open) VALVE SYSTEM #2 (LH) MALFUNCTION (STUCK OPEN) -, Diagnostic
Procedure with Diagnostic Trouble Code (DTC).>
P1093 Tumble generator valve #2(LH) mal- <Ref. to EN(D0HC TURBO)-289, DTC Pi093 - TUMBLE GENERATOR
function (stuck close) VALVE SYSTEM #2 (LH) MALFUNCTION (STUCK CLOSE) -, Diagnostic
Procedure with Diagnostic Trouble Code (DTC).>
Pi094 Tumble generator valve circuit #I <Ref. to EN(D0HC TURBO)-290, DTC Pi094 - TUMBLE GENERATOR
(opencircuit) VALVE CIRCUIT #1 (OPEN CIRCUIT) -, Diagnostic Procedure with Diag-
nostic Trouble Code (DTC).>
P i 095 Tumble generator valve circuit #I <Ref. to EN(D0HC TURBO)-292, DTC Pi095 - TUMBLE GENERATOR
(overcurrent) VALVE CIRCUIT #I (OVERCURRENT) -, Diagnostic Procedure with Diag-
nostic Trouble Code (DTC).>
Pi096 . Tumble generator valve circuit #2 <Ref. to EN(D0HC TURBO)-294, DTC P1096 - TUMBLE GENERATOR
(opencircuit) VALVE CIRCUIT #2 (OPEN CIRCUIT) -, Diagnostic Procedure with Diag-
nostic Trouble Code (DTC).>
P i 097 Tumble generator valve circuit #2 <Ref. to EN(D0HC TURBO)-296, DTC Pi097 -TUMBLE GENERATOR
(overcurrent) VALVE CIRCUIT #2 (OVERCURRENT) -, Diagnostic Procedure with Diag-
nostic Trouble Code (DTC).>

EN(D0HC TURBO)-84
 LIST OF DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

DTC
Item Index
No.
P1110 Atmospheric pressure sensor low <Ref. to EN(D0HC TURBO)-297, DTC P1110 -ATMOSPHERIC PRES-
input SURE SENSOR CIRCUIT LOW INPUT -, Diagnostic Procedure with Diag-
nostic Trouble Code (DTC).>
P1111 Atmospheric pressure sensor high <Ref. to EN(D0HC TURBO)-297, DTC P l l l l -ATMOSPHERIC PRES-
input SURE SENSOR CIRCUIT HIGH INPUT -, Diagnostic Procedure with Diag-
nostic Trouble Code (DTC).>
P1112 Atmospheric pressure sensor range/ <Ref. to EN(D0HC TURBO)-298, DTC P1112 - ATMOSPHERIC PRES-
performance problem SURE SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM -, Diag-
nostic Procedure with Diagnostic Trouble Code (DTC).>
P1130 Front oxygen sensor circuit malfunc- <Ref. to EN(D0HC TURBO)-300, DTC P1130 - FRONT OXYGEN (NF)
tion (open circuit) SENSOR CIRCUIT MALFUNCTION (OPEN CIRCUIT) -, Diagnostic Proce-
dure with Diagnostic Trouble Code (DTC).>
P1131 Front oxygen sensor circuit malfunc- <Ref. to EN(D0HC TURBO)-302, DTC P1131 - FRONT OXYGEN (NF)
tion (short circuit) SENSOR CIRCUIT MALFUNCTION (SHORT CIRCUIT) -, Diagnostic Pro-
cedure with Diagnostic Trouble Code (DTC).>
P1134 Front oxygen (A/F) sensor micro- <Ref. to EN(D0HC TURBO)-304, DTC P1134 - FRONT OXYGEN (A/F)
computer problem SENSOR MICRO-COMPUTER PROBLEM -, Diagnostic Procedure with
Diagnostic Trouble Code (DTC).>
P1139 Front oxygen (A/F) sensor #1 heater <Ref. to EN(D0HC TURBO)-306, DTC P1139 - FRONT OXYGEN (A/F)
circuit perfomancehange problem SENSOR #1 HEATER CIRCUIT RANGE/PERFORMANCE PROBLEM -,
Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P1141 Mass air flow sensor circuit range/ <Ref. to EN(D0HC TURBO)-308, DTC P1141 - MASS AIR FLOW SEN-
perfomance problem (low input) SOR CIRCUIT RANGE/PERFORMANCEPROBLEM (LOW INPUT) -,
Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P1142 Throttle position sensor circuit range/ <Ref. to EN(D0HC TURBO)-310, DTC P1142 -THROTTLE POSITION
performance problem (low input) SENSOR CIRCUIT RANGWPERFORMANCEPROBLEM (LOW INPUT) -,
Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P1146 Pressure sensor circuit range/perfor- <Ref. to EN(D0HC TURBO)-312, DTC P1146 - PRESSURE SENSOR
mance problem (high input) CIRCUIT RANGE/PERFORMANCEPROBLEM (HIGH INPUT) -, Diagnos-
tic Procedure with Diagnostic Trouble Code (DTC).>
P1230 Fuel pump control unit maifunction <Ref. to EN(D0HC TURBO)-314, DTC P1230 - FUEL PUMP CONTROL-
LER MALFUNCTION -, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P1244 Wastegate control solenoid valve <Ref. to EN(D0HC TURBO)-318, DTC P1244 - WASTEGATE CONTROL
malfunction (low input) SOLENOID VALVE RANGWPERFORMANCEPROBLEM (LOW INPUT) -,
Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P1245 Wastegate control solenoid valve <Ref. to EN(D0HC TURBO)-320, DTC P1245 - WASTEGATE CONTROL
malfunction (fail-safe) SOLENOID VALVE MALFUNCTION (FAIL-SAFE) -, Diagnostic Procedure
with Diagnostic Trouble Code (DTC).>
P1301 Fire due to increased exhaust tem- <Ref. to EN(D0HC TURBO)-322, DTC P1301 - FIRE DUE TO
perature INCREASED EXHAUST TEMPERATURE -, Diagnostic Procedure with
Diagnostic Trouble Code (DTC).>
P1312 Exhaust temperature sensor mal- <Ref. to EN(D0HC TURBO)-324, DTC P1312 - EXHAUST GAS TEMPER-
function ATURE CIRCUIT MALFUNCTION-, Diagnostic Procedure with Diagnostic
Trouble Code ( D T C b
P1400 Fuel tank pressure control solenoid <Ref. to EN(D0HC TURBO)-326, DTC P1400 - FUEL TANK PRESSURE
valve circuit low input CONTROL SOLENOID VALVE CIRCUIT LOW INPUT -, Diagnostic Proce-
dure with Diagnostic Trouble Code (DTC).>
P1420 Fuel tank pressure control solenoid <Ref. to EN(D0HC TURBO)-330, DTC P1420 - FUEL TANK PRESSURE
valve circuit high input CONTROL SOLENOID VALVE CIRCUIT HIGH INPUT -, Diagnostic Proce-
dure with Diagnostic Trouble Code (DTC).>
P1443 Evaporative emission control system <Ref. to EN(D0HC TURBO)-332, DTC P1443 - EVAPORATIVE EMIS-
vent control function problem SION CONTROL SYSTEM VENT CONTROL FUNCTION PROBLEM -,
Diaanostic Procedure with Diaanostic Trouble Code ( D T C b
P1480 Cooling fan relay 1 circuit high input <Ref. to EN(D0HC TURBO)-335, DTC P1480 - COOLING FAN RELAY 1
CIRCUIT HIGH INPUT -, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>

EN(D0HC TURBO)-85
 LIST OF DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE f DIAGNOSTICS)

DTC
Item Index
No.
P I 507 Idle control system malfunction (fail- <Ref. to EN(D0HC TURBO)-338, DTC P1507 - IDLE CONTROL SYSTEM
safe) MALFUNCTION (FAIL-SAFE) -, Diagnostic Procedure with Diagnostic
Trouble Code (DTC).>
PI518 Starter switch circuit low input <Ref. to EN(D0HC TURBO)-341, DTC PI518 - STARTER SWITCH CIR-
CUlT LOW INPUT -, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
PI544 High exhaust temperature detected <Ref. to EN(D0HC TURBO)-344, DTC PI544 - HIGH EXHAUST TEM-
PERATURE DETECTED -, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
PI560 Back-up voltage circuit malfunction <Ref. to EN(D0HC TURBO)-347, DTC PI560 - Back-up Voltage Circuit
~
Malfunction-.>
P I 590 Neutral position switch circuit high <Ref. to EN(D0HC TURBO)-350, DTC PI590 - NEUTRAL POSITION
input SWITCH CIRCUIT HIGH INPUT -, Diagnostic Procedure with Diagnostic
Trouble Code (DTC).>
PI591 Neutral position switch circuit low <Ref. to EN(D0HC TURBO)-354, DTC PI591 - NEUTRAL POSITION
input SWITCH CIRCUIT LOW INPUT -, Diagnostic Procedure with Diagnostic
Trouble Code (DTC).>
P I 594 Automatic transmission diagnosis <Ref. to EN(D0HC TURBO)-356, DTC P1594 - AUTOMATIC TRANSMIS-
input signal circuit malfunction SION DIAGNOSIS INPUT SIGNAL CIRCUIT MALFUNCTION-, Diagnostic
Procedure with Diaanostic Trouble Code ( D T C b
PI595 Automatic transmission diagnosis <Ref. to EN(D0HC TURBO)-358, DTC PI595 - AUTOMATIC TRANSMIS-
input signal circuit low input SION DIAGNOSIS INPUT SIGNAL CIRCUIT LOW INPUT -, Diagnostic
Procedure with Diagnostic Trouble Code (DTC).>
P I 596 Automatic transmission diagnosis <Ref. to EN(D0HC TURBO)-360, DTC P1596 - AUTOMATIC TRANSMIS-
input signal circuit high input SION DIAGNOSIS INPUT SIGNAL CIRCUIT HIGH INPUT -, Diagnostic
Procedure with Diagnostic Trouble Code (DTC).>
P I 698 Engine torque control cut signal cir- <Ref. to EN(D0HC TURBO)-362, DTC P1698 - ENGINE TORQUE CON-
cuit low input TROL CUT SIGNAL CIRCUIT LOW INPUT -, Diagnostic Procedure with
Diaanostic Trouble Code ( D T C b
PI699 Engine torque control cut signal cir- <Ref. to EN(D0HC TURBO)-364, DTC P1699 - ENGINE TORQUE CON-
cuit high input TROL CUT SIGNAL CIRCUIT HIGH INPUT -, Diagnostic Procedure with
Diagnostic Trouble Code (DTC).>
PI700 Throttle position sensor circuit mal- <Ref. to AT-52, DTC 31 THROTTLE POSITION SENSOR, Diagnostic Proce-
function for automatic transmission dure with Diagnostic Trouble Code (DTC).>
P I 701 Cruise control set signal circuit mal- <Ref. to EN(D0HC TURBO)-366, DTC P1701 - CRUISE CONTROL SET
function for automatic transmission SIGNAL CIRCUIT MALFUNCTION FOR AUTOMATIC TRANSMISSION -,
Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
PI703 Low clutch timing control solenoid <Ref. to AT-78, DTC 73 LOW CLUTCH TIMING SOLENOID, Diagnostic Pro-
valve circuit malfunction cedure with Diagnostic Trouble Code (DTC).>
PI711 Engine torque control signal 1 circuit <Ref. to EN(D0HC TURBO)-368, DTC P1711 - ENGINE TORQUE CON-
malfunction TROL SIGNAL 1 CIRCUIT MALFUNCTION-, Diagnostic Procedure with
Diagnostic Trouble Code (DTC).>
P1712 Engine torque control signal 2 circuit <Ref. to EN(D0HC TURBO)-370, DTC P1712 - ENGINE TORQUE CON-
malfunction TROL SIGNAL 2 CIRCUIT MALFUNCTION-, Diagnostic Procedure with
Diagnostic Trouble Code (DTC).>

EN(D0HC TURBO)-86
LIST OF DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

EN(D0HC TURBO)-87
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

18.Diagnostic Procedure with Diagnostic Trouble Code (DTC)

A: DTC PO031 - FRONT OXYGEN (NF) SENSOR HEATER CIRCUIT LOW IN-
PUT -
DTC DETECTING CONDITION:
Immediately at fault recognition
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

MAIN RELAY BATTERY

SBF-5

nFRONTOXYGEN

EN1143

EN(D0HC TURBO)-88
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK ANY OTHER DTC ON DISPLAY. )oes the Subaru Select Moni- i o to step 2. Go to step 5.
3r or OBD-II general scan tool
idicate DTC PO031 and
’0037 at the same time?
CHECK POWER SUPPLY TO FRONT OXY- s the voltage more than 10 V? i o to step 3. Repair power sup-
GEN (NF)SENSOR. ply line.
1)Turn the ignition switch to OFF. NOTE:
2)Disconnect the connector from front oxygen In this case, repaii
(NF)sensor. the following:
3)Turn the ignition switch to ON. * Open circuit in
4)Measure the voltage between front oxygen harness between
(NF)sensor connector and engine ground. main relay and
Connector & terminal front oxygen (NF)
(818) No. 2 (+) - Engine ground (-): sensor connector
* Poor contact in
front oxygen (NF)
sensor connector
Poor contact in
main relay connec.
tor
CHECK GROUND CIRCUIT OF ECM. s the resistance less than 5 o
; to step 4. Repair harness
Measure the resistance of harness between 2? and connector.
ECM connector and chassis ground. NOTE:
Connector & terminal In this case, repaii
(8137) No. 8 - Chassis ground: the following:
(8137) No. 9 - Chassis ground: Open circuit in
harness between
ECM and engine
ground terminal
9 Poor contact in
ECM connector
Poor contact in
coupling connectoi
CHECK CURRENT DATA. s the value more than 0.2 A? 3epair poor con- Go to step 5.
1)Start the engine. act in connector.
2)Read the data of front oxygen (NF)sensor JOTE:
heater current using Subaru Select Monitor or n this case, repaii
OBD-ll general scan tool. he following:
NOTE: I Poor contact in
*Subaru Select Monitor ront oxygen (NF)
For detailed operation procedure, refer to the jensor connector
“READ CURRENT DATA FOR ENGINE. <Ref. 1 Poor contact in
to EN(D0HC TURBO)-38, Subaru Select Mon ECM connector
itor.>
*OBD-II scan tool
For detailed operation procedures, refer to the
OBD-II General Scan Tool Instruction Manual.
CHECK OUTPUT SIGNAL FROM ECM. s the voltage less than 1.O V? 30 to step 7. Go to step 6.
1)Start and idle the engine.
2)Measure the voltage between ECM connec-
tor and chassis ground.
Connector & terminal
. (8137) No. 4 (+) - Chassis ground (-):
(8137) No. 5 (+) - Chassis ground (-):
CHECK OUTPUT SIGNAL FROM ECM. Ioes the voltage change less 3epair poor con- Go to step 7 .
Measure the voltage between ECM connector han 1.O V by shaking harness act in ECM con-
and chassis ground. md connector of ECM while lector.
Connector & terminal nonitoring the value with volt-
(8137) No. 4 (+) - Chassis groundI)-( ige meter?
(8137) No. 5 (+) - Chassis groundI)-(

EN(D0HC TURBO)-89
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

r
CHECK FRONT OXYGEN (NF) SENSOR. Is the resistance less than 10 Repair harness Replace the front
1)Turn the ignition switch to OFF. R? and connector. oxygen (NF)sen-
2)Measure the resistance between front oxy- NOTE: sor. <Ref. to
gen (NF) sensor connector terminals. In this case, repair FU(D0HC
Terminals the following: TURBO)-42, Front
NO. 2 -NO. 1: Open or ground Oxygen (NF) Sen-
short circuit in har- sor.>
ness between front
oxygen (NF)sen-
sor and ECM con-
nector
Poor contact in
front oxygen (NF)
sensor connector
Poor contact in
ECM connector

EN(D0HC TURBO)-QO
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENG INE (DIAG NOSTlCS)

EN(D0HC TURBO)-91
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

B: DTC PO032 - FRONT OXYGEN (NF) SENSOR HEATER CIRCUIT HIGH IN-
PUT -
DTC DETECTING CONDITION:
Immediately at fault recognition
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

MAIN RELAY BATTERY

I
SBF-5

k!
FRONT OXYGEN

EN1143

EN(D0HC TURBO)-92
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK OUTPUT SIGNAL FROM ECM. s the voltage more than 8 V? Go to step 3. i o to step 2.
1)Turnthe ignition switch to ON.
2)Measure the voltage between ECM connec-
tor and chassis ground.
Connector & terminal
(8137) No. 4 (+) - Chassis groundI)-(
(8137) No. 5 (+) - Chassis ground (-):
CHECK FRONT OXYGEN ( N F ) SENSOR s the value more than 2.3 A? Replace the ECM. END
HEATER CURRENT. <Ref. to FU(D0HC
1)Turn the ignition switch to OFF. TURBO)-47,
2)Repair the battery short circuit in harness Engine Control
between ECM and front oxygen (NF) sensor Module.>
connector.
3)Turn the ignition switch to ON.
4)Read the data of front oxygen (NF) sensor
heater current using Subaru Select Monitor or
the OBD-ll general scan tool.
NOTE:
*Subaru Select Monitor
For detailed operation procedure, refer to the
“READ CURRENT DATA FOR ENGINE. <Ref.
tq EN(D0HC TURBO)-38, Subaru Select Mon-
itor.>
*OED41 general scan tool
For detailed operation procedure, refer to the
OBD-ll General Scan Tool Instruction Manual.
CHECK OUTPUT SIGNAL FROM ECM. END
Measure the voltage between ECM connector
and chassis ground.
Connector & terminal
(8137) No. 4 (+) - Chassis ground (-): ige meter? oxygen (NF)sen-
(8137) No. 5 (+) - Chassis ground (-): sor connector.

EN(DOHC TU RB0)-93
c
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

C: DTC PO037 - REAR OXYGEN SENSOR HEATER CIRCUIT MALFUNCTION

DTC DETECTING CONDITION:

Two consecutive driving cycles with fault
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

MAIN RELAY
- BATTERY

EN1144

EN(D0HC TURBO)-94
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK GROUND CIRCUIT OF ECM. s the resistance less than 5 20 to step 2. Repair harness
1)Turnthe ignition switch to OFF. 2? and connector.
2)Disconnectthe connector from ECM. NOTE:
3)Measure the resistance of harness between In this case, repair
ECM connector and chassis ground. the following:
Connector & terminal Open circuit in
(8137) No. 8 - Chassis ground: harness between
(8137) No. 9 - Chassis ground: ECM and engine
ground terminal
Poor contact in
ECM connector
Poor contact in
coupling connector
! CHECK CURRENT DATA. s the value more than 0.2 A? 3epair the con- Go to step 3.
1)Start the engine.
2)Read the data of rear oxygen sensor heater
current using Subaru Select Monitor or OBD-ll
general scan tool.
NOTE:
*Subaru Select Monitor
For detailed operation procedure, refer to the
“QEAD CURRENT DATA FOR ENGINE”. <Ref.
to EN(D0HC TURBO)-38, Subaru Select Mon-
itor.>
*OBD-I1 scan tool
For detailed operation procedures, refer to the
OBD-ll General Scan Tool Instruction Manual.
I CHECK OUTPUT SIGNAL FROM ECM. Go to step 4.
1)Start and idle the engine.
2)Measure the voltage between ECM connec-
tor and chassis ground.
Connector & terminal
(8136) No. 13 (+) - Chassis groundI)-(
I CHECK OUTPUT SIGNAL FROM ECM. loes the voltage change less Repair poor con- Go to step 5.
Measure the voltage between ECM connector han 1 .O V by shaking harness tact in ECM con-
and chassis ground. ind connector of ECM while nector.
Connector & terminal nonitoring the value with volt-
(8136) No. 13 (+) - Chassis ground (-): ige meter?
1 CHECK OUTPUT SIGNAL FROM ECM. s the voltage less than 1.O V? Replace the ECM. Repair battery
1)Disconnectthe connector from rear oxygen <Ref. to FU(D0HC short circuit in har-
sensor. TURBO)-47, ness between
2)Measure the voltage between ECM connec- Engine Control ECM and rear oxy-
tor and chassis ground. Module.> gen sensor con-
Connector & terminal nector. After
( 8 136) No. 13 (+) - Chassis ground (-): repair, replace the
ECM. <Ref. to
FU(D0HC
TURBO)-47,
Engine Control
Module.>

EN(D0HC TURBO)-95
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK POWER SUPPLY TO REAR OXY- ;the voltage more than 10 V? 30 to step 7 . 3epair power sup-
GEN SENSOR. )ly line.
1)Turnthe ignition switch to OFF. IIOTE:
2)Disconnect the connector from rear oxygen n this case, repair
sensor. he following:
3)Turn the ignition switch to ON. Open circuit in
4)Measure the voltage between rear oxygen iarness between
sensor connector and engine ground or chas- nain relay and
sis ground. ear oxygen sen-
Connector & terminal ior connector
(B19) No. 2 (+) - Chassis groundI)-( Poor contact in
ear oxygen sen-
;or connector
Poor contact in
:oupling connectoi
CHECK REAR OXYGEN SENSOR. s the resistance less than 30 Repair harness 3eplace the rear
1)Turnthe ignition switch to OFF. 2? and connector. Ixygen sensor.
2)Measure the resistance between rear oxy- NOTE: :Ref. to FU(D0HC
gen sensor connector terminals. In this case, repair rURBO)-44, Rear
Terminals the following: lxygen Sensor.>
NO. 1 -NO. 2: Open circuit in
harness between
rear oxygen sen-
sor and ECM con-
nector
Poor contact in
rear oxygen sen-
sor connector
Poor contact in
ECM connector
Poor contact in
coupling connectoi

EN(D0HC TURBO)-96
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

EN(DOHC TURBO)-97
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE lDl AG NOSTICS)

D: DTC PO038 - REAR OXYGEN SENSOR HEATER CIRCUIT HIGH INPUT -

DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

MAIN RELAY BATTERY

REAR
1
OXYGEN SENSOR

EN1144

Step Check
1 . CHECK INPUT SIGNAL FOR ECM. Is the voltage more than 8 V?
Measure the voltage between ECM connector
and chassis ground.
Connector & terminal
(8136) No. 13 (+) - Chassis ground (-):

EN(D0HC TURBO)-98
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

! CHECK CURRENT DATA. Is the value more than 7 A? Replacethe ECM. !ND
1)Turn the ignition switch to OFF. <Ref.to FU(D0HC
2)Repair the battery short circuit in harness TURBO)-47,
between ECM and rear oxygen sensor connec- Engine Control
tor. Module.>
3)Turn the ignition switch to ON.
4)Read the data of rear oxygen sensor heater
current using Subaru Select Monitor or the
OBD-II general scan tool.
NOTE:
*Subaru Select Monitor
For detailed operation procedure, refer to the
“READ CURRENT DATA FOR ENGINE. <Ref.
to EN(D0HC TURBO)-38, Subaru Select Mon-
itor.>
*OBD-II general scan tool
For detailed operation procedure, refer to the
OBD-ll General Scan Tool Instruction Manual.
5 CHECK POOR CONTACT. Is there poor contact in ECM Repair poor con- END
Check poor contact in ECM connector. connector? tact in ECM con-
nector.
I

EN(D0HC TURBO)-99
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

E: DTC PO101 - MASS AIR FLOW SENSOR CIRCUIT RANGE/PERFORMANCE

PROBLEM (HIGH INPUT) -
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
Poor driving performance
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

BATTERY
SBF-5
3 c

1 MASS AIR FLOW AND

INTAKE A I Z E R A T U R E 1

ECM

EN1 145

EN(D0HC TURBO)-I00
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGI NE (DIAGNOSTICS)

Step Check Yes No

1 CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Moni- Inspect DTC Replace the mass
tor or OBD-II general scan tool PO102 or PO103 air flow and intake
indicate DTC PO102 or PO103? using “Diagnos- air temprature sen,
tics Chart with sor. <Ref. to
Trouble Code”. FU(D0HC
NOTE: TURBO)-34, Mass
In this case, it is Air Flow and
not necessary to intake Air Temper-
inspect DTC ature Sensor.>
PO101.

EN(D0HC TURBO)-101
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

F: DTC PO102 - MASS AIR FLOW SENSOR CIRCUIT LOW INPUT -

DTC DETECTING CONDITION:
Immediately at fault recognition
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
Poor driving performanc
WIRING DIAGRAM:

MASS AIR FLOW AND

INTAKE AIR TEMPERATURE

EN(D0HC TURBO)-I02
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CONNECT SUBARU SELECT MONITOR OR 3 the value equal to or more Even if MIL lights ;o to step 2.
THE OBD-ll GENERAL SCAN TOOL, AND han 1.3 g/sec (0.172 Ib/min)or up, the circuit has
READ DATA. 1.3V and equal to or less than returned to a nor-
1)Turn the ignition switch to OFF. 140 g/sec (32 Ib/min) or 4.58 mal condition at
2)Connect the Subaru Select Monitor or the I? this time. A tempo-
OBD-ll general scan tool to data link connec- rary poor contact
tor. of the connector or
3)Turn the ignition switch to ON and Subaru harness may be
Select Monitor or the OBD-ll general scan tool the cause. Repair
switch to ON. harness or con-
4)Start the engine. nector in the mass
5)Read the data of mass air flow sensor signal air flow sensor.
using Subaru Select Monitor or OBD-II general NOTE:
scan tool. In this case, repaii
NOTE: the following:
*Subaru Select Monitor Open or ground
For detailed operation procedure, refer to the short circuit in har-
“READ CURRENT DATA FOR ENGINE. <Ref. ness between
to EN(D0HC TURBO)-38, Subaru Select Mon mass air flow sen-
itor.> sor and ECM con-
*OBD-ll general scan tool nector
For detailed operation procedures, refer to the w Poor contact in

O b - l I General Scan Tool Instruction Manual. mass air flow sen-

sor or ECM con-
nector
CHECK INPUT SIGNAL FOR ECM. s the voltage less than 0.2 V? Go to step 4. 30 to step 3.
Measure the voltage between ECM connector
and chassis ground while engine is idling.
Connector & terminal
(B84) No. 13 (+) - Chassis ground (-):
CHECK INPUT SIGNAL FOR ECM (USING Ioes the voltage change more Repair poor con- ;ontact with SOA
SUBARU SELECT MONITOR). han 0.2 V by shaking harness tact in ECM con- distributor) ser-
Measure the voltage between ECM connector ind connector of ECM while nector. lice.
and chassis ground while engine is idling. nonitoring the value with Sub- \IOTE:
tru select monitor? nspection by DTN
s required, be.
:ause probablc
:ause is deteriora
ion of multiplt
iarts.
CHECK POWER SUPPLY TO MASS AIR s the voltage more than 1OV? Go to step 5. 3epair open circuil
FLOW SENSOR. ietween mass air
1)Turn the ignition switch to OFF. low sensor and
2)Disconnect the connector from mass air flow nain relay
sensor.
3)Turn the ignition switch to ON.
4)Measure voltage between mass air flow sen,
sor connector and chassis ground.
Connector & terminal
(B3) No. 1 (+)- Chassis ground (-):
CHECK HARNESS BETWEEN ECM AND s the resistance less than l R ? Go to step 6. 3epair open circuit
MASS AIR FLOW SENSOR CONNECTOR. ietween ECM and
- 1)Turn the ignition switch to OFF. nass air flow sen-
2)Disconnect the connector from ECM. sor connector.
3)Measure the resistance of harness between
ECM and mass air flow sensor connector.
Connector & terminal
-
(B84) NO. 13 (B3) NO. 3:
(8135) NO. 27 - (83) NO. 4:
-
(B 135) NO. 19 (B3) NO. 5:

EN(D0HC TURBO)-IO3
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check
CHECK HARNESS BETWEEN ECM AND Is the resistance more than
MASS AIR FLOW SENSOR CONNECTOR 1M a ? short circuit
Measure the resistance of harness between between ECM and
ECM and chassis ground. mass air flow sen-
Connector & terminal sor connector.
(884) No. 13 - Chassis ground:
(8135) No. 27 - Chassis ground:
( 8 135) No. 19 - Chassis ground:
CHECK POOR CONTACT Is there poor contact in mass Repair poor con- Replace the mass
Check poor contact in mass air flow sensor air flow sensor connector? tact in mass air air flow and intake
connector. flow sensor con- air temperature
nector. sensor. <Ref. to
FU(D0HC
TURBO)-34, Mass
Air Flow and
Intake Air Temper-
ature Sensor.>

EN(D0HC TURBO)-104
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

EN(D0HC TURBO)-105
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGI NE (DIAG NOSTlCS)

G: DTC PO103 - MASS AIR FLOW SENSOR CIRCUIT HIGH INPUT -

DTC DETECTING CONDITION:
Immediately at fault recognition
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
Poor driving performance
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

MAIN RELAY

BATTERY
SBF-5
3 c

I MASS AIR FLOW AND

INTAKE AIR TEMPERATURE

EN(D0HC TURBO)-I06
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLEENG
CODE (DTC)
INE (DIAGNOSTICS)

Step Check Yes No

CONNECT SUBARU SELECT MONITOR OR Is the value equal to or more Even if MIL lights o to step 2.
THE OBD-ll GENERAL SCAN TOOL, AND than 1.3 g/sec (0.172 Ib/min)or up, the circuit has
READ DATA. 0.3 V and equal to or less than returned to a nor-
1)Turnthe ignition switch to OFF. 240 g/sec (32 Ib/min) or 4.58 mal condition at
2)Connect the Subaru Select Monitor or the ? this time.
OBD-ll general scan tool to data link connec-
tor.
3)Turn the ignition switch to ON and Subaru
Select Monitor or the OBD-ll general scan tool
switch to ON.
4)Start the engine.
5) Read the data of mass air flow sensor signal
using Subaru Select Monitor or OBD-ll general
scan tool.
NOTE:
*Subaru Select Monitor
For detailed operation procedure, refer to the
“READ CURRENT DATA FOR ENGINE”. <Ref.
to EN(D0HC TURBO)-38, Subaru Select Mon-
itor.>
*OBD-ll general scan tool
For detailed operation procedures, refer to the
OBD-ll General Scan Tool Instruction Manual.
s the value more than 240 g/ Repair battery ieplace the mass
CHECK HARNESS BETWEEN ECM AND
iec (32 Ib/min) or 4.58 V in short circuit in har, .ir flow sensor.
MASS AIR FLOW SENSOR CONNECTOR.
1)Turn the ignition switch to OFF and Subaru unction mode F06? ness between
Select Monitor or the OBD-ll general scan tool mass air flow sen-
switch to OFF. sor and ECM con-
2)Disconnect the connector from mass air flow nector. After
sensor. repair, replace the
3)Turn the ignition switch to ON and Subaru ECM.
Select Monitor or the OBD-ll general scan tool
switch to ON.
4)Read the data of mass air flow sensor signal
using Subaru select monitor or OBD-ll general
scan tool.
NOTE:
*Subaru Select Monitor
For detailed operation procedure, refer to the
“READ CURRENT DATA FOR ENGINE. <Ref.
to EN(D0HC TURBO)-38, Subaru Select Mon,
itor.>
*OBD-II general scan tool
For detailed operation procedures, refer to the
OBD-ll General Scan Tool Instruction Manual.

EN(D0HC TURBO)-107
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENG INE (DIAG NOSTlCS)

H: DTC PO106 - PRESSURE SENSOR CIRCUIT RANGE/PERFORMANCE

PROBLEM (LOW INPUT) -
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
TROUBLE SYMPTOM:
Failure of engine to start
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.

I THROTTLE BODY

EN(D0HC TURBO)-I08
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)
~ _ _ _ ~ ~

Step Check Yes No

CHECK IDLE SWITCH SIGNAL. Ioes the LED of {Idle Switch 20 to step 2. Check the throttle
1)Turnthe ignition switch to ON. jignal} come on? position sensor cir,
2)Operate the LED operation mode for engine cuit. <Ref. to
using Subaru Select Monitor. EN(D0HC
NOTE: TURBO)-132,
*Subaru Select Monitor DTC PO121 -
For detailed operation procedure, refer to the THROTTLE POSI-
“LED OPERATION MODE FOR ENGINE. TION SENSOR
<Ref. to EN(D0HC TURBO)-38, Subaru CIRCUIT RANGE/
Select Monitor.> PERFORMANCE
PROBLEM (HIGH
INPUT) -, Diag-
nostic Procedure
with Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it zi
not necessary tc
inspect DTC
PO106.
! CHECK ANY OTHER DTC ON DISPLAY. loes the Subaru Select Moni- nspect DTC Go to step 3.
or or OBD-ll general scan tool ’0107 or PO108
ndicate DTC PO107 or PO1087 Jsing “List of Diag-
iostic Trouble
:ode (DTC)”.
:Ref. to EN(D0HC
TURBO)-80, List
i f Diagnostic Trou-
ile Code (DTC).>
VOTE:
in this case, it is
lot necessary to
nspect DTC
D0106.
1 CHECK CONDITION OF PRESSURE SEN- s the pressure sensor installa- 30 to step 4. iighten pressure
SOR. ion bolt tightened securely? sensor installation
bolt securely.
I CHECK CONDITION OF THROlTLE BODY. s the throttle body installation Replace the pres- Tighten throttle
iolt tightened securely? sure sensor. <Ref. body installation
to FU(D0HC bolt securely.
TURBO)-35, Pres-
sure Sensor.>

EN(D0HC TURBO)-I09
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

I: DTC PO107 - PRESSURE SENSOR CIRCUIT LOW INPUT -

DTC DETECTING CONDITION:
Immediately at fault recognition
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

THROTTLE BODY

PRESSURE

I@ ECM

EN(D0HC TURBO)-I 10
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK CURRENT DATA. s the value less than -7.2 kPa 20 to step 3. 30 to step 2.
1)Start the engine. -54 mmHg, -2.1 inHg)?
2)Read the data of intake manifold absolute
pressure signal using Subaru Select Monitor or
OBD-ll general scan tool.
NOTE:
OSubaru Select Monitor
For detailed operation procedure, refer to the
“READ CURRENT DATA FOR ENGINE”. <Ref.
to EN(D0HC TURBO)-38, Subaru Select Mon
itor.>
*OBD-ll general scan tool
For detailed operation procedures, refer to the
OBD-II General Scan Tool Instruction Manual.
I CHECK POOR CONTACT. s there poor contact in ECM or 3epair poor con- Even if MIL lights
Check poor contact in ECM and pressure sen- )ressure sensor connector? act in ECM or ~ pthe
, circuit has
sor connector. iressure sensor .eturned to a nor-
:onnector. nal condition at
his time.
I CHECK INPUT SIGNAL FOR ECM. s the voltage more than 4.5 V? 30 to step 5. 20 to step 4.
Measure the voltage between ECM connector
and chassis ground.
Connector & terminal
(6135) No. 9 (+) - Chassis ground (-):
CHECK INPUT SIGNAL FOR ECM. loes the voltage change more ’lepair poor con- Zontact with SOA
Measure the voltage between ECM connector han 4.5 V by shaking harness act in ECM con- :distributor) ser-
and chassis ground. ind connector of ECM while lector. {ice.
Connector & terminal nonitoring the value with volt- VOTE:
(6135) No. 9 (+) - Chassis ground (-): ige meter? ‘nspection by DTk
s required, be,
:ause probablc
:ause is deteriora,
:ion of multiplc
Darts.
1 CHECK INPUT SIGNAL FOR ECM. s the voltage less than 0.7 V? 30 to step 6. Zontact with SOA
Measure the voltage between ECM and chas- :distributor) ser-
sis ground. dice.
Connector & terminal VOTE:
(8135) No. 8 (+) - Chassis ground (-): Inspection by DThr
s required, be
zause probablt
zause is deteriora
tion of multiplt
Darts.
i CHECK HARNESS BETWEEN ECM AND s the voltage more than 4.5 VS 30 to step 7. Repair open circuii
PRESSURE SENSOR CONNECTOR. n harness
1)Turnthe ignition switch to OFF. Detween ECM and
2)Disconnectthe connector from pressure Dressure sensor
sensor. zonnector.
3)Turn the ignition switch to ON.
4)Measure the voltage between pressure sen-
sor connector and engine ground.
. Connector & terminal
(E21) No. 3 (+) - Engine ground (-):

EN(D0HC TURBO)-1 11
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICSI
~ ~ ~~ ~ ~ ~ ~ ~ _ _ _ _ _ _ _

Step Check Yes No

7 CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Go to step 8. Repair open circuit
PRESSURE SENSOR CONNECTOR. R? in harness
1)Turn the ignition switch to OFF. between ECM and
2)Disconnect the connector from ECM. pressure sensor
3)Measure the resistance of harness between connector.
ECM and pressure sensor connector.
Connector & terminal
-
(8135) NO. 19 (E21) NO. 2:
8 CHECK HARNESS BETWEEN ECM AND Is the resistance more than 1 Go to step 9. Repair ground
PRESSURE SENSOR CONNECTOR. Ma? short circuit in har-
Measure the resistance of harness between ness between
pressure sensor connector and engine ground. ECM and pressure
Connector & terminal sensor connector.
(E21) No. 1 - Engine ground:
9 CHECK POOR CONTACT. Is there poor contact in pres- Repair poor con- Replace the pres-
Check poor contact in pressure sensor con- sure sensor connector? tact in pressure sure sensor. <Ref.
nector. sensor connector. to FU(D0HC
TURBO)-35, Pres-
sure Sensor.>

EN(D0HC TURBO)-1 12
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

EN(D0HC TURBO)-I 13
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

J: DTC PO108 - PRESSURE SENSOR CIRCUIT HIGH INPUT -

DTC DETECTING CONDITION:
Immediately at fault recognition
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

THROTTLE BODY

PRESSURE SE

EN(D0HC TURBO)-114
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK CURRENT DATA. s the value more than 282 kPa 20 to step 9. Go to step 2.
1)Start the engine. 2121 mmHg, 83.50 inHg)?
2)Read the data of intake manifold absolute
pressure signal using Subaru Select Monitor or
OBD-II general scan tool.
NOTE:
Gubaru Select Monitor I
For detailed operation procedure, refer to the
“READ CURRENT DATA FOR ENGINE”. <Ref.
to EN(D0HC TURBO)-38, Subaru Select Mon-
itor.>
*OBD-ll general scan tool
For detailed operation procedures, refer to the
OBD-ll General Scan Tool Instruction Manual.
CHECK INPUT SIGNAL FOR ECM. s the voltage more than 4.5 V?
Measure the voltage between ECM connector
and chassis ground.
Connector & terminal
(8135) No. 9 (+)- Chassis ground (-):
, CHECK INPUT SIGNAL FOR ECM. Ioes the voltage change more 3epair poor con- Contact with SOA
Measure the voltage between ECM connector han 4.5 V by shaking harness act in ECM con- (distributor) ser-
gnd chassis ground. n d connector of ECM while lector. vice.
Connector & terminal nonitoring the value with volt- NOTE:
(8135) No. 9 (+)- Chassis ground (-): tge meter? Inspection by DTk
is required, be
cause probable
cause is deteriora
tion of multiple
parts.
1 CHECK INPUT SIGNAL FOR ECM. s the voltage less than 0.7 V? 30 to step 5. Contact with SOA
Measure the voltage between ECM connector (distributor) ser-
and chassis ground. vice.
Connector & terminal NOTE:
(8135) No. 8 (+) - Chassis ground (-): Inspection by DTk
is required, be
cause probablt
cause is deteriora
tion of multiplt
parts.
I CHECK HARNESS BETWEEN ECM AND s the voltage more than 4.5 VS 30 to step 6. Repair open circuil
PRESSURE SENSOR CONNECTOR. in harness
1)Turnthe ignition switch to OFF. between ECM and
2)Disconnectthe connector from pressure pressure sensor
sensor. connector.
3)Turn the ignition switch to ON.
4)Measure the voltage between pressure sen-
sor connector and engine ground.
Connector & terminal
(E21) No. 3 (+)- Engine ground (-):
i CHECK HARNESS BETWEEN ECM AND s the resistance less than 1 30 to step 7. Repair open circuil
PRESSURE SENSOR CONNECTOR. 2? in harness
1)Turnthe ignition switch to OFF. between ECM and
. 2)Disconnect the connector from ECM. pressure sensor
3)Measure the resistance of harness between connector.
ECM and pressure sensor connector.
Connector & terminal
(8135) NO. 8 - (E21) NO. 1:

EN(D0HC TURBO)-115
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

r CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Go to step 8. 3epair open circuit
PRESSURE SENSOR CONNECTOR. a? n harness
Measure the resistance of harness between letween ECM and
ECM and pressure sensor connector. lressure sensor
Connector & terminal :onnector.
(8135) NO. 19 - (E21) NO.2:
I CHECK POOR CONTACT. Is there poor contact in pres- Repair poor con- 3eplace the pres-
Check poor contact in pressure sensor con- sure sensor connector? tact in pressure iure sensor. <Ref.
nector. sensor connector. o FU(D0HC
rURBO)-35, Pres-
iure Sensor.>
CHECK HARNESS BETWEEN ECM AND Is the value more than 282 kPa Repair battery 3eplace the pres-
PRESSURE SENSOR CONNECTOR. (2121 mmHg, 83.50 inHg)? short circuit in har- ure sensor. <Ref.
1)Turnthe ignition switch to OFF and Subaru ness between o FU(D0HC
Select Monitor or the OBD-II general scan tool ECM and pressure rURBO)-35, Pres-
switch to OFF. sensor connector. ;ure Sensor.>
2)Disconnect the connector from pressure
sensor.
3)Turn the ignition switch to ON and Subaru
Select Monitor or the OBD-II general scan tool
switch to ON.
4)Read the data of intake manifold absolute
iressure signal using Subaru Select Monitor or
OBD-II general scan tool.
NOTE:
*Subaru Select Monitor
For detailed operation procedure, refer to the
“READ CURRENT DATA FOR ENGINE. <Ref.
to EN(D0HC TURBO)-38, Subaru Select Mon-
itor.>
*OBD-II general scan tool
For detailed operation procedures, refer to the
OBD-ll General Scan Tool Instruction Manual.

EN(D0HC TURBO)-I 16
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAG NOSTlCS)

EN(D0HC TURBO)-I 17
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE [DIAGNOSTICS)

K: DTC PO111 - INTAKE AIR TEMPERATURE SENSOR CIRCUIT RANGE/PER-

FORMANCE PROBLEM -
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
TROUBLE SYMPTOM:
Erroneous idling
Poor driving performance
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

IAIN RELAY

BATTERY
SBF-5

MASS AIR FLOW AND

INTAKE AIR TEMPERATURE

ECM

@
EN1145

EN(D0HC TURBO)-I 18
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK ANY OTHER DTC ON DISPLAY. loes the Subaru Select Moni- Inspect DTC Go to step 2.
or or OBD-ll general scan toolPOI 12, PO113,
ndicate DTC PO112, PO113, PO117, PO118 or
’0117, PO118 or P0125? PO125 using “List
of Diagnostic Trou-
ble Code (DTC)”.
<Ref. to EN(D0HC
TURBO)-80, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0111.
CHECK ENGINE COOLANT TEMPERA- s the engine coolant tempera- Replace the mass Inspect DTC
TURE. ure between 75°C (167°F) and air flow and intake PO125 using “List
1)Start the engine and warm it up completely. )5”C (203”F)? air temperature of Diagnostic Trow
2)Measure the engine coolant temperature sensor. <Ref. to ble Code (DTC)”.
using Subaru Select Monitor or OBD-11general FU(D0HC <Ref. to EN(D0HC
scan tool. TURBO)-34, Mass TURBO)-80, List
NOTE: Air Flow and of Diagnostic Trow
*Subaru Select Monitor Intake Air Temper- ble Code (DTC).>
For detailed operation procedure, refer to the ature Sensor.>
“READ CURRENT DATA FOR ENGINE. <Ref.
to EN(D0HC TURBO)-38, Subaru Select Mon-
itor.> I
*OBD-II general scan tool
For detailed operation procedures, refer to the
OBD-ll General Scan Tool Instruction Manual.

EN(D0HC TURBO)-I 19
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

L: DTC PO112 - INTAKE AIR TEMPERATURE SENSOR CIRCUIT LOW INPUT

7

DTC DETECTING CONDITION:

Immediately at fault recognition
TROUBLE SYMPTOM:
Erroneous idling
Poor driving performance
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

RATTFRY

MASS AIR FLOW AND

INTAKE AIR TEMPERATURE

ECM
E:

EN1 145

EN(D0HC TURBO)-120
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK CURRENT DATA. s the value greater than 55°C 30 to step 2. 3epair poor con-
1)Start the engine. 131OF)? 3Ct.
2)Read the data of intake air temperature sen- JOTE:
sor signal using Subaru Select Monitor or the n this case, repai
OBD-ll general scan tool. he following:
NOTE: Poor contact
Gubaru Select Monitor nass air flow and
For detailed operation procedure, refer to the itake air tempera.
“READ CURRENT DATA FOR ENGINE”. <Ref. ure sensor
to EN(D0HC TURBO)-38, Subaru Select Mon- Poor contact in
itor.> iCM
*OBD-II general scan tool Poor contact in
For detailed operation procedure, refer to the Ynt connector
OBD-II General Scan Tool Instruction Manual.
CHECK HARNESS BETWEEN MASS AIR s the value less than -36°C (- 3eplace the mass 3epair ground
FLOW AND INTAKE AIR TEMPERATURE )7”F)? air flow and intake ihort circuit in har.
SENSOR AND ECM CONNECTOR. air temperature less between
1)Turn the ignition switch to OFF. sensor. <Ref. to nass air flow and
2)Disconnect the connector from mass air flow ‘U( DOHC itake air tempera.
and intake air temperature sensor. TURBO)-34, Mass ure sensor and
3)Turn the ignition switch to ON. 4ir Flow and iCM connector.
4)Read the data of intake air temperature sen- ntake Air Temper-
sor signal using Subaru Select Monitor or the ature Sensor.>
OBD-ll general scan tool.
NOTE:
*Subaru Select Monitor
For detailed operation procedure, refer to the
“READ CURRENT DATA FOR ENGINE”. <Ref.
to EN(D0HC TURBO)-38, Subaru Select Mon-
itor.>
*OBD-ll general scan tool
For detailed operation procedure, refer to the
OBD-II General Scan Tool Instruction Manual.

EN(D0HC TURBO)-121
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

M: DTC PO113 - INTAKE AIR TEMPERATURE SENSOR CIRCUIT HIGH INPUT

-
DTC DETECTING CONDITION:
Immediately at fault recognition
TROUBLE SYMPTOM:
Erroneous idling
Poor driving performance
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

MAIN RELAY

I MASS AIR FLOW AND

INTAKE AIR TEMPERATURE

ECM

EN1145

EN(D0HC TURBO)-122
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

I CHECK CURRENT DATA. Repair poor con-
1)Start the engine. 17”F)? tact.
2)Read the data of intake air temperature sen- NOTE:
sor signal using Subaru Select Monitor or the In this case, repaii
OBD-I1 general scan tool. the following:
NOTE: Poor contact in
*Subaru Select Monitor mass air flow and
For detailed operation procedure, refer to the intake air tempera-
“READ CURRENT DATA FOR ENGINE”. <Ref. ture sensor
to EN(D0HC TURBO)-38, Subaru Select Mom * Poor contact in
itor.> ECM
*OBD-ll general scan tool Poor contact in
For detailed operation procedure, refer to the ioint connector
OBD-ll General Scan Tool Instruction Manual.
! CHECK HARNESS BETWEEN MASS AIR ;the voltage more than 10 V? Repair battery Go to step 3.
FLOW AND INTAKE AIR TEMPERATURE short circuit in har-
SENSOR AND ECM CONNECTOR. ness between
1)Turn the ignition switch to OFF. mass air flow and
2)Disconnect the connector from mass air flow intake air tempera-
and intake air temperature sensor. ture sensor and
3)Measure the voltage between mass air flow ECM connector.
?nd intake air temperature sensor connector
and engine ground.
Connector & terminal
(63)No. 2 (+) - Engine ground (-):
I CHECK HARNESS BETWEEN INTAKE AIR s the voltage more than 10 V? Repair battery Go to step 4.
TEMPERATURE AND PRESSURE SENSOR short circuit in har-
AND ECM CONNECTOR. ness between
1)Turnthe ignition switch to ON. mass air flow and
2)Measure the voltage between mass air flow intake air tempera-
and intake air temperature sensor connector ture sensor and
and engine ground. ECM connector.
Connector & terminal
(63)No. 2 (+) - Engine ground (-):
I CHECK HARNESS BETWEEN MASS AIR s the voltage more than 3 V? Go to step 5. Repair harness
FLOW AND INTAKE AIR TEMPERATURE and connector.
SENSOR AND ECM CONNECTOR. NOTE:
Measure the voltage between mass air flow In this case, repaii
and intake air temperature sensor and pres- the following:
sure sensor connector and engine ground. Open circuit in
Connector & terminal harness between
(63)No. 2 (+) - Engine groundI)-( mass air flow and
intake air tempera
ture sensor and
ECM connector
* Poor contact in
mass air flow and
intake air tempera-
ture sensor
Poor contact in
ECM
Poor contact in
joint connector

EN(D0HC TURBO)-123
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
-
ENGINE (DIAGNOSTICS)

Step Check Yes No

# CHECK HARNESS BETWEEN MASS AIR Is the resistance less than 5 Replace the mass Repair harness
FLOW AND INTAKE AIR TEMPERATURE R? air flow and intake and connector.
SENSOR AND ECM CONNECTOR. air temperature NOTE:
1)Turn the ignition switch to OFF. sensor. <Ref. to In this case, repaii
2)Measure the resistance of harness between FU(D0HC the following:
mass air flow and intake air temperature sen- TURBO)-34, Mass Open circuit in
sor and engine ground. Air Flow and nessbetween
Connector & terminal Intake Air Temper- mass air flow and
(83)No. 5 -Engine ground: ature Sensor.> intake air tempera-
ture sensor and
ECM connector
Poor contact in
mass air flow and
intake air tempera.
ture sensor
Poor contact in
ECM
Poor contact in
ioint connector

EN(D0HC TURBO)-124
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

EN(D0HC TURBO)-I25
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

N: DTC PO117 - ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT LOW

INPUT -
DTC DETECTING CONDITION:
Immediately at fault recognition
TROUBLE SYMPTOM:
Hard to start
Erroneous idling
Poor driving performance
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

I ENGINE
COOLANT
TEMPERATURE
SENSOR

EN114;

EN(D0HC TURBO)-I26
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK CURRENT DATA. s the value greater than i50°C Go to step 2. Repair poor con-
1)Start the engine. 302”F)? tact.
2)Read the data of engine coolant temperature NOTE:
sensor signal using Subaru Select Monitor or In this case, repai
OBD-II general scan tool. the following:
NOTE: Poor contact in
*Subaru Select Monitor engine coolant
For detailed operation procedure, refer to the temperature sen-
“READ CURRENT DATA FOR ENGINE”. <Ref. sor
to EN(D0HC TURBO)-38, Subaru Select Mon- Poor contact in
itor.> ECM
*OBD-ll general scan tool Poor contact in
For detailed operation procedures, refer to the coupling connect0
OBD-ll General Scan Tool Instruction Manual. Poor contact in
joint connector
CHECK HARNESS BETWEEN ENGINE s the value less than -40°C (- Replace the Repair ground
COOLANT TEMPERATURE SENSOR AND IO’F)? engine coolant short circuit in har.
ECM CONNECTOR. temperature sen- ness between
1)Turnthe ignition switch to OFF. sor. <Ref. to engine coolant
2)Disconnectthe connector from engine cocl- FU(D0HC temperature sen-
ant temperature sensor. TURBO)-29, sor and ECM con-
3)Turn the ignition switch to ON. Engine Coolant nector.
4)Read the data of engine coolant temperature Temperature Sen-
sensor signal using Subaru Select Monitor or sor.>
OBD-ll general scan tool.
NOTE:
*Subaru Select Monitor
For detailed operation procedure, refer to the
“READ CURRENT DATA FOR ENGINE. <Ref.
to EN(D0HC TURBO)-38, Subaru Select Mon-
itor.>
*OBD-ll general scan tool
For detailed operation procedures, refer to the
OBD-ll General Scan Tool Instruction Manual.

EN(D0HC TURBO)-127
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENG INE (DIAGNOSTICS)

0:DTC PO118 - ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT HIGH

INPUT -
DTC DETECTING CONDITION:
Immediately at fault recognition
TROUBLE SYMPTOM:
Hard to start
Erroneous idling
Poor driving performance
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURB0)46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

1 ENGINE
COOLANT
TEMPERATURE
SENSOR

U
@ECM

EN1147

EN(D0HC TURBO)-128
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK CURRENT DATA. I Is the value less than -40°C (- I Go to step 2. Repair poor con-
1)Start the engine. 40°F)? tact.
2)Read the data of engine coolant temperature NOTE:
sensor signal using Subaru Select Monitor or In this case, repai
OBD-II general scan tool. the following:
m Poor contact in
NOTE:
OSubaru Select Monitor engine coolant
For detailed operation procedure, refer to the temperature sen-
“READ CURRENT DATA FOR ENGINE”. <Ref. sor
to EN(D0HC TURBO)-38, Subaru Select Mom * Poor contact in
itor.> ECM
*OBD-II general scan tool Poor contact in
For detailed operation procedures, refer to the coupling connect0
OBD-ll General Scan Tool Instruction Manual. m Poor contact in

joint connector
! CHECK HARNESS BETWEEN ENGINE Is the voltage more than 10 V? Repair battery Go to step 3.
COOLANT TEMPERATURE SENSOR AND short circuit in har-
ECM CONNECTOR. ness between
1)Turnthe ignition switch to OFF. ECM and engine
2)Disconnect the connector from engine cool- coolant tempera-
ant temperature sensor. ture sensor con-
3)Measure the voltage between engine coolant nector.
temperature sensor connector and engine
ground.
Connector & terminal
(E8) No. 2 (+) - Engine ground (-):
1 CHECK HARNESS BETWEEN ENGINE Is the voltage more than 10 V? Repair battery Go to step 4.
COOLANT TEMPERATURE SENSOR AND short circuit in har-
ECM CONNECTOR. ness between
1)Turn the ignition switch to ON. ECM and engine
2)Measure the voltage between engine coolant coolant tempera-
temperature sensor connector and engine ture sensor con-
ground. nector.
Connector & terminal
(E8) No. 2 (+) - Engine ground (-):
I CHECK HARNESS BETWEEN ENGINE Is the voltage more than 4 V? Go to step 5. Repair harness
COOLANT TEMPERATURE SENSOR AND and connector.
NOTE:
In this case, repai
the following:
Open circuit in
harness between
ECM and engine
coolant tempera-
ture sensor con-
nector
Poor contact in
engine coolant
temperature sen-
sor connector
9 Poor contact in
ECM connector
Poor contact in
coupling connecta
Poor contact in
joint connector

EN(D0HC TURBO)-129
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE [DIAGNOSTICS)

Step Check Yes No

I CHECK HARNESS BETWEEN ENGINE Is the resistance less than 5 Replace the Repair harness
COOLANT TEMPERATURE SENSOR AND n? engine coolant and connector.
ECM CONNECTOR. temperature sen- NOTE:
1)Turnthe ignition switch to OFF. sor. <Ref. to In this case, repair
2)Measure the resistance of harness between FU(D0HC the following:
engine coolant temperature sensor connector TURBO)-29, Open circuit in
and engine ground. Engine Coolant harness between
Connector & terminal Temperature Sen- ECM and engine
(E8) No. 7 - Engine ground: sor.> coolant tempera-
ture sensor con-
nector
Poor contact in
engine coolant
temperature sen-
sor connector
Poor contact in
ECM connector
Poor contact in
coupling connector
Poor contact in
joint connector

EN(D0HC TURBO)-130
I
t
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

EN(D0HC TURBO)-I31
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

P: DTC PO121 - THROTTLE POSITION SENSOR CIRCUIT RANGE/PERFOR-

MANCE PROBLEM (HIGH INPUT) -
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
Poor driving performance
Fuel is cut.
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

THROTTLE
POSITION
SENSOR

c
li

EN1148

EN(D0HC TURBO)-I 32
I
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)
~

Step Check Yes No

CHECK ANY OTHER DTC ON DISPLAY. Ioes the Subaru Select Moni- Inspect DTC Replace the throt-
or or OBD-I1general scan tool P0122, PO123 or !le position sen-
ndicate DTC PO1 22, PO123 or P I 507 using " List ;or. <Ref. to
'1 507? of Diagnostic Trou- FU(D0HC
ble Code (DTC)". TURBO)-33,
<Ref. to EN(D0HC Throttle Position
TURBO)-80, List Sensor.>
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0121.

EN(D0HC TURBO)-133
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Q: DTC PO122 -THROTTLE POSITION SENSOR CIRCUIT LOW INPUT -

DTC DETECTING CONDITION:
Immediately at fault recognition
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
Poor driving performance
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

THROTTLE
POSITION
SENSOR

EN1148

EN(D0HC TURBO)-134
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE IDIAGNOSTICS)

Step Check Yes No

CHECK CURRENT DATA. s the value less than 0.1 V? 30 to step 2. Even if MIL lights
1)Start the engine. up, the circuit has
2)Read the data of throttle position sensor sig- returned to a nor-
nal using Subaru Select Monitor or OBD-ll mal condition at
general scan tool. this time. A tempo
NOTE: rary poor contact
*Subaru Select Monitor of the connector
For detailed operation procedure, refer to the may be the cause
“READ CURRENT DATA FOR ENGINE. <Ref. NOTE:
to EN(D0HC TURBO)-38, Subaru Select Mon- In this case, repar
itor.> the following:
*OBD-ll general scan tool Poor contact in
For detailed operation procedures, refer to the throttle position
OBD-II General Scan Tool Instruction Manual. sensor connector
Poor contact in
ECM connector
Poor contact in
coupling connectc
! CHECK INPUT SIGNAL FOR ECM. s the voltage more than 4.5 V‘ 30 to step 4. Go to step 3.
Measure the voltage between ECM connector
and chassis ground while throttle valve is fully
closed.
Connector & terminal
(6135) No. 9 (+) -Chassis ground (-):
I CHECK JNPUT SIGNAL FOR ECM. Ioes the voltage change more 3epair poor con- Contact with SOA
Measure the voltage between ECM connector han 4.5 V by shaking harness act in ECM con- (distributor) ser-
and chassis ground. ind connector of ECM while lector. vice.
Connector & terminal nonitoring the value with volt- NOTE:
(6135) No. 9 (+) -Chassis ground (-): ige meter? Inspection by DTL
is required, be
cause probabll
cause is deteriora
tion of multipll
parts.
I CHECK INPUT SIGNAL FOR ECM. s the voltage less than 0.1 V?
Measure the voltage between ECM connector
and chassis ground.
Connector & terminal
(8135) No. 7 (+) -Chassis ground (-):
1 CHECK INPUT SIGNAL FOR ECM. (USING joes the voltage change more
SUBARU SELECT MONITOR.) han 0.1 V by shaking harness act in ECM con-
Measure the voltage between ECM connector md connector of ECM while lector.
and chassis ground. nonitoring the value with Sub-
kru Select Monitor?

EN(D0HC TURB0)-135
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE IDIAGNOSTICS)

Step Check Yes No

CHECK HARNESS BETWEEN ECM AND s the voltage more than 4.5 V' 30 to step 7. Repair harness
THROTTLE POSITION SENSOR CONNEC- and connector.
TOR. NOTE:
1)Turn the ignition switch to OFF. In this case, repaii
2)Disconnectthe connectors from throttle posi- the following:
tion sensor. Open circuit in
3)Turn the ignition switch to ON. harness between
4)Measure the voltage between throttle posi- throttle position
tion sensor connector and engine ground. sensor and ECM
Connector & terminal connector
(€13) No. 1 (+) - Engine ground (-): Poor contact in
throttle position
sensor connector
Poor contact in
ECM connector
Poor contact in
coupling connectoi
Poor contact in
joint connector
CHECK HARNESS BETWEEN ECM AND s the resistance less than 1 30 to step 8. Repair harness
THROTTLE POSITION SENSOR CONNEC- 2? and connector.
TOR. NOTE:
'1)Turn the ignition switch to OFF. In this case, repaii
2)Measure the resistance of harness between the following:
ECM connector and throttle position sensor Open circuit in
connector. harness between
Connector & terminal throttle position
(8135) NO. 7 - (E13) NO. 3: sensor and ECM
connector
Poor contact in
ECM connector
Poor contact in
throttle position
sensor connector
Poor contact in
coupling connectoi
I CHECK HARNESS BETWEEN ECM AND s the resistance less than 10 3epair ground Go to step 9.
THROlTLE POSITION SENSOR CONNEC- 3? short circuit in har-
TOR. less between
Measure the resistance of harness between hrottle position
throttle position sensor connector and engine sensor and ECM
ground. :onnector.
Connector & terminal
(E13) No. 3 - Engine ground:
1 CHECK POOR CONTACT. s there poor contact in throttle 3epair poor con- Replace the throt-
Check poor contact in throttle position sensor iosition sensor connector? act in throttle posi, tle position sen-
connector. ion sensor sor. <Ref. to
:onnector. FU(D0HC
TURBO)-33,
Throttle Position
Sensor.>

EN(D0HC TURBO)-136
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
-
ENGINE (DIAGNOSTICS)

EN(D0HC TURBO)-I37
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

R: DTC PO123 - THROTTLE POSITION SENSOR CIRCUIT HIGH INPUT -

DTC DETECTING CONDITION:
Immediately at fault recognition
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
Poor driving performance -
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

THROTTLE
POSITION
SENSOR

I -

EN1148

EN(D0HC TURBO)-138
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)
~~

Step Check Yes No

CHECK CURRENT DATA. ;the value more than 4.9 V? i o to step 2. Even if MIL lights
1)Start the engine. up, the circuit has
2)Read the data of throttle position sensor sig. returned to a nor-
nal using Subaru Select Monitor or OBD-ll mal condition at
general scan tool. this time. A tempo-
NOTE: rary poor contact
*Subaru Select Monitor of the connector
For detailed operation procedure, refer to the may be the cause.
“READ CURRENT DATA FOR ENGINE. <Ref. NOTE:
to EN(D0HC TURBO)-38, Subaru Select Mon In this case, repair
itor.> the following:
*OBD-ll general scan tool Poor contact in
For detailed operation procedures, refer to the throttle position
OBD-ll General Scan Tool Instruction Manual. sensor connector
Poor contact in
ECM connector
Poor contact in
coupling connector
CHECK HARNESS BETWEEN THROlTLE 5 the resistance less than 5 Go to step 3. Repair harness
POSITION SENSOR AND ECM CONNEC- l? and connector.
TOR. NOTE:
1)Turn the ignition switch to OFF. In this case, repaii
2)Disconnect the connector from throttle posi- the following:
tion sensor. Open circuit in
3)Measure the resistance of harness between harness between
throttle position sensor connector and engine throttle position
ground. sensor and ECM
Connector & terminal connector
(E 13) No. 2 - Engine ground: Poor contact in
coupling connectot
Poor contact in
joint connector
CHECK HARNESS BETWEEN THROTTLE s h e voltage more than 4.9 b Aepair battery Replace the throt-
POSITION SENSOR AND ECM CONNEC- short circuit in har- tle position sen-
TOR. ness between sor. <Ref. to
1)Turn the ignition switch to ON. throttle position FU(D0HC
2)Measure the voltage between throttle posi- sensor and ECM TURBO)-33,
tion sensor connector and engine ground. connector. After Throttle Position
Connector & terminal repair, replace the Sensor.>
(E13) No. 3 (+) -Engine ground (-): ECM. <Ref. to
FU(D0HC
TURBO)-47,
Engine Control
Module.>

EN(D0HC TURBO)-139
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

S: DTC PO125 - INSUFFICIENT COOLANT TEMPERATURE FOR CLOSED

LOOP FUEL CONTROL -
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
TROUBLE SYMPTOM:
Engine would not return to idling.
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

ENGINE
COOLANT
TEMPERATURE
SENSOR

IC
I

c
-

EN(D0HC TURBO)-140
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE [DIAGNOSTICSI

Step Check Yes No

CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Moni- I Inspect DTC I Go to step 2.
tor or OBD-ll general scan tool PO117 or PO118
indicate DTC PO117 or PO118? using “List of Diag.
nostic Trouble
Code (DTC)”.
<Ref. to EN(D0HC
TURBO)-80, List
of Diagnostic Trow
ble Code (DTC).>
NOTE:
In this case, it is
not necessary tc
inspect DTC
PO125.
! CHECK ENGINE COOLING SYSTEM. Is there a fault in engine cool- Replace the ther- rleplace the
NOTE: ing system? mostat. <Ref. to engine coolant
Check the following items. CO-35, Thermo- temperature sen-
*Thermostat open stuck stat.> sor. <Ref. to
*Coolant level FU(D0HC
Coolant freeze TURBO)-29,
*Tire diameter Engine Coolant
Temperature Sen-
sor.>

EN(D0HC TURBO)-141
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

T: DTC PO128 - THERMOSTAT MALFUNCTION -

DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
TROUBLE SYMPTOM:
Thermostat remains open.
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.

Step Check Yes No

CHECK VEHICLE CONDITION. Has engine operated at idle or In this case, it is Go to step 2.
has vehicle been driven with not necessary to
part of engine submerged inspect DTC
under water? P0128.
CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Moni- Go to step 3. Inspect DTC
tor or OBD-II general scan tool PO125, P0301,
indicate DTC PO125, P0301, P0302, P0303,
P0302, P0303, P0304, PO305 P0304, PO305 and
and PO306 at same time? PO306 using “List
of Diagnostic Trou-
ble Code (DTC)”.
<Ref. to EN(D0HC
TURBO)SO, List
of Diagnostic Trou-
ble Code (DTC).>
CHECK ENGINE COOLANT. Are coolant level and mixture Go to step 4. Replace the
ratio of cooling water to anti- engine coolant.
freeze solution correct? <Ref. to CO-25,
REPLACEMENT,
Engine Coolant.>
CHECK RADIATOR FAN. Does the radiator fan continu- Repair radiator fan Replace the ther-
1)Start the engine. ously rotate for more than 3 Zircuit. <Ref. to mostat. <Ref. to
2)Check radiator fan operation. minutes during idling? EO-46, Radiator GO-35, Thermo-
Main Fan and Fan stat.>
Motor.> and <Ref.
to CO-48, Radiator
Sub Fan and Fan
Motor.>

EN(D0HC TURBO)-142
 1
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
-
ENGINE (DIAGNOSTICS)

U: DTC PO131 - FRONT OXYGEN (NF) SENSOR CIRCUIT RANGUPERFOR-

MANCE PROBLEM (LOW INPUT) -
NOTE:
I For the diagnostic procedure, refer to DTC P0132. <Ref. to EN(D0HC TURBO)-144, DTC PO132 - FRONT
OXYGEN (NF)SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM (HIGH INPUT) -, Diagnostic
Procedure with Diagnostic Trouble Code (DTC).>

EN(D0HC TURBO)-143
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
-
ENGINE (DIAGNOSTICS)

V: DTC PO132 - FRONT OXYGEN (NF) SENSOR CIRCUIT RANGWPERFOR-

MANCE PROBLEM (HIGH INPUT) -
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(DOHC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

EN1143

EN(D0HC TURBO)-I44
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGl N E (DIAGNOSTICS)
~

Step Check Yes No

CHECK ANY OTHER DTC ON DISPLAY. loes the Subaru Select Moni- nspect DTC Go to step 2.
or or OBD-ll general scan tool J0031, P0032,
ndicate DTC P0031, P0032, J1131, P1134or
J1131. Pi134or P1139? J1 139 using “List
if Diagnostic Trou-
)le Code
DTC)”.<Ref. to
!N(DOHC
rURBO)-80, List
i f Diagnostic Trou-
ile Code (DTC).>
CHECK FRONT (NF) OXYGEN SENSOR DA- s the value equal to or more 20 to step 3. Go to step 4.
TA. han 0.85 and equal to less
1)Start the engine. han 1.15 in idling?
2)While observing the Subaru Select Monitor
or OBD-ll 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 the data of front oxygen (NF) sensor
signal using Subaru Select Monitor or OBD-ll
general scan tool.
NOTE:
*Subam Select Monitor
For detailed operation procedure, refer to the
“READ CURRENT DATA FOR ENGINE”. <Ref.
to EN(D0HC TURBO)-38, Subaru Select Mon-
itor.>
*OBD-ll general scan tool
For detailed operation procedures, refer to the
OBD-ll General Scan Tool Instruction Manual.
CHECK REAR OXYGEN SENSOR SIGNAL. loes the LED of {Rear 0 2 3epair poor con- Check rear oxyger
1)Race the engine at speeds from idling to 3ich Signal} blink? act in front oxygen sensor circuit.
5,000 rpm for a total of 5 cycles. N F ) sensor and <Ref. to FU(D0HC
NOTE: ‘ear oxygen sen- TURBO)-44, Rear
To increase engine speed to 5,000 rpm, slowly ;or connector. Oxygen Sensor.>
depress accelerator pedal, taking approximate-
ly 5 seconds, and quickly release accelerator
pedal to decrease engine speed.
2)Operate the LED operation mode for engine.
NOTE:
*Subaru Select Monitor
For detailed operation procedure, refer to the
“LED OPERATION MODE FOR ENGINE.
<Ref. to EN(D0HC TURBO)-38, Subaru
Select Monitor.>
CHECK EXHAUST SYSTEM. s there a fault in exhaust sys- 3epair or replace Replace the front
Check exhaust system parts. em? aulty parts. oxygen (NF) sen-
NOTE: sor. <Ref. to
Check the following items. FU(D0HC
*Loose installation of portions TURBO)-42, Fron
. *Damage (crack, hole etc.) of parts Oxygen (NF)Sen
*Looseness of front oxygen (NF) sensor sor.>
*Looseness and ill fitting of parts between front
oxygen (NF) sensor and rear oxygen sensor
1
EN(D0HC TURBO)-145
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

W: DTC PO133 - FRONT OXYGEN (NF)SENSOR CIRCUIT SLOW RESPONSE

-
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

AIN RELAY BATTERY

RFRONTOXYGEN

EN1143

EN(D0HC TURBO)-146
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICSI

Step Check Yes No

CHECK ANY OTHER DTC ON DISPLAY. Ioes the Subaru Select Moni- Inspect DTC I Go to step 2.
or or OBD-ll general scan tool P0031, P0032,
idicate DTC P0031, P0032, PO131, PO132,
)0131, PO132, P1130, P1131, P1130, P1131,
V134 or P1139? P1134or P1139
using “List of Diag-
nostic Trouble
Code (DTC)”.
<Ref. to EN(D0HC
TURBO)-80, List
of Diagnostic Trow
ble Code (DTC).>
NOTE:
In this case, it i$
not necessary tc
inspect DTC
PO133.
! CHECK EXHAUST SYSTEM. s there a fault in exhaust sys- Repair exhaust Replace the front
NOTE: em? system. oxygen (NF) sen-
Check the following items. sor. <Ref. to
*Loose installation of front portion of exhaust FU(D0HC
pipe onto cylinder heads TURBO)-42, Front
*Loose connection between front exhaust pipe Oxygen (NF) Sen-
and front catalytic converter sor.>
*Damage of exhaust pipe resulting in a hole

EN(D0HC TURBO)-147
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
r
ENGINE DlAG NOSTICS)

X: DTC PO136 - REAR OXYGEN SENSOR CIRCUIT MALFUNCTION -

DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

AIN RELAY BATTERY

OXYGEN SENSOR

3:@

EN1144

Step Check
1 . CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Moni-
tor or OBD-II general scan tool
indicate DTC PO131 or PO132? I I

EN(D0HC TURBO)-148
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK FAILURE CAUSE OF PO131 or ;the failure cause of PO131 or ;heck fuel system. ;o to step 3.
PO132. ‘0132 in the fuel system? \IOTE:
Inspect DTC PO131 or PO132 using “List of n this case, it is
Diagnostic Trouble Code (DTC)”. <Ref. to lot necessary to
EN(D0HC TURBO)-80, List of Diagnostic nspect DTC
Trouble Code (DTC).> ’01 36.
CHECK REAR OXYGEN SENSOR DATA. boes the value fluctuate? 30 to step 7 . io to step 4.
1)Warm-upthe 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 the data of rear oxygen sensor signal
using Subaru Select Monitor or OBD-ll general
scan tool.
NOTE:
OSubaru Select Monitor
For detailed operation procedure, refer to the
“READ CURRENT DATA SHOWN ON DIS-
PLAY FOR ENGINE”. <Ref. to EN(D0HC
TURBO)-38, Subaru Select Monitor.>
.OBD-ll general scan tool
For detailed operation procedures, refer to the
OBD-I1 General Scan Tool Instruction Manual.
CHECKREAROXYGENSENSORDATA. s the value fixed between 0.2 30 to step 5. 3eplace the rear
Read the data of rear oxygen sensor signal Ind 0.4 V? )xygen sensor.
using Subaru Select Monitor or OBD-II Gen- :Ref. to FU(D0HC
eral Scan Tool. rURBO)-44, Rear
lxygen Sensor.>
CHECK HARNESS BETWEEN ECM AND ;the resistance more than 3 Repair open circuit 30 to step 6.
REAROXYGENSENSORCONNECTOR. 2? n harness
1)Turn the ignition switch to OFF. Detween ECM and
2)Disconnectthe connectors from ECM and rear oxygen sen-
rear oxygen sensor. sor connector.
3)Measure the resistance of harness between
ECM and rear oxygen sensor connector.
Connector & terminal
(6135) NO. 26 - (B19) NO. 4:
CHECKHARNESSBETWEENREAROXY- 5 the voltage more than 0.2 V I Replace the rear 3epair harness
GEN SENSOR AND ECM CONNECTOR. oxygen sensor. md connector.
1)Turn the ignition switch to OFF. <Ref. to FU(D0HC \IOTE:
2)Disconnect the connector from rear oxygen TURBO)-44, Rear n this case, repai
sensor. Oxygen Sensor.> he following:
3)Turn the ignition switch to ON. 1 Open circuit in
4)Measure voltage between rear oxygen sen- iarness between
sor harness connector and engine ground or ‘ear oxygen sen-
chassis ground. ;or and ECM con-
Connector & terminal lector
(B19) No. 3 (+) - Engine ground (-): 1 Poor contact in
‘ear oxygen sen-
jot‘ connector
1 Poor contact in
X M connector
- CHECK EXHAUST SYSTEM. s there a fault in exhaust sys- Repair or replace 3eplace the rear
Check exhaust system parts. em? faulty parts. ixygen sensor.
NOTE: :Ref. to FU(D0HC
Check the following items. TURBO)-44, Rear
*Loose installation of portions 3xygen Sensor.>
.Damage (crack, hole etc.) of parts
.Looseness and ill fitting of parts between front
oxygen (NF) sensor and rear oxygen sensor

EN(D0HC TURBO)-I49
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Y: DTC PO139 - REAR OXYGEN SENSOR CIRCUIT SLOW RESPONSE -

DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

41N RELAY BATTERY

EN1144

EN(D0HC TURBO)-150
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

1 CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Moni- Inspect DTC Replace the rear
tor or OBD-ll general scan tool PO136 using “List oxygen sensor.
indicate DTC PO136? of Diagnostic Trou- <Ref. to FU(D0HC
ble Code (DTC)”. TURBO)-44, Rear
<Ref. to EN(D0HC Oxygen Sensor.>
TURBO)-80, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
PO1 39.

EN(D0HC TURBO)-151
 m
I
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)
~~ ~

2: DTC PO171 - FUEL TRIM MALFUNCTION ( N F TOO LEAN) -

NOTE:
For the diagnostic procedure, refer to DTC P0172. <Ref. to EN(D0HC TURBO)-153, DTC PO172 - FUEL
TRIM MALFUNCTION (NF TOO RICH) -, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>

EN(D0HC TURBO)-152
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)
~

AA:DTC PO172 - FUEL TRIM MALFUNCTION ( N F TOO RICH) -

DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
Poor driving performance
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.

Step Check Yes No

CHECK EXHAUST SYSTEM. 4re there holes or loose bolts Repair exhaust Go to step 2.
i n exhaust system? system.
! CHECK AIR INTAKE SYSTEM. 4re there holes, loose bolts or Repair air intake Go to step 3.
lisconnection of hose on air system.
ntake system?
I CHECK FUEL PRESSURE. s fuel pressure between 284 Go to step 4. Repair the follow-
Warning: md 314 kPa (2.9 - 3.2 kgl ing items.
+lace “NO FIRE” signs near the working :m2, 41 - 46 psi)? Fuel pressure too
area. high
*Be careful not to spill fuel on the floor. Clogged fuel
1)Release fuel pressure. return line or bent
(1) Disconnect the connector from fuel hose
pump relay. Fuel pressure too
(2) Start the engine and run it until it stalls. low
(3) After the engine stalls, crank it for five Improper fuel
more seconds. pump discharge
(4) Turn the ignition switch to OFF. Clogged fuel
2)Connect the connector to fuel pump relay.
3)Disconnect the fuel delivery hose from fuel
filter, and connect fuel pressure gauge.
4)lnstall the fuel filler cap.
5)Start the engine and idle while gear position
is neutral.
6)Measure the fuel pressure while disconnect-
ing pressure regulator vacuum hose from
intake manifold.
Warning:
Before removing the fuel pressure gauge,
release fuel pressure.
NOTE:
If fuel pressure does not increase, squeeze fue
return hose 2 to 3 times, then measure fue
Dressure aaain.

EN(D0HC TURBO)-I53
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK FUEL PRESSURE. ; fuel pressure between 206 io to step 5. 3epair the follow-
After connecting the pressure regulator vac- nd 235 kPa (2.1 - 2.4 kg/ ng items.
uum hose, measure fuel pressure. n2,30 - 34 psi)? :uel pressuretoa
iigh
Warning:
Before removing the fuel pressure gauge Faulty pressure
release fuel pressure. egulator
Clogged fuel
NOTE:
*If fuel pressure does not increase, squeeze 'eturn line or bent
fuel return hose 2 to 3 times, then measure lose
fuel pressure again. 'uel pressure toc
*If out of specificationas measured at this step, ow
check or replace pressure regulator and pres- 1 Faulty pressure
sure regulator vacuum hose. 'egulator
1 Improper fuel
lump discharge
1 Clogged fuel
supply line
CHECK ENGINE COOLANT TEMPERATURE j temperature greater than io to step 6. 3eplace the
SENSOR. 0°C (140"F)? mgine coolant
1)Start the engine and warm-up completely. emperature sen-
2)Read the data of engine coolant temperature sor. <Ref. to
sensor signal using Subaru Select Monitor or 'U( DOHC
~ B D - Igeneral
I scan tool. rURBO)-29,
Engine Coolant
NOTE:
*Subaru Select Monitor remperature Sen-
For detailed operation procedure, refer to the ;or.>
"READ CURRENT DATA FOR ENGINE. <Ref.
to EN(D0HC TURBO)-38, Subaru Select Mon
itor.>
*OBD-ll general scan tool
For detailed operation procedures, refer to the
OBD-II General Scan Tool Instruction Manual.
CHECK PRESSURE SENSOR. jthe value within the specifi- i o to step 7. Replace the mass
1)Start the engine and warm-up engine until ations? 3ir flow and pres-
coolant temperature is greater than 60°C sure sensor. <Ref
(140°F). to FU(D0HC
2)Place the shift lever in neutral position. TURBO)-34, Mas!
3)Turn the A/C switch to OF!? Air Flow and
4)Turn all accessory switches to OFF. Intake Air Temper
5)Read the data of pressure sensor signal ature Sensor.>
using Subaru Select Monitor or OBD-ll genera
scan tool.
NOTE:
*Subaru Select Monitor
For detailed operation procedure, refer to the
"READ CURRENT DATA FOR ENGINE. <Ref
to EN(D0HC TURBO)-38, Subaru Select Mon
itor.>
*OBD-ll general scan tool
For detailed operation procedure, refer to the
OBD-ll General Scan Tool Instruction Manual.
Specification:
. *Intake manifold absolute pressure
Ignition ON
73.3 - 106.6 kPa (550 -800 mmHg,
21.65 - 31.50 inHg)
Idling
-
24.0 - 41.3 kPa (180 310 mmHg,
7.09 - 12.20 inHg)

EN(D0HC TURBO)-154
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)
~~

Step Check Yes No

CHECK INTAKE AIR TEMPERATURE SEN- s value obtained when ambi- Contact with SOA Check mass air
SOR. ?nttemperature is subtracted (distributor) ser- flow and intake air
1)Start the engine and warm-up engine until rom intake air temperature vice. temperature sen-
coolant temperature is greater than 60°C jreater than -10°C (14°F) and NOTE: sor. <Ref. to
(140°F). ess than 50°C (122”F)? Inspection by DTM FU(D0HC
2)Place the shift lever in neutral position. is required, be- TURBO)-34, Mass
3)Turn the A/C switch to OFF. cause probable Air Flow and
4)Turn all accessory switches to OFF. cause is deteriora- Intake Air Temper-
5)Open the front hood. tion of multiple ature Sensor.>
6)Measure the ambient temperature. parts,
7)Read the data of pressure sensor signal
using Subaru Select Monitor or OBD-ll general
scan tool.
NOTE:
*Subaru Select Monitor
I
For detailed operation procedure, refer to the
“READ CURRENT DATA FOR ENGINE”. <Ref. I
to EN(D0HC TURBO)-38, Subaru Select Mon-
itor.>
*OBD-I1 general scan tool
For detailed operation procedure, refer to the
OBD-I1 General Scan Tool Instruction Manual.

EN(D0HC TURBO)-I55
1
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENG INE (DIAGNOSTICS)

AB:DTC PO181 - FUEL TEMPERATURE SENSOR A CIRCUIT RANGE/PERFOR-

MANCE PROBLEM -
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
I tion Mode.>.
WIRING DIAGRAM:

FUEL TANK

/riiNIOgl
I
FUEL TEMPERATURE

F A: @ ECM
I U

B: @

m m
6 7 8 9 10 11 12

m6 7 8 9 10 11 12

FN11A!

EN(D0HC TURBO)-I 56
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

1 CHECK ANY OTHER DTC ON DISPLAY. >oesthe Subaru Select Moni- Inspect DTC Replace the fuel
or or OBD-ll general scan tool PO182 or PO183 temperature sen-
ndicate DTC PO182 or PO183? using “List of Diag- sor. <Ref. to
nostic Trouble EC(D0HC
Code (DTC)”. TURBO)-9, Fuel
<Ref. to EN(D0HC Temperature Sen-
TURBO)SO, List sor.>
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
PO181.

EN(D0HC TURBO)-157
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

AC:DTC PO182 - FUEL TEMPERATURE SENSOR A CIRCUIT LOW INPUT -

DTC DETECTING CONDITION:
Immediately at fault recognition
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-

-
tion Mode.>.
WIRING DIAGRAM:

FUEL TANK

II
FUEL TEMPERATURE
SENSOR 1

I H

4 5 6

EN1149
I

EN(D0HC TURBO)-158
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check
CHECK CURRENT DATA. s the value greater than 120°C
1)Start the engine. 248"F)? up, the circuit has
2)Read the data of fuel temperature sensor returned to a nor-
signal using Subaru Select Monitor or OBD-ll mal condition at
general scan tool. this time.
NOTE:
*Subaru Select Monitor
For detailed operation procedure, refer to the
"READ CURRENT DATA FOR ENGINE. <Ref.
to EN(D0HC TURBO)-38, Subaru Select Mon-
itor.>
*OBD-ll general scan tool
For detailed operation procedures, refer to the
OBD-ll General Scan Tool Instruction Manual.
CHECK CURRENT DATA. s the value less than -40°C 3eplace the fuel Repair ground
1)Turn the ignition switch to OFF. -4O"F)? emperature sen- short circuit in har-
2)Remove the access hole lid. ;or. <Ref. to ness between fuel
3)Disconnect the connector from fuel pump. X(DOHC pump and ECM
4)Turn the ignition switch to ON. rURBO)-9, Fuel connector.
5)Read the data of fuel temperature sensor remperature Sen-
signal using Subaru Select Monitor or the ;or.>
OBD-ll general scan tool.
N~TE:
*Subaru Select Monitor
For detailed operation procedure, refer to the
"READ CURRENT DATA FOR ENGINE. <Ref.
to EN(D0HC TURBO)-38, Subaru Select Mon-
itor.>
*OBD-ll general scan tool
For detailed operation procedures, refer to the
OBD-ll General Scan Tool Instruction Manual.

EN(D0HC TURBO)-159
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)

AD:DTC PO183 - FUEL TEMPERATURE SENSOR A CIRCUIT HIGH INPUT -

DTC DETECTING CONDITION:
Immediately at fault recognition
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

FUEL TANK
I

I FUEL TEMPERATURE
SENSOR

EN(D0HC TURBO)-I60
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK CURRENT DATA. Is the value less than -40°C \Go to step 2. 3epair poor con-
1)Start the engine. (-40"F)? act.
2)Read the data of fuel temperature sensor 4OTE:
signal using Subaru Select Monitor or OBD-II n this case, repaii
general scan tool. he following:
NOTE: Poor contact in
*Subaru Select Monitor uel pump connec-
For detailed operation procedure, refer to the or
"READ CURRENT DATA FOR ENGINE". <Ref. Poor contact in
to EN(D0HC TURBO)-38, Subaru Select Mom ICM connector
itor.> ' Poor contact in
*OBD-II general scan tool :oupling connec-
For detailed operation procedures, refer to the ors
OBD-ll General Scan Tool Instruction Manual. Poor contact in
oint connector
CHECK HARNESS BETWEEN FUEL TEM- I Is the voltage more than 10 V? I fiepair battery 30 to step 3.
PERATURE SENSOR AND ECM CONNEC- short circuit in har.
TOR. ness between
1)Turnthe ignition switch to OFF. ECM and fuel
2)Remove the access hole lid. pump connector.
3)Disconnect the connector from fuel pump.
4)Measure the voltage between fuel pump
tonnector and chassis ground.
Connector & terminal
(R58) No. 5 (+) - Chassis ground (-):
CHECK HARNESS BETWEEN FUEL TEM- Is the voltage more than 10 V? 30 to step 4.
PERATURE SENSOR AND ECM CONNEC- short circuit in har,
TOR. ness between
1)Turn the ignition switch to ON. ECM and fuel
2)Measure the voltage between fuel pump pump connector.
connector and chassis ground.
Connector & terminal
(R58)No. 5 (+) - Chassis ground (-):
I CHECK HARNESS BETWEEN FUEL TEM- Is the voltage more than 4 V? 3epair harness
PERATURE SENSOR AND ECM CONNEC- ind connector.
TOR. \IOTE:
Measure the voltage between fuel pump con- n this case, repaii
nector and chassis ground. :he following:
Connector & terminal 1 Open circuit in
(R58) No. 5 (+) - Chassis ground (-): iarness between
ECM and fuel
x m p connector
1 Poor contact in

'uel pump connec-

:or
1 Poor contact in
X M connector
1 Poor contact in

:oupling connec-
:ors

EN(D0HC TURBO)-I61
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK HARNESS BETWEEN FUEL TEM- s the resistance less than 5 Replace the fuel Repair harness
PERATURE SENSOR AND ECM CONNEC- 2? temperature sen- and connector.
TOR. sor. <Ref. to NOTE:
1)Turn the ignition switch to OFF. EC(D0HC In this case, repai
2)Measure the resistance of harness between TURBO)-9, Fuel the following:
fuel pump connector and chassis ground. Temperature Sen- Open circuit in
Connector & terminal so r.> harness between
(R58)No. 4 - Chassis ground: ECM and fuel
pump connector
Poor contact in
fuel pump connec-
tor
Poor contact in
ECM connector
Poor contact in
coupling connec-
tors
Poor contact in
joint connector

EN(D0HC TURBO)-162
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

EN(D0HC TURBO)-1 63
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

AE:DTC PO244 - WASTEGATE CONTROL SOLENOID VALVE MALFUNCTION

(HIGH INPUT) -
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
Poor driving performance
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

MAIN RELAY

BATTERY
n

n
5 6

@ ECM

t 71

1 1
WASTE

CONTROL
VALVE
ITE
LENOID
I

EN1150

EN(D0HC TURBO)-I64
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

1 CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Moni- Inspect DTC Replace the
tor or OBD-II general scan tool PO245 or PO246 wastegate control
indicate DTC PO245 or P0246? using “List of Diag- solenoid valve.
nostic Trouble <Ref. to FU(D0HC
Code (DTC)”. TURBO)-41,
<Ref.to EN(D0HC Wastegate Con-
TURBO)-80, List trol Solenoid
of Diagnostic Trou- Valve.>
ble Code (DTC).>
NOTE:
In this case, it is
not necessary tc
inspect DTC
P0244.

EN(D0HC TURBO)-165
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
-
ENGINE (DIAGNOSTICS)

AF:DTC PO245 - WASTEGATE CONTROL SOLENOID VALVE CIRCUIT LOW

INPUT -
DTC DETECTING CONDITION:
Immediately at fault recognition
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

MAIN RELAY

f
l
u & BATTERY
SBF 5
3 c

. @

I
f
WASTEGATE
CONTROL SOLENOID
VALVE
-

EN(D0HC TURBO)-166
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)
- ~~

Step Check Yes No

CHECK OUTPUT SIGNAL FROM ECM. s the voltage more than 10 V? Even if MIL lights 20 to step 2.
1)Turn the ignition switch to ON. JP,the circuit has
2)Measure the voltage between ECM and ,eturnedto a nor-
chassis ground. nal condition at
Connector & terminal his time. Contact
(6137) No, 24 (+) - Chassis ground (-): with SOA (distribu-
or) service.
UOTE:
nspection by DTM
s required, be-
:ause probable
:ause is deteriora-
:ion of multiple
Darts.
CHECK HARNESS BETWEEN WASTEGATE s the resistance less than 10 3epair ground 30 to step 3.
CONTROL SOLENOID VALVE AND ECM 3? short circuit in har-
CONNECTOR. less between
1)Turn the ignition switch to OFF: ECM and waste-
2)Disconnect the connectors from wastegate aate control sole-
control solenoid valve and ECM. ioid valve
3)Measure the resistance of harness between Zonnector.
wastegate control solenoid valve connector
atid engine ground.
Connector & terminal
-
(8127) No, 1 Engine ground:
CHECK HARNESS BETWEEN WASTEGATE s the resistance less than 1 %loto step 4. Repair open circuij
CONTROL SOLENOID VALVE AND ECM n? in harness
CONNECTOR. between ECM and
Measure the resistance of harness between wastegate control
ECM and wastegate control solenoid valve of solenoid valve
harness connector. connector.
Connector & terminal NOTE:
(8137) NO. 24 - (8127) NO. 1: In this case, repai
the following:
Open circuit in
harness between
ECM and waste-
gate control sole-
noid valve
connector
CHECK WASTEGATE CONTROL SOLE- Is the resistance between 30 Go to step 5. Replace the
NOID VALVE. m d 34 R? wastegate control
1)Remove the purge control solenoid valve. solenoid valve.
2)Measure the resistance between purge con- <Ref. to FU(D0HC
trol solenoid valve terminals. TURBO)-41,
Terminals Wastegate Con-
NO. 1 -NO. 2: trol Solenoid
Valve.>
CHECK POWER SUPPLY TO WASTEGATE Is the voltage more than 10 V? Go to step 6. Repair open circui
CONTROL SOLENOID VALVE. in harness
1)Turn the ignition switch to ON. between main
2)Measure the voltage between wastegate relay and waste-
. control solenoid valve and engine ground. gate control sole-
Connector & terminal noid valve
-
(8127) No. 2 (+) Engine ground (-): connector.

EN(D0HC TURBO)-167
I
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

6 CHECK POOR CONTACT. Is there poor contact in waste- Repair poor con- Contact with SOA
Check poor contact in wastegate control sole- gate control solenoid valve tact in wastegate (distributor) ser-
connector? control solenoid vice.
valve connector. NOTE:
Inspection by DTM
is required, be-
cause probable
cause is deteriora-
tion of multiple
parts.

EN(D0HC TURBO)-168
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

EN(D0HC TURBO)-I69
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

AG:DTC PO246 - WASTEGATE CONTROL SOLENOID VALVE CIRCUIT HIGH

INPUT -
DTC DETECTING CONDITION:
Immediately at fault recognition
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

AIN RELAY

. @

&@ ECM

WASTEGATE I
CONTROL SOLENOID
VALVE

EN(D0HC TURBO)-170
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

1 CHECK OUTPUT SIGNAL FROM ECM. Is the voltage more than 10 V? Go to step 3. Go to step 2.
1)Turnthe ignition switch to ON.
2)Measure the voltage between ECM and
chassis ground.
Connector & terminal
(8137) No. 24 (+) - Chassis ground (-):
2 CHECK POOR CONTACT. Is there poor contact in ECM Repair poor con- Replace the ECM.
Check poor contact in ECM connector. connector? tact in ECM con- <Ref. to FU(D0HC
nector. TURBO)-47,
Engine Control
Module.>
3 CHECK HARNESS BETWEEN WASTEGATE Is the voltage more than 10 V? Repair battery Go to step 4.
CONTROL SOLENOID VALVE AND ECM short circuit in har-
CONNECTOR. ness between
1)Turn the ignition switch to OFF. ECM and waste-
2)Disconnect the connector from wastegate gate control sole-
control solenoid valve. noid valve
3)Turn the ignition switch to ON. connector. After
4)Measure the voltage between ECM and repair, replace the
chassis ground. ECM. <Ref. to
Connector & terminal FU(D0HC
(8137) No. 24 (+) - Chassis ground (-): TURBO)-47,
Engine Control
Module.>
4 CHECK WASTEGATE CONTROL SOLE- Is the resistance less than 1 Replace the Go to step 5.
NOlD VALVE. a? wastegate control
1)Turnthe ignition switch to OFF. solenoid valve
2)Measure the resistance between wastegate <Ref. to FU(D0HC
control solenoid valve terminals. TURBO)-41,
Terminals Wastegate Con-
NO. 1 -NO. 2: trol Solenoid
Valve.> and ECM
<Ref. to FU(D0HC
TURBO)-47,
Engine Control
Module.>
5 CHECK POOR CONTACT. Is there poor contact in ECM Repair poor con- Replace the ECM.
Check poor contact in ECM connector. connector? tact in ECM con- <Ref. to FU(D0HC
nector. TURBO)-47,
Engine Control
Module.>

EN(D0HC TURBO)-I71
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE IDIAGNOSTICS)

AH:DTC PO301 - CYLINDER 1 MISFIRE DETECTED -

NOTE:
For the diagnostic procedure, refer to DTC P0304. <Ref. to EN(D0HC TURBO)-173, DTC PO304 - CYLIN-
DER 4 MISFIRE DETECTED -, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>

AI: DTC PO302 - CYLINDER 2 MISFIRE DETECTED -

NOTE:
For the diagnostic procedure, refer to DTC P0304. <Ref. to EN(D0HC TURBO)-173, DTC PO304 - CYLIN-
DER 4 MISFIRE DETECTED -, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>

AJ:DTC PO303 - CYLINDER 3 MISFIRE DETECTED -

NOTE:
For the diagnostic procedure, refer to DTC P0304. <Ref. to EN(D0HC TURBO)-173, DTC PO304 - CYLIN-
DER 4 MISFIRE DETECTED -, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>

EN(D0HC TURBO)-172
 -
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE [DIAGNOSTICS)

AK:DTC PO304 - CYLINDER 4 MISFIRE DETECTED -

DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
Immediately at fault recognition (A misfire which could damage catalyst occurs.)
TROUBLE SYMPTOM:
Engine stalls.
Erroneous idling
Rough driving
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.

EN(D0HC TURBO)-173
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

WIRING DIAGRAM:

MAIN RELAY

SBF-5
3 c

FUEL INJECTORS
M

EN1142

EN(D0HC TURBO)-174
 Step Check Yes No
Does the Subaru Select Moni- Inspect DTC Go to step 2.
CHECK ANY OTHER DTC ON DISPLAY.
tor or OBD-II general scan tool P0106, P0107,
indicate DTC P0106, P0107, P0108, P0117,
PO108, PO117, PO118 or PO118 or PO125
PO125? using “List of Diag.
nostic Trouble
Code (DTC)”.
<Ref. to EN(D0HC
TURBO)-80, List
of Diagnostic Trou,
ble Code (DTC).>
NOTE:
In this case, it i!
not necessary c t
inspect DT(
P0301, PO302
PO303 and PO304
Is the voltage more than 10 V? Go to step 7. ;o to step 3.
CHECK OUTPUT SIGNAL FROM ECM.
1)Turn the ignition switch to ON.
2)Measure the voltage between ECM connec-
tor and chassis ground on faulty cylinders.
Connector & terminal
#1 (6137) No. 1 (+) - Chassis
ground (-):
#2 (6136) No,6 (+) - Chassis
ground (-):
#3 (8136) No. 5 (+) - Chassis
ground (-):
#4 (6136) No. 4 (+) - Chassis
I .,
around (-1:
3epair ground 30 to step 4.
CHECK HARNESS BETWEEN FUEL INJEC- Is the resistance less than 10
TOR AND ECM CONNECTOR. R? ;hort circuit in ha1
less between fue
1)Turn the ignition switch to OFF.
njector and ECM
2)Disconnect the connector from fuel injector
:onnector.
on faulty cylinders.
3)Disconnect the connector from ECM.
4)Measure the voltage between ECM connec-
tor and engine ground on faulty cylinders.
Connector & terminal
-
#1 (€5) No. 1 (+) Engine ground (-):
#2 (€16) No. 1 (+) - Engine ground (-):
#3 (E6) No. 1 (+) - Engine ground (-):
#4 (El 7) No. 1 (+) - Engine ground (-):
Is the resistance less than 1 Go to step 5. Repair harness
I CHECK HARNESS BETWEEN FUEL INJEC-
Q? and connector.
TOR AND ECM CONNECTOR.
Measure the resistance of harness connector NOTE:
In this case, rep?
between ECM connector and fuel injector on
the following:
faulty cylinders.
Open circuit in
Connector & terminal
harness between
#1 (6137) NO. 1 -(E5) NO. 1:
ECM and fuel
#2 (8136) NO. 6 - (E16) NO. 1:
injector connect0
#3 (8136) NO. 5 - (E6) NO. 1:
Poor contact in
#4 (6136) NO. 4 - (E17) NO. 1:
coupling connect
Is the resistance between 5 Go to step 6. Replace the faulty
5 CHECK FUEL INJECTOR. fuel injector. <Ref.
Measure the resistance between fuel injector and 20 R?
to FU(D0HC
terminals on faulty cylinder.
TURBO)-37, Fuel
Terminals
Injector.>
NO. 1 - NO. 2: 1

EN(D0HC TURBO)-175
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

I CHECK POWER SUPPLY LINE. Is the voltage more than 10 V? 3epair poor con- Repair harness
1)Turnthe ignition switch to ON. act in all connec- and connector.
ors in fuel injector NOTE:
:ircuit. In this case, repa
the following:
Open circuit in
harness between
main relay and fue
injector connector
on faulty cylinders
Poor contact in
coupling connectc
Poor contact in
main relay connec
tor
Poor contact in
fuel injector con-
nector on faulty
cylinders
CHECK HARNESS BETWEEN FUEL INJEC- Is the voltage more than 10 V? 3epair battery Go to step 8.
TOR AND ECM CONNECTOR. ;hort circuit in har-
1)Turn the ignition switch to OFF. less between
2)Disconnect the connector from fuel injector ICM and fuel
on faulty cylinder. njector. After
3)Turn the ignition switch to ON. epair, replace the
4)Measure the voltage between ECM connec- ICM. <Ref. to
tor and chassis ground on faulty cylinders. W(D0HC
Connector & terminal rURBO)-47,
#1 (8137) No. 1 (+) - Chassis Ingine Control
groundI)-( vlodu1e.B
#2 (8136) No. 6 (+) - Chassis
ground (-):
#3 (8136) No. 5 (+) - Chassis
ground (-):
#4 (8136) NO. 4 (+) - Chassis
ground (-):
I CHECK FUEL INJECTOR. 3eplace the faulty Go to step 9.
Is the resistance less than 1
1)Turn the ignition switch to OFF. R? uel injector <Ref.
2)Measure the resistance between fuel injector o FU(D0HC
terminals on faulty cylinder. rURBO)-37, Fuel
Terminals njector.> and
NO. 1 -NO. 2: ICM <Ref. to
W(D0HC
rURBO)-47,
Ingine Control
vlodule.>
1 CHECK INSTALLATION OF CAMSHAFT PO- Is the camshaft position sensor righten camshaft Go to step 10.
SlTlON SENSOWCRANKSHAFTPOSITION or crankshaft position sensor iosition sensor or
SENSOR. loosely installed? :rankshaft posi-
ion sensor.
10 CHECK CRANKSHAFT SPROCKET. Is the crankshaft sprocket 3eplace the crank- Go to step 11.
Remove the timing belt cover. rusted or does it have broken ;haft sprocket.
teeth? :Ref. to
vlE(D0HC
rURBO)-58,
;rankshaft
Sprocket.>

EN(D0HC TURBO)-I76
 m
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)
~

Step Check Yes No

1 CHECK INSTALLATION CONDITION OF 5 the timing belt dislocated Repair installation 30 to step 12.
TIMING BELT. rom its proper position? condition of timing
Turn the crankshaft using ST, and align align- belt. <Ref. to
ment mark on crankshaft sprocket with align- ME(D0HC
ment mark on cylinder block. TURBO)-48, Tim-
ST 499987500 CRANKSHAFT SOCKET ing Belt Assem-
bly.>
2 CHECK FUEL LEVEL. s the fuel meter indication Go to step 13. Replenish fuel so
bigher than the “Lower” level? bel meter indica-
tion is higher than
the “Lower” level.
After replenishing
fuel, Go to step 13
3 CHECK STATUS OF CHECK ENGINE MAL- s the MIL coming on or blink- Go to step 15. So to step 14.
FUNCTION INDICATOR LAMP (MIL). ng?
1)Clear the memory using Subaru Select Mon-
itor.
<Ref. to EN(D0HC TURBO)-49, Clear Mem-
ory Mode.>
2)Start the engine, and drive the vehicle more
than 10 minutes.
4 CHECK CAUSE OF MISFIRE DIAGNOSED. Mas the cause of misfire diag- Finish diagnostics Repair poor con-
iosed when the engine is run- operation, if the tact.
ling? engine has no NOTE:
abnormality. In this case, repai
NOTE: the following:
Ex. Remove the Poor contact in
spark plug cord, ignitor connector
etc. Poor contact in
ignition coil con-
nector
Poor contact in
fuel injector con-
nector on faulty
cylinders
Poor contact in
ECM connector
Poor contact in
coupling connectc
5 CHECK AIR INTAKE SYSTEM. s there a fault in air intake sys Repair air intake Go to step 16.
em? system.
NOTE:
Check the follow.
ing items:
Are there air
leaks or air suction
caused by loose or
dislocated nuts
and bolts?
Are there cracks
or any disconnec-
tion of hoses?

EN(D0HC TURBO)-177
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

6 CHECK MISFIRE SYMPTOM. 30 to step 17.
1)Turn the ignition switch to ON. tor or OBD-ll general scan tool
2)Read the diagnostic trouble code (DTC). indicate only one DTC?
*Subaru Select Monitor
<Ref. to EN(D0HC TURBO)-38, Subaru
Select Monitor.>
*OBD-II general scan tool
For detailed operation procedures, refer to the
OBD-ll General Scan Tool Operation Manual.
NOTE:
Perform diagnosis according to the items listec
below.
7 CHECK DIAGNOSTIC TROUBLE CODE Does the Subaru Select Moni- Go to step 22. 30 to step 18.
(DTC) ON DISPLAY. tor or OBD-ll general scan tool
indicate DTC PO301 and
P0302?
8 CHECK DIAGNOSTIC TROUBLE CODE Does the Subaru Select Moni- Go to step 23. 30 to step 19.
(DTC) ON DISPLAY. tor or OBD-II general scan tool
indicate DTC PO303 and
P0304?
9 CHECK DIAGNOSTIC TROUBLE CODE Does the Subaru Select Moni- Go to step 24. 20 to step 20.
(DTC) ON DISPLAY. tor or OBD-ll general scan tool
indicate DTC PO301 and
P0303?
0 CHECK DIAGNOSTIC TROUBLE CODE Does the Subaru Select Moni- Go to step 25. 30 to step 26.
(DTC) ON DISPLAY. tor or OBD-I1 general scan tool
indicate DTC PO302 and
P0304?
1 ONLY ONE CYLINDER Is there a fault in that cylinder? Repair or replace 30 to DTC PO171
faulty parts. md P0172. <Ref.
NOTE: o EN(D0HC
Check the follow- rURBO)-152,
ing items. ITC PO171 -
Spark plug 'UEL TRIM MAL-
Spark plug cord UNCTION (NF
Fuel injector '00 LEAN) -,
Compression Iiagnostic Proce-
ratio lure with Diagnos
ic Trouble Code
DTC).>

EN(D0HC TURBO)-178
 a
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

!2 GROUP OF #1 AND #2 CYLINDERS 4re there faults in #1 and #2 Repair or replace Go to DTC PO171
:ylinders? faulty parts. and P0172. <Ref.
NOTE: to EN(D0HC
Check the fol- TURBO)-152,
lowing items. DTC PO171 -
Spark plugs FUEL TRIM MAL-
Fuel injectors FUNCTION ( N F
Ignition coil TOO LEAN) -,
Compres- Diagnostic Proce-
sion ratio dure with Diagnos-
If no abnormal is tic Trouble Code
discovered, check (DTC).>
for “IGNITION
CONTROL SYS-
TEM” of #1 and #2
cylinders side.
<Ref. to EN(D0HC
TURBO)-72, IGNI-
TION CONTROL
SYSTEM, Diag-
nostics for Engine
Starting Failure.>
23 GROUP OF #3 AND #4 CYLINDERS Ire there faults in #3 and #4 Repair or replace Go to DTC PO171
:ylinders? faulty parts. and P0172. <Ref.
NOTE: to EN(D0HC
Check the fol- TURBO)-152,
lowing items. DTC PO171 -
Spark plugs FUEL TRIM MAL-
Fuel injectors FUNCTION (NF
Ignition coil TOO LEAN) -,
If no abnormal is Diagnostic Proce-
discovered, check dure with Diagnos-
for “IGNITION tic Trouble Code
CONTROL SYS- (DTC).>
TEM” of #3 and #4
cylinders side.
<Ref. to EN(D0HC
TURBO)-72, IGNI-
TION CONTROL
SYSTEM, Diag-
nostics for Engine
Starting Failure.>
24 GROUP OF #1 AND #3 CYLINDERS 4re there faults in #1 and #3 Repair or replace Go to DTC PO171
:ylinders? faulty parts. and PO172. <Ref.
NOTE: to EN(D0HC
Check the follow- TURBO)-152,
ing items. DTC PO171 -
Spark plugs FUEL TRIM MAL-
Fuel injectors FUNCTION ( N F
Skipping timing TOO LEAN) -,
belt teeth Diagnostic Proce-
dure with Diagnos
tic Trouble Code
(DTCb

EN(D0HC TURBO)-I79
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

!5 GROUP OF #2 AND #4 CYLINDERS Are there faults in #2 and #4 Repair or replace Go to DTC PO171
cylinders? faulty parts. and P0172. <Ref.
NOTE: to EN(D0HC
Check the follow- TURBO)-152,
ing items. DTC PO171 -
Spark plugs FUEL TRIM MAL-
Fuel injectors FUNCTION ( N F
Compression TOO LEAN) -,
ratio Diagnostic Proce-
Skipping timing dure with Diagnos-
belt teeth tic Trouble Code
(DTC).>
!6 CYLINDER AT RANDOM Is the engine idle rough? Go to DTC PO171 Repair or replace
and P0172. <Ref. faulty parts.
to EN(D0HC NOTE:
TURBO)-152, Check the follow.
DTC PO171 - ing items.
FUEL TRIM MAL- Spark plugs
FUNCTION ( N F Fuel injectors
TOO LEAN) -, Compression
Diagnostic Proce- ratio
dure with Diagnos-
tic Trouble Code
(DTC).>

EN(D0HC TURBO)-I80
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

EN(D0HC TURBO)-181
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGlNE (DIAGNOSTICS)

AL:DTC PO327 - KNOCK SENSOR CIRCUIT LOW INPUT -

DTC DETECTING CONDITION:
Immediately at fault recognition
TROUBLE SYMPTOM:
Poor driving performance
Knocking occurs.
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

KNOCK
SENSOR

,I,I-
c -1
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
t

I
L:
I
-
4
I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I
t

h @ECM

EN0975

EN(D0HC TURBO)-182
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)
~ ~~

Step Check Yes No

CHECK HARNESS BETWEEN KNOCK SEN- s the resistance more than 20 to step 2. Repair harness
SOR AND ECM CONNECTOR. 700 kR? and connector.
1)Turn the ignition switch to OFF. NOTE:
2)Disconnect the connector from ECM. In this case, repaii
3)Measure the resistance between ECM har- the following:
ness connector and chassis ground. Open circuit in
Connector & terminal harness between
(8135) No. 4 - Chassis ground: knock sensor and
ECM connector
Poor contact in
knock sensor con-
nector
Poor contact in
coupling connectoi
! CHECK KNOCK SENSOR. s the resistance more than 30 to step 3. Repair harness
1)Disconnectthe connector from knock sensor 700 kR? and connector.
2)Measure the resistance between knock sen- NOTE:
sor connector terminal and engine ground. In this case, repai
Terminal the following:
No. 2 - €ngine ground: Open circuit in
harness between
knock sensor and
ECM connector
Poor contact in
knock sensor con-
nector
Poor contact in
coupling connect0
I CHECK CONDITION OF KNOCK SENSOR Is the knock sensor installation 3eplace the knock Tighten knock sen
INSTALLATION. solt tightened securely? sensor. <Ref. to sor installation bolt
W(D0HC securely.
TURBO)-32,
h o c k Sensor.>

EN(D0HC TURBO)-I83
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)
~ ~~

AM:DTC PO328 - KNOCK SENSOR CIRCUIT HIGH INPUT -

DTC DETECTING CONDITION:
Immediately at fault recognition
TROUBLE SYMPTOM:
Poor driving performance
Knocking occurs.
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

KNOCK
SENSOR

I@
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I

I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I
I
i
@ECM

EN0975

EN(D0HC TURBO)-184
I
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check
CHECK HARNESS BETWEEN KNOCK SEN- Is the resistance less than 400
SOR AND ECM CONNECTOR. kR?
Measure the resistance of harness between
ECM connector and chassis ground.
Connector & terminal
(8135) No. 4 - Chassis ground:
! CHECK KNOCK SENSOR. Is the resistance less than 400 Replace the knock Repair ground
1)Disconnectthe connector from knock sensor. kR? sensor. <Ref. to short circuit in har
FU(D0HC ness between
TURBO)-32, knock sensor con-
Knock Sensor.> nector and ECM
connector.
NOTE:
The harness be
tween both con
nectors i!
shielded. Repai
short circuit of har
ness together witt
shield.
I CHECK INPUT SIGNAL FOR ECM. s the voltage more than 2 V? Even if MIL lights Repair poor con-
1)Connect the connectors to ECM and knock up, the circuit has tact in ECM con-
sensor. returned to a nor- nector.
2)Turn the ignition switch to ON.
3)Measure the voltage between ECM and
chassis ground.
Connector & terminal
(6135) No. 4 (+) - Chassis ground (-):

EN(D0HC TURBO)-185
I
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

AN:DTC PO335 - CRANKSHAFT POSITION SENSOR CIRCUIT MALFUNCTION

-
DTC DETECTING CONDITION:
immediately at fault recognition
TROUBLE SYMPTOM:
Engine stalls.
Failure of engine to start
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

n
CRANKSHAFT

E
POSITION
SENSOR

c
I
I
I
I
I
I
I
I
t

I
F
I
I
I
I
I
I
t

IC

0@ECM

EN097f

EN(D0HC TURBO)-186
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK HARNESS BETWEEN CRANK- s the resistance more than Repair harness 30 to step 2.
SHAFT POSITION SENSOR AND ECM CON- 100 kR? and connector.
NECTOR. NOTE:
1)Turn the ignition switch to OFF. In this case, repaii
2)Disconnect the connector from crankshaft the following:
position sensor. Open circuit in
3)Measure the resistance of harness between harness between
crankshaft position sensor connector and crankshaft posi-
engine ground. tion sensor and
Connector & terminal ECM connector
(E10) No. 1 - Engine ground: Poor contact in
ECM connector
Poor contact in
coupling connectoi
CHECK HARNESS BETWEEN CRANK- s the resistance less than 10 Repair ground 30 to step 3.
SHAFT POSITION SENSOR AND ECM CON- 2? short circuit in har-
NECTOR. ness between
Measure the resistance of harness between crankshaft posi-
crankshaft position sensor connector and tion sensor and
engine ground. ECM connector.
Connector & terminal NOTE:
(€10) No. 1 - Engine ground: The harness be-
tween both con-
nectors are
shielded. Repaii
ground short circuii
in harness togeth-
er with shield.
CHECK HARNESS BETWEEN CRANK- s the resistance less than 5 Go to step 4. 3epair harness
SHAFT POSITION SENSOR AND ECM CON- 2? 2nd connector.
NECTOR. IOTE:
Measure the resistance of harness between n this case, repaii
crankshaft position sensor connector and he following:
engine ground. I Open circuit in
Connector & terminal iarness between
(E10) No. 2 - Engine ground: :rankshaft posi-
ion sensor and
ICM connector
1 Poor contact in
ECM connector
1 Poor contact in
:oupling connectoi
CHECK CONDITION OF CRANKSHAFT PO- s the crankshaft position sen- Go to step 5. righten the crank-
SITION SENSOR. ;or installation bolt tightened ;haft position sen-
securely? ;or installation bolt
securely.
I CHECK CRANKSHAFT POSITION SENSOR. 3eplace the crank.
1)Remove the crankshaft position sensor. 2nd 4 kR? tact in crankshaft ;haft position sen-
2)Measure the resistance between connector position sensor ;or. <Ref. to
terminals of crankshaft position sensor. connector. U(D0HC
Terminals rURBO)-30,
NO. 1 -NO. 2: 2 rankshaft Posi-
I ion Sensor.>

EN(D0HC TURBO)-187
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

A0:DTC PO336 - CRANKSHAFT POSITION SENSOR CIRCUIT RANGE/PER-

FORMANCE PROBLEM -
DTC DETECTING CONDITION:
Immediately at fault recognition
TROUBLE SYMPTOM:
Engine stalls.
Failure of engine to start
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

CRANKSHAFT
POSITION
SENSOR

I
I I
EN097(

EN(D0HC TURBO)-I88
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Moni- Inspect DTC Go to step 2.
tor or OBD-ll general scan tool PO335 using “List
indicate DTC P0335? of Diagnostic Trou-
ble Code (DTC)”.
<Ref.to EN(D0HC
TURBO)-80, List
of Diagnostic Trou-
ble Code (DTC).>
I
CHECK CONDITION OF CRANKSHAFT PO- Is the crankshaft position sen- Go to step 3. Tighten crank-
SITION SENSOR. sor installation bolt tightened shaft position sen-
Turn the ignition switch to OFF. securely? sor installation bolt
securely.
I CHECK CRANKSHAFT SPROCKET. Are crankshaft sprocket teeth Replace the crank- Go to step 4.
Remove the front belt cover. cracked or damaged? shaft sprocket.
<Ref. to FU(D0HC
TURBO)-30,
Crankshaft Posi-
tion Sensor.>
I CHECK INSTALLATION CONDITION OF Is the timing belt dislocated Repair installation Replace the crank-
TIMING BELT. from its proper position? condition of timing shaft position sen-
Turn the crankshaft using ST, and align align- belt. <Ref. to sor. <Ref. to
ment mark on crankshaft sprocket with align- ME(D0HC FU(D0HC
ment mark on cylinder block. TURBO)-48, Tim- TURBO)-30,
ST 499987500 CRANKSHAFT SOCKET ing Belt Assem- Crankshaft Posi-
bly.> tion Sensor.>

EN(D0HC TURBO)-189
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)

AP:DTC PO340 - CAMSHAFT POSITION SENSOR CIRCUIT MALFUNCTION -

DTC DETECTING CONDITION:
Immediately at fault recognition
TROUBLE SYMPTOM:
Engine stalls.
Failure of engine to start
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

nCAMSHAFT
POSITION

tr
SENSOR

j@
F I
I I
I I
I I
I I
I I
I I
I I
I I
t

1
I
F I
I
I I
I I
I I

\
I I
I I
t

F
U@ECM

EN097

EN(D0HC TURBO)-190
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK HARNESS BETWEEN CAMSHAFT ;the resistance more than Repair harness Go to step 2.
POSITION SENSOR AND ECM CONNEC- 00 kR? and connector.
TOR. NOTE:
1)Turn the ignition switch to OFF. In this case, repair
2)Disconnect the connector from camshaft the following:
position sensor. * Open circuit in
3)Measure the resistance of harness between harness between
camshaft position sensor connector and camshaft position
engine ground. sensor and ECM
Connector & terminal connector
(€15) No. 1 - Engine ground: * Poor contact in
ECM connector
Poor contact in
coupling connector
! CHECK HARNESS BETWEEN CAMSHAFT s the resistance less than 10 Repair ground Go to step 3.
POSITION SENSOR AND ECM CONNEC- L?
TOR.
Measure the resistance of harness between
camshaft position sensor connector and
engine ground.
Connector & terminal
(E15) No. 1 - Engine ground:

I CHECK HARNESS BETWEEN CAMSHAFT s the resistance less than 5 Go to step 4. Repair harness
POSITION SENSOR AND ECM CONNEC- 2? and connector.
TOR. NOTE:
Measure the resistance of harness between In this case, repai
camshaft position sensor connector and the following:
engine ground. Open circuit in
Connector & terminal harness between
(E15) No. 2 - Engine ground: camshaft position
sensor and ECM
connector
Poor contact in
ECM connector
Poor contact in
coupling connect0
1 CHECK CONDITION OF CAMSHAFT POSI- s the camshaft position sensor Go to step 5. Tighten camshaft
TION SENSOR. nstallation bolt tightened position sensor
jecurely? installation bolt
securely.
5 CHECK CAMSHAFT POSITION SENSOR. s the resistance between 1 Repair poor con- Replace the cam-
1)Remove the camshaft position sensor. md 4 kR? tact in camshaft shaft position sen.
2)Measure the resistance between connector position sensor sor. <Ref. to
terminals of camshaft position sensor. connector. FU(D0HC
Terminals TURBO)-31, Cam
NO. 1 - NO. 2: shaft Position Sen
sor.>

EN(D0HC TURBO)-191
 a
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)

AQ:DTC PO341 - CAMSHAFT POSITION SENSOR CIRCUIT RANGE/PERFOR-

MANCE PROBLEM -
DTC DETECTING CONDITION:
Immediately at fault recognition
TROUBLE SYMPTOM:
Engine stalls.
Failure of engine to start
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

CAMSHAFT
POSITION
SENSOR

h
E
I
I
I
I
I
I
I
I
t

1
F
I
I
I
I
I
I
t

IC

I@ECM

ENO97;

EN(D0HC TURBO)-I92
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE ID1AGNOSTICS)

Step Check Yes No

CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Moni- Inspect DTC Go to step 2.
tor or OBD-I1 general scan tool PO340 using “List
indicate DTC P0340? of Diagnostic Trou-
ble Code (DTC)”.
<Ref. to EN(D0HC
TURBO)-80, List
of Diagnostic Trou-
ble Code (DTC).>
CHECK HARNESS BETWEEN CAMSHAFT 1 Is the resistance more than Repair harness Go to step 3.
POSITION SENSOR AND ECM CONNEC- 100 kR? and connector.
TOR. NOTE:
1)Turnthe ignition switch to OFF. In this case, repair
2)Disconnect the connector from camshaft the following:
position sensor. Open circuit in
3)Measure the resistance of harness between harness between

+
camshaft position sensor connector and camshaft position
engine ground. sensor and ECM
Connector & terminal connector
(€15) No. 1 - Engine ground: Poor contact in
ECM connector
Poor contact in
coupling connector
I CHECK HARNESS BETWEEN CAMSHAFT Is the resistance less than 10 Repair ground Go to step 4.
POSITION SENSOR AND ECM CONNEC- short circuit in har-
TOR. ness between
Measure the resistance of harness between camshaft position
camshaft position sensor connector and sensor and ECM
engine ground. connector.
Connector & terminal NOTE:
(€75) No, 1 - Engine ground: I The harness be-
tween both con-
nectors are
shielded. Repair
ground short circuit
in harness togeth-
er with shield.
I CHECK HARNESS BETWEEN CAMSHAFT Is the resistance less than 5 Go to step 5. Repair harness
POSITION SENSOR AND ECM CONNEC- Q? and connector.
NOTE:
In this case, repai
the following:
Open circuit in
harness between
camshaft position
sensor and ECM
connector
Poor contact in
ECM connector
Poor contact in
coupling
. - connect0

securely? installation bolt

securely.

EN(D0HC TURBO)-I93
i DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK CAMSHAFT POSITION SENSOR. Is the resistance between 1 Go to step 7. Replace the cam-
1)Remove the camshaft position sensor. and 4 kR? shaft position sen-
2)Measure the resistance between connector sor. <Ref. to
terminals of camshaft position sensor. FU(D0HC
Terminals TURBO)-31, Cam-
NO. 1 -NO. 2: shaft Position Sen-
sor.>
CHECK CONDITION OF CAMSHAFT POSI- Is the camshaft position sensor Go to step 8. Tighten camshaft
TlON SENSOR. installation bolt tightened position sensor
Turn the ignition switch to OFF. securely? installation bolt
securely.
CHECK CAMSHAFT SPROCKET. Are camshaft sprocket teeth Replace the cam- Go to step 9.
Remove the front belt cover. <Ref. to cracked or damaged? shaft sprocket.
ME(S0HC)-46, Belt Cover.> <Ref. to
ME(D0HC
TURBO)-57, Cam-
shaft Sprocket.>
CHECK INSTALLATION CONDITION OF Is the timing belt dislocated Repair installation Replace the cam-
TIMING BELT. from its proper position? condition of timing shaft position sen-
Turn the camshaft using ST, and align align- belt. <Ref. to sor. <Ref. to
ment mark on camshaft sprocket with align- ME(D0HC FU(D0HC
ment mark on timing belt cover LH. TURBO)-48, Tim- TURBO)-31, Cam-
ST 499207100 CAMSHAFT SPROCKET ing Belt Assem- shaft Position Sen-
WRENCH bly.> sor.>

EN(D0HC TURBO)-I 94
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

EN(D0HC TURBO)-I95
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

AR:DTC PO420 - CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD -

DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
TROUBLE SYMPTOM:
Engine stalls.
Idle mixture is out of specifications.
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

I T

43

F
1
0 :o0
8: 8135 C 8136 D: 8137 ECM
I

EN1151

EN(D0HC TURBO)-I96
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

1 CHECK ANY OTHER DTC ON DISPLAY. )oes the Subaru Select Moni- nspect the rele- 20 to step 2.
i r or OBD-ll general scan tool rant DTC using
idicate DTC P0031, P0032, List of Diagnostic
'0131, P0132, P0133, P1130, rrouble Code
'1 131, P1134, P1139, P0037, DTC)". <Ref. to
'0038, PO136 and PO139? EN(D0HC
rURBO)-80, List
If Diagnostic Trou-
)le Code (DTC).>
\IOTE:
n this case, it is
lot necessary to
nspect DTC
'0420.
2 CHECK EXHAUST SYSTEM. s there a fault in exhaust sys- 3epair or replace ;o to step 3.
Check for gas leaks or air suction caused by em? he exhaust sys-
loose or dislocated nuts and bolts, and open em. <Ref. to
hole at exhaust pipes. IX(D0HC
NOTE: rURBO)-2, Gen-
Check the following positions. ?ral Description.>
*Between cylinder head and front exhaust pipe
*Between front exhaust pipe and front catalytic
converter
*Between front catalytic converter and rear cat-
alytic converter
3 CHECK REAR CATALYTIC CONVERTER. s there damage at rear face of 3eplace the front o
; to step 4.
Separate rear catalytic converter from rear ear catalyst? :atalytic converter
<Ref.to EC(D0HC
TURBO)-3, Front
Satalytic Con-
terter.> and rear
:atalytic converter
<Ref.to EC(D0HC
TURBO)-4, Rear
Catalytic Con-
werter.>
4 CHECK FRONT CATALYTIC CONVERTER. s there damage at rear face or Replace the front Contact with SOA
Remove the front catalytic converter. ront face of front catalyst? catalytic con- (distributor) ser-
verter. <Ref. to vice.
EC(D0HC NOTE:
TURBO)-3, Front Inspection by DTL
Catalytic Con- is required, be
ve rter.z cause probabl,
cause is deteriora
tion of multipl'
parts.

EN(D0HC TURBO)-197
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
a
ENGINE (DIAGNOSTICS)

EN(D0HC TURBO)-I98
 ls
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

AS:DTC PO442 - EVAPORATIVE EMISSION CONTROL SYSTEM MALFUNC-

TION -
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
TROUBLE SYMPTOM:
Gasoline smell
There is a hole of more than 1 .O mm (0.04 in) dia. in evaporation system or fuel tank.
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49,Operation.> OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-
46, Inspection Mode.>.

EN(D0HC TURBO)-I 99
I
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

WIRING DIAGRAM:

-
- - -
-

Ln

A
00
E134 B B137 ENGINECONTROLMODULE

m
6 7 8 9 10 11 12

EN1152

EN(D0HC TURBO)-200
 m
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK ANY OTHER DTC ON DISPLAY. IS there any other DTC on dis- nspect the rele- 30 to step 2.
,lay? /ant DTC using
‘List of Diagnostic
rrouble Code
DTC)”. <Ref. to
IN(D0HC
rURBO)-80, List
i f Diagnostic Trou.
ile Code (DTC).>
CHECK FUEL FILLER CAP. Is the fuel filler cap tightened 30 to step 3. Tighten fuel filler
1)Turn the ignition switch to OFF. 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.
CHECK FUEL FILLER PIPE PACKING. Is there any damage to the 3epair or replace Go to step 4.
seal between fuel filler cap and he fuel filler cap
fuel filler pipe? m d fuel filler pipe.
:Ref. to FU(D0HC
TURBO)-55, Fuel
-.
-iller Pipe.>
CHECK DRAIN VALVE. Does the drain valve produce 30 to step 5. Replace the drain
1)Connect the test mode connector. operating sound? valve. <Ref. to
2)Turn the ignition switch to ON. EC(D0HC
3)Operate the drain valve. TURBO)-17, Drair
NOTE: Valve.>
Drain valve operation can also be executed us-
ing Subaru Select Monitor. For the procedure.
refer to “Compulsory Valve Operation Check
Mode”. <Ref. to EN(D0HC TURBO)-50, Com-
pulsory Valve Operation Check Mode.>
CHECK PURGE CONTROL SOLENOID Does the purge control sole- So to step 6. Replace the purge
VALVE. noid valve produce operating control solenoid
Operate the purge control solenoid valve. sound? valve. <Ref. to
NOTE: EC(D0HC
Purge control solenoid valve operation can alsc TURBO)-7, Purge
be executed using Subaru Select Monitor. Foi Control Solenoid
the procedure, refer to “Compulsory Valve Op. Valve.>
eration Check Mode”. <Ref. to EN(D0HC TUR-
BO)-50, Compulsory Valve Operation Check
Mode.>
CHECK PRESSURE CONTROL SOLENOID Does the pressure control Go to step 7. Replace the pres-
VALVE. solenoid valve produce operat- sure control sole-
Operate the pressure control solenoid valve. ing sound? noid valve. <Ref.
NOTE: to EC(D0HC
Pressure control solenoid valve operation car TURBO)-I2, Pres
also be executed using Subaru Select Monitor sure Control Sole-
For the procedure, refer to “Compulsory Valve noid Valve.>
Operation Check Mode”. <Ref. to EN(D0HC
TURBO)-50, Compulsory Valve Operatior
Check Mode.>
CHECK EVAPORATIVE EMISSION CON- IS there a hole of more than 1.O Repair or replace Go to step 8.
TROL SYSTEM LINE. mm (0.04 in) dia. on fuel line? the fuel line. <Ref.
Turn the ignition switch to OFF. to FU(D0HC
TURBO)-68, Fuel
Delivery, Return
and Evaporation
Lines.>

EN(DOHC TU R BO)-201
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

8 CHECK CANISTER. Is the canister damaged or is
Repair or replace Go to step 9.
there a hole of more than 1.O
the canister. <Ref.
mm (0.04 in) dia. in it? to EC(D0HC
TURBO)B, Canis-
ter.>
9 CHECK FUEL TANK. Is the fuel tank damaged or is Repair or replace Go to step 10.
Remove the fuel tank. <Ref. to FU(D0HC there a hole of more than 1.O the fuel tank. <Ref.
TURBO)-52, Fuel Tank.> mm (0.04 in) dia. in it? to FU(D0HC
TURBO)-52, Fuel
Tank.>
10 CHECK ANY OTHER MECHANICAL TROU- Are there holes of more than Repair or replace Contact with SOA
BLE IN EVAPORATIVE EMISSION CON- 1.O mm (0.04 in) dia., cracks, the hoses or pipes. (distributor) ser-
TROL SYSTEM. clogging or disconnections of vice.
hoses or pipes in evaporative NOTE:
emission control system? Inspection by DTN
is required, be.
cause probable
cause is deteriora-
tion of multiple
parts.

EN(D0HC TURBO)-202
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

EN(D0HC TURBO)-203
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

AT:DTC PO444 - EVAPORATIVE EMISSION CONTROL SYSTEM PURGE CON-

TROL VALVE CIRCUIT LOW INPUT -
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

41N RELAY

SBF-5
BATTERY

3 c
" 5 6

U
PURGE CONTROL
SOLENOID VALVE
EN1 153

EN(DOHC TURB0)-204
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGI NE (DIAG NOSTlCS)

Step Check Yes No

CHECK OUTPUT SIGNAL FROM ECM. 5 the voltage more than 10 V? Even if MIL lights So to step 2.
1)Turn the ignition switch to ON. up, the circuit has
2)Measure the voltage between ECM and returned to a nor-
chassis ground. mal condition at
Connector & terminal this time. Contact
(B 137) No. 16 (+) - Chassis ground (-): with SOA (distribu-
tor) service.
NOTE:
Inspection by DTW
is required, be.
cause probable
cause is deteriora,
tion of multiple
parts.
! CHECK HARNESS BETWEEN PURGE CON. s the resistance less than 10 Repair ground 20 to step 3.
TROL SOLENOID VALVE AND ECM CON- 2? short circuit in har-
NECTOR. ness between
1)Turn the ignition switch to OFF. ECM and purge
2)Disconnect the connectors from purge con- control solenoid
trol solenoid valve and ECM. valve connector.
3)Measure the resistance of harness between
purge control solenoid valve connector and
engine ground.
Connector & terminal
(E4) No. 2 - Engine ground:
1 CHECK HARNESS BETWEEN PURGE CON, s the resistance less than 1 Go to step 4. 3epair open circuit
TROL SOLENOID VALVE AND ECM CON- 2? n harness
NECTOR. letween ECM and
Measure the resistance of harness between )urge control sole-
ECM and purge control solenoid valve of har- ioid valve connec-
ness connector. or.
Connector & terminal rlOTE:
(6137) NO. 16 - (E4) NO. 2: n this case, repair
he following:
Open circuit in
iarness between
X M and purge
:ontrol solenoid
ialve connector
Poor contact in
:oupling connectoi
I CHECK PURGE CONTROL SOLENOID s the resistance between 10 20 to step 5. 3eplace the purge
VALVE. 2nd 100 Q? :ontrol solenoid
1)Remove the purge control solenoid valve. ialve. <Ref. to
2)Measure the resistance between purge con- IC(D0HC
trol solenoid valve terminals. TURBO)--/, Purge
Terminals 2ontrol Solenoid
NO. 1 -NO. 2: Jake.>
> CHECK POWER SUPPLY TO PURGE CON- s the voltage more than 10 V? ;o to step 6. 3epair open circuit
TROL SOLENOID VALVE. n harness
1)Turn the ignition switch to ON. letween main
2)Measure the voltage between purge control 'elay and purge
solenoid valve and engine ground. :ontrol solenoid
Connector & terminal ialve connector.
(E4) No. 1 (+) - Engine ground (-):

EN(D0HC TURBO)-205
I DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes

6 CHECK POOR CONTACT. Repair poor con-
Check poor contact in purge control solenoid control solenoid valve connec- tact in purge con- (distributor) ser-
tor? trol solenoid valve vice.
connector. NOTE:
Inspection by DTN
is required, be.
cause probablc
cause is deteriora
tion of multiple
Darts.

EN(D0HC TURBO)-206
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
m
ENGINE (DIAGNOSTICS)

EN(D0HC TURBO)-207
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICSI

AU:DTC PO445 - EVAPORATIVE EMISSION CONTROL SYSTEM PURGE CON-

TROL VALVE CIRCUIT HIGH INPUT -
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

MAIN RELAY

SBF-5
BATTERY

3 c " 5 6

n@ ECM

PURGE CONTROL
SOLENOID VALVE
EN1 153

EN(D0HC TURBO)-208
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check No
CHECK OUTPUT SIGNAL FROM ECM. Even if MIL light
1)Turn the ignition switch to OFF. )etween 0 and 10 V? up, the circuit has
2)Connect the test mode connector at the returned to a nor-
lower portion of instrument panel (on the mal condition at
driver’s side), to the side of the center console this time. In this
box. case, repair poor
3)Turn the ignition switch to ON. :ontact in ECM
4)While operating the purge control solenoid sonnector.
valve, measure voltage between ECM and
chassis ground.
NOTE:
Purge control solenoid valve operation can be
executed using Subaru Select Monitor. For pro-
cedure, refer to “Compulsory Valve Operation
Check Mode”. <Ref. to EN(D0HC TURBO)-50,
Compulsory Valve Operation Check Mode.>
Connector & terminal
(6137) No. 16 (+) - Chassis ground (-):
CHECK OUTPUT SIGNAL FROM ECM.
1)Turn the ignition switch to ON.
2)Measure the voltage between ECM and
-----I-
s the voltage more than 10 V? Go to step 4. Go to step 3.

chassis ground.
Connector & terminal
(6137) No. 16 (+) - Chassis ground (-):
CHECK POOR CONTACT. s there poor contact in ECM Repair poor con- Replace the ECM.
Check poor contact in ECM connector. :onnector? tact in ECM con- <Ref. to FU(D0HC
nector. TURBO)-47,
Engine Control
Module.>
CHECK HARNESS BETWEEN PURGE CON- s the voltage more than 10 V? Repair battery Go to step 5.
TROL SOLENOID VALVE AND ECM CON- short circuit in har,
NECTOR. ness between
1)Turn the ignition switch to OFF. ECM and purge
2)Disconnectthe connector from purge control control solenoid
solenoid valve. valve connector.
3)Turn the ignition switch to ON. After repair,
4)Measure the voltage between ECM and replace the ECM.
chassis ground. <Ref. to FU(D0HC
Connector & terminal TURBO)-47,
(6137) No. 16 (+) - Chassis ground (-): Engine Control
Module.>
CHECK PURGE CONTROL SOLENOID s the resistance less than 1 Replace the purge Go to step 6.
VALVE. n? control solenoid
1)Turn the ignition switch to OFF. valve <Ref. to
2)Measure the resistance between purge con- EC(D0HC
trol solenoid valve terminals. TURBO)-7, Purge
Terminals Control Solenoid
NO. 1 -NO. 2: Valve.> and ECM
<Ref. to FU(D0HC
TURBO)-47,
Engine Control
Module.>
CHECK POOR CONTACT. s there poor contact in ECM Repair poor con- Replace the ECM.
Check poor contact in ECM connector. :onnector? tact in ECM con- <Ref. to FU(D0HC
nector. TURBO)-47,
Engine Control
Module.>

EN(D0HC TURBO)-209
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

AV:DTC PO447 - EVAPORATIVE EMISSION CONTROL SYSTEM VENT CON-

TROL LOW INPUT -
DTC DETECTING CONDITION:
Immediately at fault recognition
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

41N RELAY BATTERY

n
SBF-5
'3
3 c q-

A:@ B:@ ECM I I

EN1154

Step Check Yes No

1 CHECK OUTPUT SIGNAL FROM ECM. Is the voltage more than 10 V? Go to step 2. Go to step 3.
1)Turn the ignition switch to ON.
2)Measure the voltage between ECM and
chassis ground.
Connector & terminal
(6137) No. 11 (+) - Chassis ground (-):

EN(D0HC TURBO)-210
I DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
m
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK POOR CONTACT. there poor contact in ECM lepair poor con- Even if MIL lights
Check poor contact in ECM connector. mnector? ict in ECM con- up, the circuit has
ector. returned to a nor-
mal condition at
this time. (How-
ever, the possibilit)
of poor contact stil
remains.)
NOTE:
In this case, repai
the following:
Poor contact in
drain valve con-
nector
Poor contact in
ECM connector
Poor contact in
coupling connec-
tors
CHECK HARNESS BETWEEN DRAIN ; the resistance less than 10 lepair ground Go to step 4.
VALVE AND ECM CONNECTOR. !? hort circuit in har-
1)Turnthe ignition switch to OFF. ess between
2)Disconnect the connectors from drain valve iCM and drain
and ECM. alve connector.
3)Measure the resistance of harness between
drain valve connector and chassis ground.
Connector & terminal
(R69) No. 2 - Chassis ground:
CHECK HARNESS BETWEEN DRAIN ;the voltage less than 1 R? i o to step 5. Repair harness
VALVE AND ECM CONNECTOR. and connector.
Measure the resistance of harness between NOTE:
ECM and drain valve connector. In this case, repa
Connector & terminal the following:
(8137) NO. 11 - (R69) NO. 2: Open circuit in
harness between
ECM and drain
valve connector
Poor contact in
coupling connec-
tors
CHECK DRAIN VALVE. 5the resistance between 10 ;o to step 6. Replace the drain
Measure the resistance between drain valve .nd 100 a? valve. <Ref. to
terminals. EC(D0HC
Terminals TURBO)-I 7, Draii
NO. 1 - NO. 2: Valve.>
CHECK POWER SUPPLY TO DRAIN VALVE 5 the voltage more than 10 V' o
; to step 7. Repair harness
1)Turn the ignition switch to ON. and connector.
2)Measure the voltage between drain valve NOTE:
and chassis ground. In this case, repa
Connector & terminal the following:
(R69) No. 1 (+) - Chassis ground (-): Open circuit in
harness between
main relay and
drain valve
Poor contact in
coupling connec-

EN(D0HC TURBO)-21 1
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

7 CHECK POOR CONTACT. Is there poor contact in drain Repair poor con- Contact with SOA
Check poor contact in drain valve connector. valve connector? tact in drain valve (distributor) ser-
connector. vice.
NOTE:
Inspection by DTM
is required, be-
cause probable
cause is deteriora-
tion of multiple
Darts.

EN(D0HC TURBO)-212
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE IDlAGNOSTlCSl

EN(D0HC TURBO)-213
I DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

AW:DTC PO448 - EVAPORATIVE EMISSION CONTROL SYSTEM VENT CON-

TROL HIGH INPUT -
DTC DETECTING CONDITION:
Immediately at fault recognition
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

4IN RELAY BATTERY

€3
SBF-5

1CANISTER

I A:@ B:@ ECM

- I I

EN1154

EN(D0HC TURBO)-214
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

I CHECK OUTPUT SIGNAL FROM ECM. Ioes the voltage change Go to step 2. Even if MIL lights
1)Turn the ignition switch to OFF. letween 0 and 10 V? up, the circuit has
2)Connect the test mode connector at the returned to a nor-
lower portion of instrument panel (on the mal condition at
driver’s side), to the side of the center console this time. In this
box. case, repair poor
3)Turn the ignition switch to ON. contact in ECM
4)While operating the drain valve, measure connector.
voltage between ECM and chassis ground.
NOTE:
Drain valve operation can be excecuted using

c
Subaru Select Monitor. For procedure, refer to
“Compulsory Valve Operation Check Mode”.
<Ref. to EN(D0HC TURBO)dO, Compulsory
Valve Operation Check Mode.>
Connector & terminal
(8137) No. 11 (+) - Chassis ground (-):
! CHECK OUTPUT SIGNAL FROM ECM. s the voltage more than 10 V? Go to step 4. Go to step 3.
1)Turn the ignition switch to ON.
2)Measure the voltage between ECM and
chassis ground.
Connector & terminal
(8137) No. 11 (+) - Chassis ground (-):
j CHECK POOR CONTACT. s there poor contact in ECM Repair poor con- Replace the ECM.
Check poor contact in ECM connector. :onnector? tact in ECM con- <Ref. to FU(D0HC
nector. TURBO)-47,
Engine Control
Module.>
I CHECK HARNESS BETWEEN DRAIN s the voltage more than 10 V? Repair battery Go to step 5.
VALVE AND ECM CONNECTOR. short circuit in har-
1)Turn the ignition switch to OFF. ness between
2)Disconnect the connector from drain valve. ECM and drain
3)Turn the ignition switch to ON. valve connector.
4)Measure the voltage between ECM and After repair,
chassis ground. replace the ECM.
Connector & terminal <Ref. to FU(D0HC
(B137) No. 11 (+) - Chassis ground (-): TURBO)-47,
Engine Control
Module.>
i CHECK DRAIN VALVE. s the resistance less than 1 Replace the drain Go to step 6.
1)Turn the ignition switch to OFF. 2? valve <Ref. to
2)Measure the resistance between drain valve EC(D0HC
terminals. TURBO)-I 7, Drain
Terminals Valve.> and ECM
NO. 1 - NO.2: <Ref. to FU(D0HC
TURBO)-47,
Engine Control
Module.>
i CHECK POOR CONTACT. s there poor contact in ECM Repair poor con- Replace the ECM.
Check poor contact in ECM connector. :onnector? tact in ECM con- <Ref. to FU(D0HC
nector. TURBO)-47,
Engine Control
Module.>

EN(D0HC TURBO)-215
I DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENG INE (DIAG NOSTlCS)

AX:DTC PO451 - EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE

SENSOR RANGE/PERFORMANCE PROBLEM -
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

1
JEL TANK
3ESSURE
;ENSOR

#
I
[,I-
=-I
@

EN(D0HC TURBO)-216
 m
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

1 CHECK ANY OTHER DTC ON DISPLAY. Is there any DTC on display? Inspect the rele- Go to step 2.
vant DTC using
“List of Diagnostic
Trouble Code
(DTC)”. <Ref. to
EN(D0HC
TURBO)-80, List
of Diagnostic Trou-
ble Code (DTC).>
2 CHECK FUEL FILLER CAP. Is the fuel filler cap tightened Go to step 3. Tighten fuel filler
1)Turnthe ignition switch to OFF. securely? cap securely.
2)Open the fuel flap.
3 CHECK PRESSURENACUUM LINE. Is there a fault in pressurehac- Repair or replace Replace the fuel
NOTE: uum line? the hoses and tank pressure sen-
Check the following items. pipes. sor. <Ref. to
*Disconnection, leakage and clogging of the EC(D0HC
vacuum hoses and pipes between fuel tank TURBO)-I 1 , Fuel
pressure sensor and fuel tank Tank Pressure
*Disconnection, leakage and clogging of air Sensor.>
ventilation hoses and pipes between fuel filler
DiDe and fuel tank

EN(D0HC TURBO)-217
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

AY:DTC PO452 -
EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE
SENSOR LOW INPUT -
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

IEL TAN1
IESSURI
,ENSOR

EN1155

EN(D0HC TURBO)-21 8
 EiN
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)
~~

Step Check Yes No

CHECK CURRENT DATA. s the value less than -2.8 kPa IGo to step 2. Even if MIL lights
1)Turn the ignition switch to OFF. -21 .O mmHg, -0.827 inHg)? JP,the circuit has
2)Remove the fuel filler cap. ,eturned to a nor-
3)lnstall the fuel filler cap. nal condition at
4)Turn the ignition switch to ON. his time.
5)Read the data of fuel tank pressure sensor
signal using Subaru Select Monitor or the
OBD-ll general scan tool.
NOTE:

*Subaru Select Monitor

Fordetailed operation procedure, refer to the
“READ CURRENT DATA FOR ENGINE”. <Ref.
to EN(D0HC TURBO)-38, Subaru Select Mon.
itor.>
*OBD-II general scan tool
For detailed operation procedures, refer to the
OBD-II General Scan Tool Instruction Manual.
CHECK POWER SUPPLY TO FUEL TANK s the voltage more than 4.5 V? Go to step 4. 30 to step 3.
PRESSURE SENSOR.
Measure the voltage between ECM connector
and chassis ground.
Connector & terminal
I
(6135) No. 9 (+) - Chassis ground (-):
CHECK POWER SUPPLY TO FUEL TANK loes the voltage change more Repair poor con- ;ontact with SOA
PRESSURE SENSOR. han 4.5 V by shaking harness tact in ECM con- distributor) ser-
Measure the voltage between ECM connector ind connector of ECM while nector. lice.
and chassis ground. nonitoring the value with volt- \JOTE:
Connector i? terminal ige meter? nspection by DTL
(B 135) No. 9 (+) - Chassis ground (-): s required, be
:ause probablc
:ause is deteriora
ion of multipli
)arts.
CHECK INPUT SIGNAL FOR ECM. s the voltage less than 0.2 V? Go to step 6. 30 to step 5.
Measure the voltage between ECM and chas-
sis ground.
Connector & terminal
(6135) No. 15 (+) - Chassis ground (-):
CHECK INPUT SIGNAL FOR ECM. (USING loes the value change more Repair poor con- 30 to step 6.
SUBARU SELECT MONITOR.) han -2.8 kPa (-21 .O mmHg, - tact in ECM con-
Read the data of fuel tank pressure sensor sig. 1.827 inHg) by shaking har- nector.
nal using Subaru Select Monitor. less and connector of ECM
NOTE: while monitoring the value with
*Subaru Select Monitor Subaru Select Monitor?
For detailed operation procedure, refer to the
“READ CURRENT DATA FOR ENGINE”. <Ref.
to EN(D0HC TURBO)-38, Subaru Select Mon.
itor.>

EN(D0HC TURBO)-219
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)

Step Check Yes No

CHECK HARNESS BETWEEN ECM AND j the voltage more than 4.5 V? o
; to step 7. 3epair harness
COUPLING CONNECTOR IN REAR WIRING and connector.
HARNESS. UOTE:
1)Turn the ignition switch to OFF. n this case, repair
2)Remove the rear seat cushion (Sedan) or he following:
move rear seat cushion (Wagon). 1 Open circuit in
3)Separate rear wiring harness and fuel tank iarness between
cord. X M and rear wir-
4)Turn the ignition switch to ON. ng harness con-
5)Measure the voltage between rear wiring lector
harness connector and chassis ground. 1 Poor contact in

Connector & terminal :oupling connector

(R15) No. 9 (+) - Chassis ground (-):
CHECK HARNESS BETWEEN ECM AND s the resistance less than 1 20 to step 0. 3epair harness
COUPLING CONNECTOR IN REAR WIRING 2? 3nd connector.
HARNESS. VOTE:
1)Turn the ignition switch to OFF. In this case, repair
2)Disconnect the connector from ECM. :he following:
3)Measure the resistance of harness between 1 Open circuit in

ECM and rear wiring harness connector. iarness between

Connector & terminal ECM and rear wir-
(6135) NO. 19 - (R15) NO. 11: ng harness con-
lector
1 Poor contact in

2oupling connector
Poor contact in
loint connector
CHECK HARNESS BETWEEN ECM AND s the resistance more than 30 to step 9. Repair ground
COUPLING CONNECTOR IN REAR WIRING 500 kR? short circuit in har-
HARNESS. ness between
Measure the resistance of harness between ECM and rear wir-
rear wiring harness connector and chassis ing harness con-
ground. nector.
Connector & terminal
(R15) No. 11 - Chassis ground:
3 CHECK FUEL TANK CORD. s the resistance less than 1 30 to step 10. Repair open circuit
1)Disconnectthe connector from fuel tank 2? in fuel tank cord.
pressure sensor.
2)Measure the resistance of fuel tank cord.
Connector & terminal
(R57) NO. 9 - (R47) NO. 3:
IO CHECK FUEL TANK CORD. s the resistance less than 1 So to step 11. Repair open circuit
Measure the resistance of fuel tank cord. 3? in fuel tank cord.
Connector & terminal
(R57) NO. 11 - (R47) NO. 1:
I1 CHECK FUEL TANK CORD. s the resistance more than Go to step 12. Repair ground
Measure the resistance of harness between 500 kR? short circuit in fuel
fuel tank pressure sensor connector and chas tank cord.
sis ground.
Connector & terminal
(R47) No. 2 - Chassis ground:
12 CHECK POOR CONTACT. s there poor contact in fuel Repair poor con- Replace the fuel
Check poor contact in fuel tank pressure sen- ank pressure sensor connec- tact in fuel tank tank pressure sen.
sor connector. or? pressure sensor sor. <Ref. to
connector. EC(D0HC
TURBO)-11, Fuel
Tank Pressure
Sensor.>

EN(D0HC TURBO)-220
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

EN(D0HC TURBO)-221
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

AZ:DTC PO453 - EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE

SENSOR HIGH INPUT -
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

EN1155

EN(D0HC TURBO)-222
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)
~

Step Check Yes No

CHECK CURRENT DATA. s the value more than 2.8 kPa 20 to step 12. 30 to step 2.
1)Turn the ignition switch to OFF. 21 .O mmHg, 0.827 inHg)?
2)Remove the fuel filler cap.
3)lnstall the fuel filler cap.
4)Turn the ignition switch to ON.
5)Read the data of fuel tank pressure sensor
signal using Subaru Select Monitor or OBD-ll
general scan tool.
NOTE:
4ubaru Select Monitor
For detailed operation procedure, refer to the
“READ CURRENT DATA FOR ENGINE”. <Ref.
to EN(D0HC TURBO)-38, Subaru Select Mon.
itor.>
*OBD-ll general scan tool
For detailed operation procedures, refer to the
OBD-ll General Scan Tool Instruction Manual.
CHECK POWER SUPPLY TO FUEL TANK s the voltage more than 4.5 V? 30 to step 4. 30 to step 3.
PRESSURE SENSOR.
Measure the voltage between ECM connector
and chassis ground.
Connector & terminal
(8135) No. 9 (+) - Chassis ground (-):
CHECK POWER SUPPLY TO FUEL TANK Does the voltage change more 3epair poor con- Replace the ECM.
PRESSURE SENSOR. ;han 4.5 V by shaking harness act in ECM con- <Ref.to FU(D0HC
Measure the voltage between ECM connector and connector of ECM while lector. TURBO)-47,
and chassis ground. nonitoring the value with volt- Engine Control
Connector & terminal 3ge meter? Module.>
(8135) No. 9 (+) - Chassis ground (-):
CHECK INPUT SIGNAL FOR ECM. Is the voltage less than 0.2 V? 20 to step 6. So to step 5.
Measure the voltage between ECM and chas-
sis ground.
Connector & terminal
(8135) No. 15 (+) - Chassis ground (-):
CHECK INPUT SIGNAL FOR ECM. (USING Does the value change more 3epair poor con- So to step 6.
SUBARU SELECT MONITOR.) than -2.8 kPa (-21 .O mmHg, :act in ECM con-
Read the data of fuel tank pressure sensor sig -0.827 inHg) by shaking har- lector.
nal using Subaru Select Monitor. ness and connector of ECM
NOTE: while monitoring the value with
Gubaru Select Monitor Subaru Select Monitor?
For detailed operation procedure, refer to the
“READ CURRENT DATA FOR ENGINE”. <Ref.
to EN(D0HC TURBO)-38, Subaru Select Mon
itor.>
CHECK HARNESS BETWEEN ECM AND Is the voltage more than 4.5 VS 30 to step 7. Repair harness
COUPLING CONNECTOR IN REAR WIRING and connector.
HARNESS. NOTE:
1)Turn the ignition switch to OFF. In this case, repai
2)Remove the rear seat cushion (Sedan) or the following:
move rear seat cushion (Wagon). a Open circuit in

3)Separate rear wiring harness and fuel tank harness between

cord. ECM and rear wir.
4)Turn the ignition switch to ON. ing harness con-
5)Measure the voltage between rear wiring nector
harness connector and chassis ground. Poor contact in
Connector & terminal coupling connectc
(R15) No. 9 (+) - Chassis ground (-):

EN(D0HC TURBO)-223
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)
~~

Step Check Yes No

CHECK HARNESS BETWEEN ECM AND j the resistance less than 1 30 to step 8. 3epair harness
COUPLING CONNECTOR IN REAR WIRING I? md connector.
HARNESS. \IOTE:
1)Turnthe ignition switch to OFF. n this case, repaii
2)Disconnect the connector from ECM. he following:
3)Measure the resistance of harness between Open circuit in
ECM and rear wiring harness connector. iarness between
Connector & terminal X M and rear wir-
(6135) NO. 15 - (R 15) NO. 10: ng harness con-
lector
Poor contact in
:oupling connectoi
CHECK HARNESS BETWEEN ECM AND ;the resistance less than 1 30 to step 9. 3epair ground
COUPLING CONNECTOR IN REAR WIRING 2? ;hort circuit in har-
HARNESS. less between
Measure the resistance of harness between X M and rear wir-
rear wiring harness connector and chassis ng harness con-
ground. lector.
Connector & terminal
(8135) NO. 9 - (R15) NO. 9:
I CHECK FUEL TANK CORD. j the resistance less than 1 So to step 10. 3epair open circuit
1)Disconnectthe connector from fuel tank 1? n fuel tank cord.
pressure sensor.
2)Measure the resistance of fuel tank cord.
Connector & terminal
(R57) NO. 11 - (R47) NO. 2:
0 CHECK FUEL TANK CORD. ;the resistance less than 1 Go to step 11. 3epair open circuit
Measure the resistance of fuel tank cord. I? n fuel tank cord.
Connector & terminal
(R57) NO. 10 - (R47) NO. 1:
1 CHECK POOR CONTACT. ;there poor contact in fuel Repair poor con- 3eplace the fuel
Check poor contact in fuel tank pressure sen- snk pressure sensor connec- tact in fuel tank ank pressure sen-
sor connector. x? pressure sensor ;or. <Ref. to
connector. X(DOHC
rURBO)-I 1, Fuel
rank Pressure
Sensor.>
I2 CHECK HARNESS BETWEEN ECM AND s the value more than 2.8 kPa Repair battery 3eplace the fuel
FUEL TANK PRESSURE SENSOR CONNEC, 21 .O mmHg, 0.827 inHg)? short circuit in har :ank pressure sen.
TOR. ness between ;or. <<Ref. to
1)Turn the ignition switch to OFF. ECM and fuel tank EC(D0HC
2)Disconnect the connector from fuel tank pressure sensor rURBO)-I 1, Fuel
pressure sensor. connector. rank Pressure
3)Turn the ignition switch to ON. Sensor.>
4)Read the data of fuel tank pressure sensor
signal using Subaru Select Monitor or the
OBD-ll general scan tool.
NOTE:
Gubaru Select Monitor
For detailed operation procedure, refer to the
“READ CURRENT DATA FOR ENGINE”. <Ref.
to EN(D0HC TURBO)-38, Subaru Select Mon
itor.>
-0BD-II general scan tool
For detailed operation procedures, refer to the
OBD-ll General Scan Tool Instruction Manual.

EN(D0HC TURBO)-224
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
m
ENGINE (DIAGNOSTICS)

BA:DTC PO461 - FUEL LEVEL SENSOR CIRCUIT RANGE/PERFORMANCE

PROBLEM -
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.

EN(D0HC TURBO)-225
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

WIRING DIAGRAM:

I 1

EN1156

EN(DOHC TURB0)-226
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
a
ENGINE (DIAGNOSTICS)

Step Check Yes No

1 CHECK ANY OTHER DTC ON DISPLAY. loes the Subaru Select Moni- Inspect DTC Replace the fuel
or or OED-ll general scan tool PO462 or PO463 level sensor <Ref.
ndicate DTC PO462 or P0463? using “List of Diag- to FU(D0HC
nostic Trouble TURBO)-62, Fuel
Code (DTC)”. Level Sensor.>
<Ref. to EN(D0HC and fuel sub level
TURBO)-80, List sensor <Ref. to
of Diagnostic Trou- FU(D0HC
ble Code (DTC).s TURBO)-63, Fuel
NOTE: Sub Level Sen-
In this case, it is sor.>
not necessary tc
inspect this trou-
ble.

EN(D0HC TURBO)-227
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)
~

BB:DTC PO462 - FUEL LEVEL SENSOR CIRCUIT LOW INPUT -

DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

I
No 13

=&%-=-
IGNITION SWITCH
@
SBF-4 SBF-1

-
3 c

I 1

@
FUEL SUB FUEL LEVEL
LEVEL SEI SENSOR

-@-
a
112131415161 n 171819110111
a
1121314151 n 16171819110111

EN1156
 m
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK SPEEDOMETER AND TACHOME- >oesthe speedometer and i o to step 2. Repair or replace
TER OPERATION IN COMBINATION achometer operate normally? !he combination
METER. meter. <Ref. to
IDI-4, Combina-
tion Meter Sys-
tem.>
CHECK INPUT SIGNAL FOR ECM. s the voltage less than 0.12 i o to step 6. So to step 3.
1)Turn the ignition switch to ON. (Engine OFF) I?
2)Measure the voltage between ECM connec-
tor and chassis ground.
Connector & terminal
(6135) No, 25 (+) - Chassis groundI)-(
CHECK INPUT SIGNAL FOR ECM. (USING Toes the value change less jepair poor con- Even if MIL lights
SUBARU SELECT MONITOR.) han 0.12 V by shaking har- act in ECM con- up, the circuit has
Read the data of fuel level sensor signal using less and connector of ECM lector. returned to a nor-
Subaru Select Monitor. vhile monitoring the value with mal condition at
jubaru Select Monitor? this time. A tempo-
NOTE:
Gubaru Select Monitor rary poor contact
For detailed operation procedure, refer to the of the connector
“READ CURRENT DATA FOR ENGINE”. <Ref. may be the cause.
to EN(D0HC TURBO)-38, Subaru Select Mon- NOTE:
itor.> In this case, repaii
the following:
Poor contact in
combination meter
connector
Poor contact in
ECM connector
Poor contact in
coupling connec-
tors
CHECK INPUT VOLTAGE OF ECM. s the voltage more than 0.12 30 to step 4. Go to step 7.
1)Turn the ignition switch to OFF. d?
2)Separate fuel tank cord connector (R57) and
rear wiring harness connector (R15).
3)Turn the ignition switch to ON.
4)Measure the voltage of harness between
ECM connector and chassis ground.
Connector & terminal
(6135) No. 25 (+) - Chassis ground (-):
CHECK HARNESS BETWEEN ECM AND s the resistance more than 1 io to step 6. 3epair ground
COMBINATION METER. An? short circuit in har-
1)Turn the ignition switch to OFF. less between
2)Disconnect the connector from connector I C M and combi-
(ilo), (i12) and ECM connector. iation meter con-
3)Measure the resistance between ECM and lector.
chassis ground.
Connector & terminal
(6135) No. 25 - Chassis ground:
CHECK HARNESS BETWEEN ECM AND s the resistance less than 10 iepair or replace Repair open circuit
COMBINATION METER. L? l e combination oetween ECM and
Measure the resistance between ECM and ieter. <Ref. to :ombination meter
combination meter connector. DI-4, Combina- :onnector.
Connector & terminal on Meter Sys- NOTE:
(6135) No. 25 - (i12) No. 2: 3m.> In this case, repaii
the following:
Poor contact in
coupling connectot

EN(D0HC TURBO)-229
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

r CHECK FUEL TANK CORD. Is the resistance more than 1 Go to step 8. Repair ground
1)Turn the ignition switch to OFF. MR? short circuit in fuel
2)Disconnect the connector from fuel sub level tank cord.
sensor.
3)Measure the resistance between fuel sub
level sensor and chassis ground.
Connector & terminal
(R59) No. 1 - Chassis ground:
5 CHECK FUEL TANK CORD. Is the resistance more than 1 Go to step 9. Repair ground
1)Disconnectthe connector from fuel pump MR? short circuit in fuel
assembly. tank cord.
2)Measure the resistance between fuel pump
assembly and chassis ground.
Connector & terminal
(R59) No. 2 - Chassis ground:
b CHECK FUEL LEVEL SENSOR. Is the resistance between 0.5 Go to step 10. Replace the fuel
1)Remove the fuel pump assembly. <Ref. to and 2.5 R? level sensor.
FU(D0HC TURBO)-60, Fuel Pump.>
2)Measure the resistance between fuel level
sensor and terminals with its float set to the full
position.
Terminals
NO. 2 - NO. 3:
IO CHECK FUEL SUB LEVEL SENSOR. Is the resistance between 0.5 Repair poor con- Replace the fuel
1)Remove the fuel sub level sensor. <Ref. to and 2.5 R? tact in harness sub level sensor.
FU(D0HC TURBO)-63, Fuel Sub Level Sen- between ECM and
sor.> combination meter
2)Measure the resistance between fuel sub connector.
level sensor and terminals with its float set to
the full position.
Terminals
NO. 1 -NO. 2:

EN(D0HC TURBO)-230
 im
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

EN(D0HC TURBO)-231
I
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

BC:DTC PO463 - FUEL LEVEL SENSOR CIRCUIT HIGH INPUT -

DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

No.13 SBF-4 SBF-1

I IGNITION SWITCH
@

COMBINATION

FUEL LEVEL
LEVEL SENSOR SENSOR

EN(DOHC TU RB0)-232
I a
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICSI
~~ ~

Step Check Yes No

CHECK SPEEDOMETER AND TACHOME- Ioes the speedometer and i o to step 2. Repair or replace
TER OPERATION IN COMBINATION achometer operate normally? the combination
METER. meter. <Ref. to
IDI-4, Combina-
tion Meter Sys-
tem.>
! CHECK INPUT SIGNAL FOR ECM. s the voltage more than 4.75 ;o to step 3. Even if MIL lights
1)Turnthe ignition switch to ON. (Engine OFF) I? dp, the circuit has
2)Measure the voltage between ECM connec- returned to a nor-
tor and chassis ground. mal condition at
Connector & terminal this time. A tempo-
(8135) No. 25 (+) - Chassis ground (-): rary poor contact
3f the connector
may be the cause.
NOTE:
In this case, repait
the following:
Poor contact in
fuel pump connec-
tor
Poor contact in
coupling connectoi
3 CHECK INPUT VOLTAGE OF ECM. s the voltage more than 4.75 20 to step 4. Repair battery
1)Turnthe ignition switch to OFF. I? short circuit
2)Disconnect the combination meter connector between ECM and
(i10) and ECM connector. combination meter
3)Turn the ignition switch to ON. connector.
4)Measure the voltage of harness between
ECM and chassis ground.
Connector & terminal
(8135) No. 25 (+) - Chassis ground (-):
1 CHECK HARNESS BETWEEN ECM AND s the resistance less than 5 i o to step 5. Repair open circuit
FUEL TANK CORD. 3? between ECM and
1)Turn the ignition switch to OFF. fuel tank cord.
2)Separate fuel tank cord connector (R57) and
rear wiring harness connector (R15).
3)Measure the resistance between ECM and
fuel tank cord.
Connector & terminal
(8135) NO. 25 - (R15) NO. 2:
> CHECK HARNESS BETWEEN FUEL TANK s the resistance less than 5 30 to step 6. Repairopen circuit
CORD AND CHASSIS GROUND. n? between fuel tank
Measure the resistance between fuel tank cord cord and chassis
and chassis ground. ground.
Connector & terminal NOTE:
(R15) No. 8 - Chassis ground: In this case, repaii
the following:
Poor contact in
coupling connec-
tors
5 CHECK FUEL TANK CORD. s the resistance less than 10 o
; to step 7. Repair open circuit
1)Disconnectthe connector from fuel level sen. n? between coupling
sor. connector and fuel
2)Measure the resistance between fuel level level sensor.
sensor and coupling connector.
Connector & terminal
(R57)NO. 8 - (R58)NO. 2:

EN(D0HC TURBO)-233
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check
I
CHECK FUEL TANK CORD. the resistance less than 10
1)Disconnectthe connector from fuel sub level ? between fuel level
sensor. sensor and fuel
2)Measure the resistance between fuel level sub level sensor.
sensor and fuel sub level sensor.
Connector & terminal
-
(R58) NO. 3 (R59) NO. 2:
I CHECK FUEL TANK CORD. the resistance less than 10 Go to step 9. Repair open circuit
Measure the resistance between fuel sub level ? between coupling
sensor and coupling connector. connector and fuel
Connector & terminal sub level sensor.
-
(R57) NO. 3 (R59) NO. 1:
1 CHECK FUEL LEVEL SENSOR. the resistance more than 53 Replace the fuel Go to step 10.
1)Remove the fuel pump assembly. <Ref. to ? level sensor. <Ref.
FU(D0HC TURBO)-60, Fuel Pump.> to FU(D0HC
2)While moving the fuel level sensor float up TURBO)-62, Fuel
and down, measure resistance between fuel Level Sensor.>
level sensor terminals.
Terminals
NO. 2 - NO. 3:
IO CHECK FUEL SUB LEVEL SENSOR. the resistance more than 45 Replace the fuel Replace the com-
1)Remove the fuel sub level sensor. <Ref. to ? sub level sensor. bination meter.
FU(D0HC TURBO)-63, Fuel Sub Level Sen- <Ref. to FU(D0HC <Ref. to IDI-11,
sor.> TURBO)-63, Fuel Combination
2)While moving the fuel sub level sensor float Sub Level Sen- Meter Assembly.>
up and down, measure resistance between s0r.z
fuel sub level sensor terminals.
Terminals
NO. 1 - NO. 2:

EN(D0HC TURBO)-234
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

EN(D0HC TURBO)-235
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

BD:DTC PO464 - FUEL LEVEL SENSOR INTERMITTENT INPUT-

* DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

I -
e-N0.13

IGNITION SWITCH
SBF-4 SBF-1
-ac

COMBINATION
METER
GAUGE
' A

EN1 156

EN(D0HC TURBO)-236
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Moni- nspect DTC Go to step 2.
tor or OBD-II general scan tool ’0462 or PO463
indicate DTC PO462 or P0463? ising “List of Diag-
iostic Trouble
;ode (DTC)”.
:Ref. to EN(D0HC
TURBO)-~O, List
i f Diagnostic Trou-
)le Code (DTC).>
! CHECK FUEL LEVEL SENSOR. Does the resistance change 30 to step 3. Replace the fuel
1)Remove the fuel pump assembly. <Ref. to smoothly between approx. 0.5 level sensor. <Ref.
FU(D0HC TURBO)-60, Fuel Pump.> R and approx. 52 R? to FU(D0HC
2)While moving the fuel level sensor float up TURBO)-62, Fuel
and down, make sure that the resistance Level Sensor.>
between fuel level sensor terminals changes
smoothly.
Terminals
NO. 2 - NO. 3:
I CHECK FUEL SUB LEVEL SENSOR. Does the resistance change 3epair poor con- Replace the fuel
1)Remove the fuel sub level sensor. <Ref. to smoothly between approx. 0.5 act in ECM, com- sub level sensor.
FU(D0HC TURBO)-63, Fuel Sub Level Sen- Q and approx. 44 SZ? iination meter and <Ref. to FU(D0HC
sor.> :oupling connec- TURBO)-63, Fuel
2)While moving the fuel sub level sensor float ors. Sub Level Sen-
up and down, make sure that the resistance sor.>
between fuel level sensor terminals changes
smoothly.
Terminals
NO. 1 - NO. 2:

EN(D0HC TURBO)-237
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

EN(DOHC TU RB0)-238
I DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) m
ENGINE (DIAGNOSTICS)

BE:DTC PO480 - COOLING FAN RELAY 1 CIRCUIT LOW INPUT-

DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
TROUBLE SYMPTOM:
Radiator fan does not operate properly.
Overheating
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.

EN(D0HC TURBO)-239
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

WIRING DIAGRAM:

SBF-1
3 e-- T

7
N0.17

EN1157

EN(D0HC TURBO)-240
 im
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK OUTPUT SIGNAL FROM ECM. Ioes the voltage change lepair poor con- ;o to step 2.
1)Turn the ignition switch to OFF. tetween 0 and 10 V? 3ct in ECM con-
2)Connect the test mode connector at the lector.
lower portion of instrument panel (on the
driver’s side), to the side of the center console
box.
3)Turn the ignition switch to ON.
4)While operating the radiator fan relay, mea-
sure voltage between ECM terminal and
ground.
NOTE:
Radiator fan relay operation can be executed
using Subaru Select Monitor. For procedure,
refer to “Compulsory Valve Operation Check
Mode”.<Ref. to EN(D0HC TURBO)-38, Subaru
Select Monitor.>
Connector & terminal
(8137) No. 17 (+) - Chassis ground (-):
(8137) No. 28 (+) - Chassis ground (-):
? CHECK GROUND SHORT CIRCUIT IN RADI- s the resistance less than 10 lepair ground 20 to step 3.
ATOR MAIN FAN RELAY CONTROL CIR- 2? ihort circuit in
CUIT. adiator main fan
1)Turn the ignition switch to OFF. elay control cir-
2)Disconnect the connectors from ECM. uit.
3)Measure the resistance of harness between
ECM connector and chassis ground.
Connector & terminal
(8137) No. 17 - Chassis ground:
(8137) No. 28 - Chassis ground:
% CHECK POWER SUPPLY FOR RELAY. s the voltage more than 10 V? ;o to step 4. qepair open circui
1)Removethe main fan relay 1 and 2 from A/C n harness
relay holder. ietween ignition
2)Turn the ignition switch to ON. ;witch and fuse
3)Measure the voltage between fuse and relay md relay box (F/B:
box (F/B) connector and chassis ground. :onnector.
Connector & terminal
(F66) No. 27 (+) - Chassis ground (-):
(F30) No. 22 (+) - Chassis ground (-):
3 CHECK MAIN FAN RELAY. s the resistance between 87 o
; to step 5. 3eplace the main
1)Turnthe ignition switch to OFF. and 107 Q? an relay.
2)Measure the resistance between main fan
relay terminals.
Terminal
No. 27 - No. 28:(Main fan relay 1)
No. 22 - No. 21:(Main fan relay 2)
5 CHECK OPEN CIRCUIT IN MAIN FAN RE- s the resistance less than 1 20 to step 6. 3epair harness
LAY CONTROL CIRCUIT. n? and connector.
Measure the resistance of harness between VOTE:
ECM and main fan relay connector. n this case, repai
Connector & terminal :he following:
(8137) NO. 17 - (F66) NO. 28: 1 Open circuit in

(8137) NO. 28 - (F30) NO. 21: iarness between

ECM and main far
’elay connector
1 Poor contact in

:oupling connectc
5 CHECK POOR CONTACT. s there poor contact in ECM of 3epair poor con- 2ontact with SOA
Check poor contact in ECM or main fan relay nain fan relay connector? act in ECM or [distributor) ser-
connector. nain fan relay con ice.
lector.

EN(D0HC TURBO)-241
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

EN(D0HC TURBO)-242
 II
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

BF:DTC PO483 - COOLING FAN FUNCTION PROBLEM -

DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
TROUBLE SYMPTOM:
Occurrence of noise
Overheating
CAUTION:
After repair or replacement of faulty parts, conwct Clear llemory Mode <Re to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
NOTE:
If the vehicle, with the engine idling, is placed very close to a wall or another vehicle, preventing normal cool-
ing function, the OBD system may detect malfunction.

EN(D0HC TURBO)-243
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

WIRING DIAGRAM:

SBF-1
3 e m
T

L”r”l
N0.17

I @ECM
I

1
-I T-

0 0 0
I SUB FAN
RELAY2
SUB FAN
RELAY1
MAIN FAN MAIN FAN
RELAY2 RELAY1

SUB FAN
MOTOR AIR CONDITIONING RELAY HOLDER

EN1157

EN(D0HC TURBO)-244
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
a
ENGINE (DIAGNOSTICS)

Step Check Yes No

1 CHECK ANY OTHER DTC ON DISPLAY. Is there any other DTC on dis- Inspect the rele- Check radiator fan,
play? vant DTC using fan motor and ther-
“List of Diagnostic mostat. <Ref. to
Trouble Code CO-9, Radiator
(DTC)”. <Ref. to Main Fan Sys-
EN(D0HC tem.> and <Ref. to
TURBO)-80, List CO-17, Radiator
of Diagnostic Trou- Sub Fan Sys-
ble Code (DTC).> tem.> If thermostat
is stuck, replace
thermostat.

EN(D0HC TURBO)-245
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

BG:DTC PO500 - VEHICLE SPEED SENSOR MALFUNCTION -

DTC DETECTING CONDITION:
Immediately at fault recognition
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

Fa
r
IGNITION
RELAY BATTERY

-
-
m

@: AT VEHICLES
@: MT VEHICLES
VEHICLE
SPEED
SENSOR

COMBINATION
METER

F
@ECM I& EN1158

Step Check Yes No

1 CHECK TRANSMISSION TYPE. Is the transmission type AT? Go to step 2. Go to step 3.

EN(DOHC TU R BO)-246
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK DTC PO720 ON DISPLAY. Does the Subaru Select Moni- Check front vehi- Go to step 3.
tor or OBD-ll general scan tool cle speed sensor
indicate DTC P0720? signal circuit. <Ref.
to AT-57, DTC 33
FRONT VEHICLE
SPEED SENSOR,
Diagnostic Proce-
dure with Diagnos-
tic Trouble Code
(DTC).>
1 CHECK SPEEDOMETER OPERATION IN Does speedometer operate Go to step 4. Check speedome-
COMBINATION METER. normally? ter and vehicle
speed sensor.
<Ref. to IDI-13,
Speedometer.>
and <Ref. to AT-32,
Front Vehicle
Speed Sensor.>
I CHECK HARNESS BETWEEN ECM AND Is the resistance less than 10 Repair poor con- Repair harness
COMBINATION METER CONNECTOR. Q? tact in ECM con- and connector.
nector. NOTE:
In this case, repai
the following:
Open circuit in
harness between
ECM and combi-
nation meter con-
nector
Poor contact in
ECM connector
Poor contact in
combination meter
connector
Poor contact in
coupling connect0

EN(D0HC TURBO)-247
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

BH:DTC PO506 - IDLE CONTROL SYSTEM RPM LOWER THAN EXPECTED -

DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
TROUBLE SYMPTOM:
Engine is difficult to start.
Engine does not start.
Erroneous idling
Engine stalls.
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

MAIN RELAY

BATTERY

SBF-5
3 c 5 6 7 8

AIR CONTROL
SOLENOID
VALVE

@ ECM

EN1160

EN(D0HC TURBO)-248
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE fDIAGNOSTICS)

Step Check Yes No

CHECK ANY OTHER DTC ON DISPLAY. Ioes the Subaru Select Moni- Inspect DTC 20 to step 2.
or or OBD-ll general scan tool PO505 or P I 505
ndicate DTC PO508 or P509? using “List of Diag-
nostic Trouble
Code (DTC)”.
<Ref. to EN(D0HC
TURBO)-80, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0506.
CHECK IDLE AIR CONTROL SOLENOID Ioes air flow out? Go to step 4. 3eplace the idle
VALVE. iir control solenoid
1)Turn the ignition switch to OFF. ialve. <Ref. to
2)Remove the idle air control solenoid valve -U(DOHC
from throttle body. <Ref. to FU(D0HC rURBO)-36, Idle
TURBO)-36, REMOVAL, Idle Air Control Sole. 4ir Control Sole-
noid Valve.> ioid Valve.> After
3)Using an air gun, force air into the idle air .eplace,Go to step
control solenoid valve by-pass air inlet. Con- 5.
firm that forced air subsequently escapes from
both main air passage and assist air passage.
CHECK IDLE AIR CONTROL SOLENOID s the value more than 60%? Go to step 4. END.
VALVE DUTY RATIO.
1)Turn the ignition switch to ON.
2)Start the engine, and warm-up the engine.
3)Turn all accessory switches to OFF.
4)Read the data of idle air control solenoid
valve duty ratio using Subaru Select Monitor 01
OBD-II general scan tool.
NOTE:
Gubaru Select Monitor
For detailed operation procedures, refer to the
“READ CURRENT DATA FOR ENGINE”. <Ref.
to EN(D0HC TURBO)-38, Subaru Select Mon
itor.>
*OBD-ll general scan tool
For detailed operation procedures, refer to the
OBD-II General Scan Tool Instruction Manual.
1 CHECK BY-PASS AIR LINE. loes air flow out? Replace the idle 3eplace the throt-
1)Turn the ignition switch to OFF. air control solenoid le body. <Ref. to
2)Remove the idle air control solenoid valve valve. <Ref. to ‘U(D0HC
from throttle body. <Ref. to FU(D0HC FU(D0HC rURBO)-14,
TURBO)-36, REMOVAL, Idle Air Control Sole, TURBO)-36, Idle Throttle Body.>
noid Valve.> Air Control Sole-
3)Remove the throttle body to intake manifold. noid Valve.>
<Ref. to FU(D0HC TURBO)-14, REMOVAL,
Throttle Body.>
4)Using an air gun, force air into the solenoid
valve installation area and throttle valve inte-
rior. Confirm that forced air subsequently I
escapes from both these areas.

EN(D0HC TURBO)-249
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

BI: DTC PO507 - IDLE CONTROL SYSTEM RPM HIGHER THAN EXPECTED -
DTC DETECTING CONDITION:

. Two consecutive driving cycles with fault

TROUBLE SYMPTOM:
Engine keeps running at higher revolution than specified idling revolution.
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

MAIN RELAY

m SBF-5
BATTERY

(3c 5 6 7 8

-1 AIR CONTROL

SOLENOID

IgI

I
- EN116(

EN(D0HC TURBO)-250
 51
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)
__

Step Check Yes No

I CHECK ANY OTHER DTC ON DISPLAY. loes the Subaru Select Moni- Inspect DTC 20 to step 2.
or or OBD-ll general scan tool PO508 or PO509
ndicate DTC PO508 or P0509? Jsing “List of Diag-
iostic Trouble
:ode (DTC)”.
<Ref.to EN(D0HC
TURBO)-80, List
Df Diagnostic Trou-
de Code (DTC).>
NOTE:
In this case, it is
l o t necessary tc
inspect DTC
P0507.
2 CHECK THROTTLE CABLE. loes the throttle cable have Go to step 3. 4djust throttle
,lay for adjustment? :able. <Ref. to
SP-7, INSTALLA-
TION, Accelerator
2ontrol Cable.>
3 CHECK AIR INTAKE SYSTEM. s there a fault in air intake sys- Repair air suction 3eplace the idle
1)Turnthe ignition switch to ON. em? and leaks. iir control solenoid
2)Start the engine, and idle it. ialve. <Ref. to
3)Check the following items. -U(DOHC
*Loose installation of intake manifold, idle air rURBO)-36, Idle
control solenoid valve and throttle body 4ir Control Sole-
Cracks of intake manifold gasket, idle air con- ioid Valve.>
trol solenoid valve gasket and throttle body
gasket
*Disconnections of vacuum hoses

EN(DOHC TU RB0)-251
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

BJ:DTC PO508 - IDLE CONTROL SYSTEM CIRCUIT LOW INPUT -

DTC DETECTING CONDITION:
Immediately at fault recognition
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
Engine breathing
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

MAIN RELAY

BATTERY

SBF-5

5 6 7 8

1-111 I

AIR CONTROL
SOLENOID
VALVE

EN(D0HC TURBO)-252
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)
~~ ~

Step Check Yes No

CHECK OUTPUT SIGNAL FROM ECM. s the voltage more than 3 V? 3epair poor con- Go to step 2.
1)Turn the ignition switch to ON. act in ECM con-
2)Measure the voltage between ECM and lector.
chassis ground.
Connector & terminal
(8136) No. 10 (+) - Chassis ground (-):
! CHECK POWER SUPPLY TO IDLE AIR CON- s the voltage more than 10 V? o
; to step 3. Repair harness
TROL SOLENOID VALVE. and connector.
1)Turnthe ignition switch to OFF. NOTE:
2)Disconnectthe connector from idle air con- In this case, repair
trol solenoid valve. the following:
3)Turn the ignition switch to ON. Open circuit in
4)Measure the voltage between idle air control harness between
solenoid valve and engine ground. idle air control
Connector & terminal solenoid valve and
(E7) No. 2 (+) - Engine groundI)-( main relay connec-
tor
Poor contact in
coupling connector
I CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 20 to step 4. Repair harness
IDLE AIR CONTROL SOLENOID VALVE Q? and connector.
NOTE:
In this case, repair
the following:
Open circuit in
harness between
ECM and idle air
control solenoid
valve connector
Poor contact in
coupling connector
I CHECK HARNESS BETWEEN ECM AND IS the resistance less than 10 3epair ground Go to step 5.
IDLE AIR CONTROL SOLENOID VALVE a? short circuit in har-
CONNECTOR. less between
Measure the resistance of harness between X M and idle air
ECM and chassis ground. :ontrol solenoid
Connector & terminal /alve connector.
(8136) No. 10 - Chassis ground:
I CHECK GROUND CIRCUIT OF IDLE AIR Is the resistance less than 5 20 to step 6. Repair open circuit
CONTROL SOLENOID VALVE. Q? in harness
Measure the resistance of harness between between idle air
idle air control solenoid valve connector and control solenoid
engine ground. valve connector
Connector & terminal and engine ground
(E7) No. 3 - Engine ground: terminal.
i CHECK POOR CONTACT. Is there poor contact in ECM 3epair poor con- Replace the idle
Check poor contact in ECM and idle air control and idle air control solenoid :act in ECM and air control solenoid
solenoid valve connectors. valve connectors? dle air control valve. <Ref. to
;olenoid valve FU(D0HC
:onnectors. TURBO)-36, Idle
Air Control Sole-
noid Valve.>

EN(DOHC TURB0)-253
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

BK:DTC PO509 - IDLE CONTROL SYSTEM CIRCUIT HIGH INPUT -

DTC DETECTING CONDITION:
Immediately at fault recognition
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
Engine breathing
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

MAIN RELAY

BATTERY

SBF-5

AIR CONTROL
SOLENOID
VALVE

lrOl
a-
%
@!
H
EN1160

EN(D0HC TURBO)-254
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step No
CHECK THROTTLE CABLE. Adjust throttle
'lay for adjustment? :able. <Ref. to
SP-7, INSTALLA-
TION, Accelerator
Control Cable.>
! CHECK OUTPUT SIGNAL FROM ECM. Go to step 4.
1)Turn the ignition switch to ON.
2)Measure the voltage between ECM and
chassis ground.
Connector & terminal
(6136) No. 10 (+) - Chassis ground (-):
I CHECK OUTPUT SIGNAL FROM ECM. s the voltage more than 10 V? Repair battery Replace the idle
1)Turn the ignition switch to OFF. short circuit in har- air control solenoic
2)Disconnect the connector from idle air con- ness between valve <Ref. to
trol solenoid valve. ECM and idle air FU(D0HC
3)Turn the ignition switch to ON. control solenoid TURBO)-36, Idle
4)Measure the voltage between ECM and valve connector. Air Control Sole-
chassis ground. After repair, noid Valve.> and
Connector & terminal replace the ECM. ECM <Ref. to
(6136) No. 10 (+) - Chassis ground (-): <Ref. to FU(D0HC FU(D0HC
TURBO)-47, TURBO)-47,
Engine Control Engine Control
Module.> Module.>.
I CHECK OUTPUT SIGNAL FROM ECM. Ioes the voltage change more Repair battery Contact with SOA
Measure the voltage between ECM and chas- han 10 V by shaking harness short circuit in har- (distributor) ser-
sis ground. ind connector of ECM while ness between vice.
Connector & terminal nonitoring the value with volt- ECM and idle air NOTE:
(6136) No. 10 (+) -Chassis ground (-): kge meter? control solenoid lnsepction by DTL
valve connector. is required, be
After repair, cause probablc
replace the ECM. cause is deteriora
<Ref. to FU(D0HC tion of multiplf
TU RB0)-47, parts.
Engine Control
Module.>

EN(D0HC TURBO)-255
I DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

EN(D0HC TURBO)-256
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE IDIAGNOSTICS)
~ ~ ~ ~
~ ~ ~

BL:DTC PO512 - STARTER SWITCH CIRCUIT HIGH INPUT -

DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
TROUBLE SYMPTOM:
Failure of engine to start
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.

EN(D0HC TURBO)-257
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

WIRING DIAGRAM:

IGNITION
SWITCH

INTERRUPT
RELAY El AT : AT VEHICLES

ITO SECURITY SYSTEM]

RE LAY(MT)

STARTER

SWITCH
(MT)

B U @ ECM

7 8 9 10 11 12

EN1139

EN(D0HC TURBO)-258
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

1 CHECK OPERATION OF STARTER MOTOR. Does the starter motor operate Repair battery Check starter
NOTE: when ignition switch to “ON”? short circuit in motor circuit.
Place the inhibitor switch in each position. starter motor cir- <Ref. to EN(D0HC
cuit. After repair, TURBO)-64,
replace the ECM. STARTER
<Ref. to FU(D0HC MOTOR CIR-
TURBO)-47, CUIT, Diagnostics
Engine Control for Engine Start-
Module.> ing Failure.>

EN(D0HC TURB0)-259
 lill
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

BM:DTC PO545 - EXHAUST GAS TEMPERATURE SENSOR CIRCUIT LOW IN-

PUT -
DTC DETECTING CONDITION:
Immediately at fault recognition
TROUBLE SYMPTOM:
Hard to start
Erroneous idling
Poor driving performance
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

EXHAUSTGAS
TEMPERATURE
SENSOR

IC

F
EN1161

EN(D0HC TURBO)-260
 Em
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

I CHECK CURRENT DATA. s the value greater than Go to step 2. Repair poor con-
1)Start the engine. 1200°C (2192”F)? tact.
2)Read the data of exhaust gas temperature NOTE:
sensor signal using Subaru Select Monitor or In this case, repaii
OBD-II general scan tool. the following:
NOTE: Poor contact in
*Subaru Select Monitor exhaust gas tem-
For detailed operation procedure, refer to the perature sensor
“READ CURRENT DATA FOR ENGINE”. <Ref. Poor contact in
to EN(D0HC TURBO)-38, Subaru Select Mon- ECM
itor., Poor contact in
*OBD-II general scan tool joint connector
For detailed operation procedures, refer to the
OBD-II General Scan Tool Instruction Manual.
! CHECK HARNESS BETWEEN EXHAUST s the value less than 372°C Replace the Repair ground
GAS TEMPERATURE SENSOR AND ECM 702”F)? exhaust gas tem- short circuit in har-
CONNECTOR. perature sensor. ness between
1)Turn the ignition switch to OFF. <Ref. to FU(D0HC exhaust gas tem-
2)Disconnect the connector from exhaust gas TURBO)-46, perature sensor
temperature sensor. Exhaust Tempera- and ECM connec-
3)Turn the ignition switch to ON. ture Sensor.> tor.
4)Read the data of exhaust gas temperature
sensor signal using Subaru Select Monitor or
OBD-II general scan tool.
NOTE:
*Subaru Select Monitor
For detailed operation procedure, refer to the
“READ CURRENT DATA FOR ENGINE. <Ref.
to EN(D0HC TURBO)-38, Subaru Select Mon-
itor.>
*OBD-II general scan tool
For detailed operation procedures, refer to the
OBD-II General Scan Tool Instruction Manual.

EN(D0HC TURBO)-261
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

BN:DTC PO546 - EXHAUST GAS TEMPERATURE SENSOR CIRCUIT HIGH IN-

PUT -
DTC DETECTING CONDITION:
Immediately at fault recognition
TROUBLE SYMPTOM:
Hard to start
Erroneous idling
Poor driving performance
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

EXHAUST GAS
TEMPERATURE
SENSOR

10

F
I @ECM

EN1 I61

EN(D0HC TURBO)-262
 p19
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK CURRENT DATA. ;the value less than 372°C 20 to step 2. lepair poor con-
1)Start the engine. 702”F)? act.
2)Read the data of exhaust gas temperature JOTE:
sensor signal using Subaru Select Monitor or n this case, repair
OBD-II general scan tool. he following:
NOTE: Poor contact in
*Subaru Select Monitor !xhaust gas tem-
For detailed operation procedure, refer to the )erature sensor
“READ CURRENT DATA FOR ENGINE”. <Ref. Poor contact in
to EN(D0HC TURBO)-38, Subaru Select Mon- iCM
itor.> Poor contact in
*OBD-ll general scan tool Dint connector
For detailed operation procedures, refer to the
OBD-II General Scan Tool Instruction Manual.
! CHECK HARNESS BETWEEN EXHAUST s the voltage more than 10 V? 3epair battery ;o to step 3.
GAS TEMPERATURE SENSOR AND ECM short circuit in har-
CONNECTOR. less between
1)Turnthe ignition switch to OFF. ECM and exhaust
2)Disconnect the connector from exhaust gas jas temperature
temperature sensor. sensor connector.
3)Measure the voltage between exhaust gas
temperature sensor connector and engine
ground.
Connector & terminal
(8279) No. 1 (+) - Engine ground (-):
I CHECKHARNESSBETWEENEXHAUST s the voltage more than 10 V? ?epair battery 30 to step 4.
GAS TEMPERATURE SENSOR AND ECM ;hort circuit in har-
CONNECTOR. less between
1)Turnthe ignition switch to ON. ECM and exhaust
2)Measure the voltage between exhaust gas gas temperature
temperature sensor connector and engine ;ensor connector.
ground.
Connector & terminal
(8279) No. 1 (+) - Engine ground (-):
I CHECK HARNESS BETWEEN EXHAUST s the voltage more than 4 V? 30 to step 5. lepair harness
GAS TEMPERATURE SENSOR AND ECM ind connector.
CONNECTOR. 4OTE:
Measure the voltage between exhaust gas n this case, repaii
temperature sensor connector and engine he following:
ground. Open circuit in
Connector & terminal iarness between
(8279) No. 1 (+) - Engine ground (-): X M and exhaust
jas temperature
;ensor connector
Poor contact in
?xhaustgas tem-
ierature sensor
:onnector
Poor contact in
X M connector
1 Poor contact in
oint connector

EN(D0HC TURBO)-263
I DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK HARNESS BETWEEN EXHAUST s the resistance less than 5 3eplace the Repair harness
GAS TEMPERATURE SENSOR AND ECM n? ?xhaustgas tem- and connector.
CONNECTOR. Ierature sensor. NOTE:
1)Turn the ignition switch to OFF. :Ref. to FU(D0HC In this case, repair
2)Measure the resistance of harness between
exhaust gas temperature sensor connector
and engine ground.
rURBO)-46,
Exhaust Tempera-
ure
.
the following:
Open circuit in
harness between
Connector & terminal ECM and exhaust
-
(B279) No. 2 Engine ground: gas temperature
sensor connector
I
Poor contact in
exhaust gas tem-
perature sensor
connector
Poor contact in
ECM connector
Poor contact in
joint connector

EN(DOHC TURB0)-264
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
a
ENGINE (DIAGNOSTICS)

EN(D0HC TURBO)-265
I DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

B0:DTC PO604 - INTERNAL CONTROL MODULE MEMORY CHECK SUM ER-

ROR -
DTC DETECTING CONDITION:
Immediately at fault recognition
TROUBLE SYMPTOM:
Engine does not start.
Engine stalls.
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.

EN(D0HC TURBO)-266
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

WIRING DIAGRAM:

M A I N RELAY

FRONT OXYGEN(A/F) SENSOIR -

IGNITION
SWITCH BATTERY
No.11 SBF-4 SBF-1

EN1171

Step Check Yes No

1 CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Moni- Replace the ECM. It is not necessary
tor or OBD-ll general scan tool <Ref. to FU(D0HC to inspect DTC
indicate DTC P0604? TURBO)-47, P0604.
Engine Control
Module.>

EN(DOHC TURB0)-267
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

BP:DTC PO703 - BRAKE SWITCH INPUT MALFUNCTION -

DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

BATTERY
n
r
I2 BRAKE LIGHT

Ip,
0
z

i I I T 0 STOP LIGHTS1

TCM

B2M4366

Step Check Yes No

1 CHECK OPERATION OF BRAKE LIGHT. Does the brake light come on Go to step 2. Repair or replace
when depressing the brake the brake light cir-
pedal? cuit.

EN(DOHC TURB0)-268
 U
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK HARNESS BETWEEN TCM AND Is the resistance less than 1 20 to step 3. Repair or replace
BRAKE LIGHT SWITCH CONNECTOR. R? the harness and
1)Disconnectthe connectors from TCM and connector.
brake light switch. NOTE:
2)Measure the resistance of harness between In this case, repai
TCM and brake light switch connector. the following:
Connector & terminal Open circuit in
-
(B55) NO. 12 (965) NO. 3: harness between
TCM and brake
light switch con-
nector
Poor contact in
TCM connector
Poor contact in
brake light switch
connector
I CHECK HARNESS BETWEEN TCM AND Is the resistance more than 1 30 to step 4. Repair ground
BRAKE LIGHT SWITCH CONNECTOR. MR? short circuit in har.
Measure the resistance of harness between ness between
TCM and chassis ground. TCM and brake
Connector & terminal light switch con-
(B55) No. 12 - Chassis ground: nector.
1 CHECK INPUT SIGNAL FOR TCM. Is the voltage less than 1 V 30 to step 5. Adjust or replace
1)Connect the connectors to TCM and brake when releasing the brake the brake light
light switch. pedal? switch. <Ref. to LI.
2)Measure the voltage between TCM and 7, STOP LIGHT
chassis ground. SWITCH,
Connector & terminal INSPECTION,
(B55) No. 12 (+) - Chassis ground (-): Stop Light Sys-
tem.>
B CHECK INPUT SIGNAL FOR TCM. Is the voltage more than 10 V 30 to step 6. Adjust or replace
Measure the voltage between TCM and chas- when depressing the brake the brake light
sis ground. pedal? switch. <Ref. to LI-
Connector & terminal 7, STOP LIGHT
(955) No. 12 (+) - Chassis ground (-): SWITCH,
INSPECTION,
Stop Light Sys-
tem.>
i CHECK POOR CONTACT. Is there poor contact in TCM 3epair poor con- Replace the TCM.
Check poor contact in TCM connector. connector? act in TCM con- <Ref. to AT-45,
lector. Transmission Con,
trol Module
(TCM).>

EN(D0HC TURBO)-269
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

BQ:DTC PO731 - GEAR 1 INCORRECT RATIO -

NOTE:
For the diagnostic procedure, refer to DTC P0734. <Ref. to EN(D0HC TURBO)-270, DTC PO734 - GEAR
4 INCORRECT RATIO -, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>

BR:DTC PO732 - GEAR 2 INCORRECT RATIO -

NOTE:
For the diagnostic procedure, refer to DTC P0734. <Ref. to EN(D0HC TURBO)-270, DTC PO734 - GEAR
4 INCORRECT RATIO -, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>

BS:DTC PO733 - GEAR 3 INCORRECT RATIO -

NOTE:
For the diagnostic procedure, refer to DTC P0734. <Ref. to EN(D0HC TURBO)-270, DTC PO734 - GEAR
4 INCORRECT RATIO -, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>

BT:DTC PO734 - GEAR 4 INCORRECT RATIO -

DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
TROUBLE SYMPTOM:
Shift point too high or too low; engine brake not effective in “3’ range; excessive shift shock; excessive
tight corner “braking”
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

Step Check Yes No

1 CHECK ANY OTHER DTC ON DISPLAY. Is there any other DTC on dis- Inspect relevant Go to step 2.
play? DTC using “List of
Diagnostic Trou-
ble Code (DTC)”.
<Ref. to EN(D0HC
TURBO)-80, List
of Diagnostic Trou-
ble Code (DTC).>
2 CHECK THROTTLE POSITION SENSOR Is there any trouble in throttle Repair or replace Go to step 3.
CIRCUIT. position sensor circuit? the throttle posi-
Check throttle position sensor circuit. <Ref. to tion sensor circuit.
AT-52, DTC 31 THROTTLE POSITION SEN-
SOR, Diagnostic Procedure with Diagnostic
Trouble Code (DTC).>
3 CHECK FRONT VEHICLE SPEED SENSOR Is there any trouble in vehicle Repair or replace Go to step 4.
CIRCUIT. speed sensor 2 circuit? the vehicle speed
Check front vehicle speed sensor circuit. <Ref. sensor 2 circuit.
to AT-57, DTC 33 FRONT VEHICLE SPEED
SENSOR, Diagnostic Procedure with Diagnos-
tic Trouble Code (DTC).> I

1 CHECK TORQUE CONVERTER TURBINE Is there any trouble in torque

SPEED SENSOR CIRCUIT. converter turbine speed sensor the torque con-
Check torque converter turbine speed sensor circuit? verter turbine
circuit. <Ref. to AT-62, DTC 36 TORQUE CON- speed sensor cir-
VERTER TURBINE SPEED SENSOR, Diag-
nostic Procedure with Diagnostic Trouble Code
(DTC).>

EN(DOHC TU RB0)-270
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

5 CHECK POOR CONTACT. Is there poor contact in TCM Repair poor con- Go to step 6.
Check poor contact in TCM connector. connector? tact in TCM con-
nector.
6 CHECK MECHANICAL TROUBLE. Is there any mechanicaltrouble Repair or replace Replace the TCM.
Check mechanical trouble in automatic trans- in automatic transmission? the automatic <Ref. to AT-45,
mission. transmission. Transmission Con-
<Ref. to AT-12, trol Module
INSPECTION, (TCM).>
Road Test.>

EN(D0HC TURB0)-271
 -
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

BU:DTC PO741 - TORQUE CONVERTER CLUTCH SYSTEM MALFUNCTION -

DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
TROUBLE SYMPTOM:
No lock-up (after engine warm-up)
No shift or excessive tight corner “braking”
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.

Step Check Yes No

1 CHECK ANY OTHER DTC ON DISPLAY. Is there any other DTC on dis- Inspect the rele- Go to step 2.
play? vant DTC using
“List of Diagnostic
Trouble Code
(DTC)”. <Ref. to
EN(D0HC
TURBO)-80, List
of Diagnostic Trou,
ble Code (DTC).>
2 CHECK LOCK-UP DUTY SOLENOID CIR- Is there any trouble in lock-up Repair or replace Go to step 3.
CUIT. duty solenoid circuit? the lock-up duty
Check lock-up duty solenoid circuit. <Ref. to solenoid circuit.
AT-94, DTC 77 LOCK-UP DUTY SOLENOID,
Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
3 CHECK THROTTLE POSITION SENSOR Is there any trouble in throttle Repair or replace Go to step 4.
CIRCUIT. position sensor circuit? the throttle posi-
Check throttle position sensor circuit. <Ref. to tion sensor circuit.
AT-52, DTC 31 THROTTLE POSITION SEN-
SOR, Diagnostic Procedure with Diagnostic
Trouble Code (DTC).>
4 CHECK TORQUE CONVERTER TURBINE Is there any trouble in torque Repair or replace Go to step 5.
SPEED SENSOR CIRCUIT. converter turbine speed sensor the torque con-
Check torque converter turbine speed sensor circuit? verter turbine
circuit. <Ref. to AT-62, DTC 36 TORQUE CON. speed sensor cir-
VERTER TURBINE SPEED SENSOR, Diag- cuit.
nostic Procedure with Diagnostic Trouble Code
(DTC).>
5 CHECK ENGINE SPEED INPUT CIRCUIT. Is there any trouble in engine Repair or replace Go to step 6.
Check engine speed input circuit. <Ref. to AT- speed input circuit? the engine speed
44, DTC 11 ENGINE SPEED SIGNAL, Diag- input circuit.
nostic Procedure with Diagnostic Trouble Code
(DTC).>
6 CHECK INHIBITOR SWITCH CIRCUIT. Is there any trouble in inhibitor Repair or replace Go to step 7.
Check inhibitor switch circuit. <Ref. to AT-1 15, switch circuit? the inhibitor switch
CHECK INHIBITOR SWITCH., Diagnostic Pro. circuit.
cedure for No-DiagnosticTrouble Code
(DTC).>
7 CHECK BRAKE LIGHT SWITCH CIRCUIT. Go to step 8.
- Check brake light switch circuit. <Ref. to AT- light switch circuit? the brake light
112, CHECK BRAKE SWITCH., Diagnostic switch circuit.
Procedure for No-DiagnosticTrouble Code
(DTC).>

EN(D0HC TURBO)-272
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

8 CHECK ATF TEMPERATURE SENSOR CIR- Is there any trouble in ATF tem- Repair or replace Go to step 9.
CUIT. perature sensor circuit? the ATF tempera-
Check ATF temperature sensor circuit. <Ref. to ture sensor circuit.
AT-48, DTC 27 ATF TEMPERATURE SEN-
SOR, Diagnostic Procedure with Diagnostic
Trouble Code (DTC).>
9 CHECK POOR CONTACT. Is there poor contact in TCM Repair poor con- Go to step 10.
Check poor contact in TCM connector. connector? tact in TCM con-
nector.
Is there any mechanicaltrouble Repair or replace Replace the TCM.
Check mechanical trouble in automatic trans- in automatic transmission? the automatic <Ref. to AT-45,
mission. transmission. Transmission Con-
<Ref. to AT-12, trol Module
INSPECTION, (TCM).>
Road Test.>

EN(D0HC TURBO)-273
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

BV: DTC PI086 - TUMBLE GENERATOR VALVE #2 (LH) POSITION SENSOR

CIRCUIT LOW INPUT -
DTC DETECTING CONDITION:
Immediately at fault recognition
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
Poor driving performance
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

TUMBLE GENERATOR VALVE

POSITION SENSOR

" -

EN(DOHC TURB0)-274
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK CURRENT DATA. s the value less than 0.1 V? 30 to step 2. Even if MIL lights
1)Start the engine. up, the circuit has
2)Read the data of tumble generator valve returned to a nor-
position sensor signal using Subaru Select mal condition at
Monitor or OBD-ll general scan tool. this time. A tempo.
NOTE: rary poor contact
*Subaru Select Monitor of the connector
For detailed operation procedure, refer to the may be the cause.
“READ CURRENT DATA FOR ENGINE”. <Ref. NOTE:
to EN(D0HC TURBO)-38, Subaru Select Mon- In this case, repaii
itor.> the following:
*OBD-ll general scan tool Poor contact in
For detailed operation procedures, refer to the throttle position
OBD-II General Scan Tool Instruction Manual. sensor connector
Poor contact in
ECM connector
Poor contact in
coupling connect0
! CHECK INPUT SIGNAL FOR ECM. s the voltage more than 4.5 V? 20 to step 4. Go to step 3.
Measure the voltage between ECM connector
and chassis ground while tumble generator
valve is fully closed.
‘Connector & terminal
(8135) No. 9 (+) - Chassis ground (-):
I CHECK INPUT SIGNAL FOR ECM. loes the voltage change more 3epair poor con- Contact with SOA
Measure the voltage between ECM connector han 4.5 V by shaking harness act in ECM con- (distributor)ser-
and chassis ground. md connector of ECM while lector. vice.
Connector & terminal nonitoring the value with volt- NOTE:
(8135) No. 9 (+) - Chassis ground (-): ige meter? Inspection by DTk
is required, be
cause probable
cause is deteriora
tion of multiple
parts.
I CHECK INPUT SIGNAL FOR ECM. s the voltage less than 0.1 V? 30 to step 6. Go to step 5.
Measure the voltage between ECM connector
and chassis ground.
Connector & terminal
(8135) No. 13 (+) - Chassis ground (-):
I CHECK INPUT SIGNAL FOR ECM. (USING loes the voltage change more 3epair poor con- Go to step 6.
SUBARU SELECT MONITOR.) han 0.1 V by shaking harness :act in ECM con-
Measure the voltage between ECM connector md connector of ECM while lector.
and chassis ground. nonitoring the value with Sub-
3ru Select Monitor?

EN(D0HC TURBO)-275
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

6 CHECK HARNESS BETWEEN ECM AND s the voltage more than 4.5 V' 20 to step 7. Repair harness
TUMBLE GENERATOR VALVE POSITION and connector.
SENSOR CONNECTOR. NOTE:
1)Turn the ignition switch to OFF. In this case, repai
2)Disconnectthe connectors from tumble gen- the following:
erator valve position sensor. Open circuit in
3)Turn the ignition switch to ON. harness between
4)Measure voltage between tumble generator tumble generator
valve position sensor connector and engine valve position sen
ground. sor and ECM con-
Connector & terminal nector
(E50) No. 1 (+)- Engine ground (-): Poor contact in
tumble generator
valve position sen
sor connector
Poor contact in
ECM connector
Poor contact in
coupling conneck
Poor contact in
joint connector
7 CHECK HARNESS BETWEEN ECM AND s the resistance less than 1 20 to step 8. Repair harness
TUMBLE GENERATOR VALVE POSITION 2? and connector.
SENSORCONNECTOR. NOTE:
1)Turn the ignition switch to OFF. In this case, repa
2)Measure the resistance of harness between the following:
ECM connector and tumble generator valve Open circuit in
position sensor connector. harness between
Connector & terminal tumble generator
(8135) NO. 13 - (E50) NO. 3: valve position sen
sor and ECM con-
nector
Poor contact in
ECM connector
Poor contact in
tumble generator
valve position sen
sor connector
Poor contact in
coupling connectc
8 CHECK HARNESS BETWEEN ECM AND s the resistance less than 10 3epair ground Go to step 9.
TUMBLE GENERATOR VALVE POSITION 2? short circuit in har-
SENSOR CONNECTOR. less between tum-
Measure the resistance of harness between )le generator valve
tumble generator valve position sensor con- losition sensor
nector and engine ground. and ECM connec-
Connector & terminal or.
(€50) No. 3 - Engine ground:
9 CHECK POOR CONTACT. s there poor contact in tumble 3epair poor con- Replace the tum-
Check poor contact in tumble generator valve lenerator valve position sensoi act in tumble gen- ble generator valvc
position sensor connector. :onnector? ?ratorvalve assembly. <Ref. tc
iosition sensor FU(D0HC
:onnector. TURBO)-40, Tum-
ble Generator
Valve Assembly.>

EN(D0HC TURBO)-276
EN(D0HC TURBO)-277
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

BW:DTC PI087 -TUMBLE GENERATOR VALVE #2 (LH) POSITION SENSOR

CIRCUIT HIGH INPUT -
DTC DETECTING CONDITION:
immediately at fault recognition
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
Poor driving performance
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

TUMBLE GENERATOR VALVE

POSITION SENSOR

U@ECM

EN1162

EN(DOHC TURB0)-278
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)
~~

Step Check Yes No

CHECK CURRENT DATA. s the value more than 4.9 V? Go to step 2. Even if MIL lights
1)Start the engine. up, the circuit has
2)Read the data of tumble generator valve returned to a nor-
position sensor signal using Subaru Select mal condition at
Monitor or OBD-ll general scan tool. this time. A tempo-
NOTE: rary poor contact
*Subaru Select Monitor Df the connector
For detailed operation procedure, refer to the may be the cause.
“READ CURRENT DATA FOR ENGINE”. <Ref. NOTE:
to EN(D0HC TURBO)-38, Subaru Select Mon- In this case, repair
itor.> the following:
*OBD-ll general scan tool b Poor contact in
For detailed operation procedures, refer to the tumble generator
OBD-II General Scan Tool Instruction Manual. valve position sen-
sor connector
b Poor contact in
ECM connector
Poor contact in
soupling connectot
! CHECK HARNESS BETWEEN TUMBLE s the resistance less than 5 Go to step 3. Repair harness
GENERATOR VALVE POSITION SENSOR 3? and connector.
4ND ECM CONNECTOR. NOTE:
1)Turnthe ignition switch to OFF. In this case, repair
2)Disconnect the connector from tumble gen- the following:
erator valve position sensor. b Open circuit in

3)Measure the resistance of harness between harness between

throttle position sensor connector and engine tumble generator
ground. valve position sen-
Connector & terminal sor and ECM con-
(€50) No. 2 - Engine ground: nector
b Poor contact in
soupling connector
b Poor contact in
ioint connector
I CHECK HARNESS BETWEEN TUMBLE Replace the tum-
GENERATOR VALVE POSITION SENSOR short circuit in har- ble generator valve
AND ECM CONNECTOR. ness between tum- assembly. <Ref. to
1)Turn the ignition switch to ON. ble generator valve FU(D0HC
2)Measure the voltage between throttle posi- position sensor TURBO)-40, Tum-
tion sensor connector and engine ground. and ECM connec- ble Generator
Connector & terminal tor. After repair, Valve Assembly.>
(€50) No. 3 (+) - Engine ground (-): replace the ECM.
<Ref. to FU(D0HC
TURBO)-47,
Engine Control
Module.>

EN(D0HC TURBO)-279
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENG I N E (DIAGNOSTICS)

BX: DTC PI088 -TUMBLE GENERATOR VALVE #I(RH) POSITION SENSOR

CIRCUIT LOW INPUT -
DTC DETECTING CONDITION:
Immediately at fault recognition
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
Poor driving performance
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

TUMBLE GENERATOR VALVE

POSITION SENSOR

EN1163

EN(D0HC TURBO)-280
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

I CHECK CURRENT DATA. the value less than 0.1 V? 20 to step 2. Even if MIL lights
1)Start the engine. up, the circuit has
2)Read the data of tumble generator valve returned to a nor-
position sensor signal using Subaru Select mal condition at
Monitor or OBD-II general scan tool. this time. A tempo-
NOTE: rary poor contact
*Subaru Select Monitor of the connector
For detailed operation procedure, refer to the may be the cause.
“READ CURRENT DATA FOR ENGINE”. <Ref NOTE:
to EN(D0HC TURBO)-38, Subaru Select Mon In this case, repaii
itor.> the following:
*OBD-II general scan tool Poor contact in
For detailed operation procedures, refer to the tumble generator
OBD-II General Scan Tool Instruction Manual. valve position sen-
sor connector
8 Poor contact in

-
ECM connector
Poor contact in
coupling connectoi
! CHECK INPUT SIGNAL FOR ECM. the voltage more than 4.5 V? 30 to step 4. Go to step 3.
Measure the voltage between ECM connector
and chassis ground while throttle valve is fully
clised.
Connector & terminal
(8135) No. 9 (+) - Chassis ground (-):
I CHECK INPUT SIGNAL FOR ECM. )es the voltage change more 3epair poor con- Contact with SOA
Measure the voltage between ECM connector %n4.5 V by shaking harness act in ECM con- (distributor) ser-
and chassis ground. d connector of ECM while lector. vice.
Connector & terminal mitoring the value with volt- NOTE:
(6135) No. 9 (+) - Chassis ground (-): e meter? Inspection by DTM
is required, be.
cause probable
cause is deteriora.
tion of multiple
parts.
I CHECK INPUT SIGNAL FOR ECM. the voltage less than 0.1 V? ;o to step 6. Go to step 5.
Measure the voltage between ECM connector
and chassis ground.
Connector & terminal
(8135) No. 23 (+) - Chassis ground (-):
1 CHECK INPUT SIGNAL FOR ECM. (USING )es the voltage change more 3epair poor con- Go to step 6.
SUBARU SELECT MONITOR.) %n0.1 V by shaking harness act in ECM con-
Measure the voltage between ECM connector d connector of ECM while lector.
and chassis ground. mitoring the value with Sub-
J Select Monitor?

EN(D0HC TURBO)-281
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK HARNESS BETWEEN ECM AND I Is the voltage more than 4.5 VI; 30 to step 7. Repair harness
TUMBLE GENERATOR VALVE POSITION and connector.
SENSOR CONNECTOR. NOTE:
1)Turnthe ignition switch to OFF. In this case, repai
2)Disconnect the connectors from tumble gen- the following:
erator valve position sensor. Open circuit in
3)Turn the ignition switch to ON. harness between
4)Measure the voltage between throttle posi- tumble generator
tion sensor connector and engine ground. valve position sen-
Connector & terminal sor and ECM con-
(E54) No. 1 (+) - Engine ground (-): nector
Poor contact in
tumble generator
valve position sen-
sor connector
Poor contact in
ECM connector
Poor contact in
coupling connect0
Poor contact in
joint connector
resistance less than 1 20 to step 8. Repair harness
and connector.
SENSOR CONNECTOR. NOTE:
1)Turnthe ignition switch to OFF. In this case, repai
2)Measure the resistance of harness between the following:
ECM connector and tumble generator valve Open circuit in
position sensor connector. harness between
Connector & terminal tumble generator
(8135) NO. 23 - (E54) NO. 3: valve position sen-
sor and ECM con-
nector
Poor contact in
ECM connector
Poor contact in
tumble generator
valve position sen-
sor connector
Poor contact in
coupling connectoi
CHECK HARNESS BETWEEN ECM AND IS the resistance less than 10 3epair ground Go to step 9.
THROlTLE POSITION SENSOR CONNEC- Q? ;hort circuit in har-
TOR. less between tum-
Measure the resistance of harness between ile generator valve
tumble generator valve position sensor con- iosition sensor
nector and engine ground. and ECM connec-
Connector & terminal or.
(E54) No. 3 - Engine ground:
CHECK POOR CONTACT. Is there poor contact in tumble 3epair poor con- Replace the tum-
Check poor contact in tumble generator valve generator valve position sensor act in tumble gen- ble generator valve
position sensor connector. connector? ?ratorvalve assembly. <Ref. to
iosition sensor FU(D0HC
:onnector. TURBO)-40, Tum-
ble Generator
Valve Assembly.>

EN(D0HC TURBO)-282
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

EN(D0HC TURBO)-283
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)
~~

BY:DTC PI089 - TUMBLE GENERATOR VALVE #I(RH) POSITION SENSOR

CIRCUIT HIGH INPUT -
DTC DETECTING CONDITION:
Immediately at fault recognition
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
Poor driving performance
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

TUMBLE GENERATOR VALVE

POSITION SENSOR

" -

U@ECM

EN(DOHC TURB0)-284
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

I CHECK CURRENT DATA. s the value more than 4.9 V? 20 to step 2. Even if MIL lights
1)Start the engine. up, the circuit has
2)Read the data of tumble generator valve returned to a nor-
position sensor signal using Subaru Select mal condition at
Monitor or OBD-ll general scan tool. this time. A tempo
NOTE: rary poor contact
Gubaru Select Monitor of the connector
For detailed operation procedure, refer to the may be the cause
“READ CURRENT DATA FOR ENGINE”. <Ref. NOTE:
to EN(D0HC TURBO)-38, Subaru Select Mon In this case, repai
itor.> the following:
*OBD-ll general scan tool Poor contact in
For detailed operation procedures, refer to the tumble generator
OBD-II General Scan Tool Instruction Manual. valve position sen
sor connector
Poor contact in
ECM connector
Poor contact in
coupling connectc
2 CHECK HARNESS BETWEEN TUMBLE s the resistance less than 5 30 to step 3. Repair harness
GENERATOR VALVE POSITION SENSOR 2? and connector.
AND ECM CONNECTOR. NOTE:
1 !Turn the ignition switch to OFF. In this case, repai
2)Disconnect the connector from tumble gen- the following:
erator valve position sensor. Open circuit in
3)Measure the resistance of harness between harness between
tumble generator valve position sensor con- tumble generator
nector and engine ground. valve position sen.
Connector & terminal sor and ECM con-
(E54) No. 2 - Engine ground: nector
8 Poor contact in
coupling connect0
Poor contact in
joint connector
B CHECK HARNESS BETWEEN TUMBLE s the voltage more than 4.9 V? 3epair battery Replace the tum-
GENERATOR VALVE POSITION SENSOR ;hort circuit in har- ble generator valve
AND ECM CONNECTOR. less between tum- assembly. <Ref. tc
1)Turn the ignition switch to ON. )le generator valve FU(D0HC
2)Measure the voltage between tumble gener- )osition sensor TURBO)-40, Tum-
ator valve position sensor connector and ind ECM connec- ble Generator
engine ground. or. After repair, Valve Assembly.>
Connector & terminal eplace the ECM.
(E54) No. 3 (+) - Engine ground (-): :Ref. to FU(D0HC
-URBO)-47,
ingine Control
Aodule.>

EN(DOHC TURBO)-285
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

BZ:DTC P1090 -TUMBLE GENERATOR VALVE SYSTEM #1 (RH) MALFUNC-

TION (STUCK OPEN) -
DTC DETECTING CONDITION:
immediately at fault recognition
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.

Step Check Yes No

1 CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Moni- Inspect DTC Go to step 2.
tor or OBD-ll general scan tool
P1088, P1089,
indicate P1088, P1089, P1094 PI094 or PI095
or P I 095? using List of Diag-
nostic Trouble
Code (DTC) <Ref.
to EN(D0HC
TURBO)-80, List
of Diagnostic Trou-
ble Code (DTC).>
2 FHECK TUMBLE GENERATOR VALVE RH Does the tumble generator Replace the tum- Clean tumble gen-
1)Removethe tumble generator valve assem- valve move smoothly? (No dirt ble generator valve erator valve.
bly. or foreign materials clogged) assembly. <Ref. to
2)Check tumble generator valve body. FU(D0HC
TURBO)-40, Tum-
ble Generator
Valve Assembly.>

EN(D0HC TURBO)-286
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

CA:DTC PI091 -TUMBLE GENERATOR VALVE SYSTEM #I(RH) MALFUNC-

TION (STUCK CLOSE) -
DTC DETECTING CONDITION:
Immediately at fault recognition
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.

Step Check Yes No

1 CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Moni- Inspect DTC Go to step 2.
tor or OBD-ll general scan tool
P I 088, P I 089,
P I094 or P I 095
indicate P I 088, P I 089, P I 094
or P1095? using List of Diag-
nostic Trouble
Code (DTC) <Ref.
to EN(D0HC
TURBO)-80, List
of Diagnostic Trou-
ble Code (DTC).>
2 CHECK TUMBLE GENERATOR VALVE RH Does the tumble generator Replace the tum- Clean tumble gen-
1)Remove the tumble generator valve assem- valve move smoothly? (No dirt ble generator valve erator valve.
bly. or foreign materials clogged) assembly. <Ref. to
2)Check tumble generator valve body. FU(DOHC
TURBO)-40, Tum-
ble Generator
Valve Assemblw

EN(DOHC TURB0)-287
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

CB:DTC PI092 -TUMBLE GENERATOR VALVE SYSTEM #2 (LH) MALFUNC-

TION (STUCK OPEN) -
DTC DETECTING CONDITION:
Immediately at fault recognition
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.

Step Check Yes No

1 CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Moni- Inspect DTC Go to step 2.
tor or OBD-ll general scan toolP1086, P1087,
indicate P1086, P1087, P1096 P1096 or P I 097
or P1097? using List of Diag-
nostic Trouble
Code (DTC) <Ref.
to EN(D0HC
TURBO)-80, List
of Diagnostic Trou-
ble Code (DTC).>
2 CHECK TUMBLE GENERATOR VALVE RH Does the tumble generator Replace the tum- :lean tumble gen-
‘1)Remove the tumble generator valve assem- valve move smoothly? (No dirt ble generator valve srator valve.
bly. or foreign materials clogged) assembly. <Ref. to
2)Check tumble generator valve body. FU(D0HC
TURBO)-40, Tum-
ble Generator
Valve Assembly.>

EN(D0HC TURBO)-288
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

CC:DTC PI093 -TUMBLE GENERATOR VALVE SYSTEM #2 (LH) MALFUNC-

TION (STUCK CLOSE) -
DTC DETECTING CONDITION:
Immediately at fault recognition
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.

Step Check Yes No

1 CHECK ANY OTHER DTC ON DISPLAY. 3oes the Subaru Select Moni- Inspect DTC Go to step 2.
:or or OBD-II general scan tool
P1086, P1087,
ndicate P1086, P1087, P1096 P1096 or P1097
3r P1097? using List of Diag-
nostic Trouble
Code (DTC) <Ref.
to EN(D0HC
TURBO)-80, List
of Diagnostic Trou-
ble Code (DTC).>
2 CHECK TUMBLE GENERATOR VALVE RH Does the tumble generator Replace the tum- Clean tumble gen-
1)Remove the tumble generator valve assem- valve move smoothly? (No dirt ble generator valve erator valve.
bly. 3r foreign materials clogged) assembly. <Ref. to
2)Check tumble generator valve body. FU(D0HC
TURBO)-40, Tum-
ble Generator
Valve Assembly.>

EN(D0HC TURBO)-289
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

CD:DTC PI094 - TUMBLE GENERATOR VALVE CIRCUIT #I(OPEN CIRCUIT)

-
DTC DETECTING CONDITION:
Immediately at fault recognition
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

TUMBLE
GENERATOR VALVE
ACTUATOR RH

EN(D0HC TURBO)-290
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK HARNESS BETWEEN ECM AND s the resistance less than 1Q? I Go to step 2. Repair open circuit
TUMBLE GENERATOR VALVE ACTUATOR between ECM and
CONNECTOR. tumble generator
1)Turnthe ignition switch to OFF. valve connector.
2)Disconnectthe connector from tumble gen- NOTE:
erator valve and ECM connector. In this case, repaii
3)Measure the resistance between tumble the following:
generator valve actuator and ECM connector. Open circuit in
Connector & terminal harness between
(E55) NO. 1 - (B84) N0.4: ECM and tumble
(E55) NO. 2 - (B84) NO.5: generator valve
actuator connec-
tor.
Poor contact in
coupling connec-
tor.
! CHECK POOR CONTACT. s there poor contact in tumble rlepair poor con- Replace the tum-
Check poor contact in tumble generator valve jenerator valve actuator con- tact in tumble gen- ble generator valve
actuator connector. lector. erator valve assembly. <Ref. to
actuator connec- FU(D0HC
tor. TURBO)-40, Tum-
ble Generator
Valve Assembly.>

EN(D0HC TURBO)-291
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

CE:DTC PI095 -TUMBLE GENERATOR VALVE CIRCUIT #I (OVERCURRENT)

DTC DETECTING CONDITION:

Immediately at fault recognition
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

TUMBLE
GENERATOR VALVE
ACTUATORRH

EN116r

EN(D0HC TURB0)-292
I
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

1 CHECK HARNESS BETWEEN ECM AND Is the voltage less than 5V? Replace the tum- Repair battery
TUMBLE GENERATOR VALVE ACTUATOR ble generator valve short circuit
CONNECTOR. assembly. <Ref. to between ECM and
1)Turn the ignition switch to OFF. FU(D0HC tumble generator
2)Disconnect the connector from tumble gen- TURBO)-40, Tum- valve actuator.
erator valve connector. ble Generator
3)Measure the voltage between tumble gener- Valve Assembly.>
ator valve actuator and chassis ground.
Connector & terminal
(E55) No. 1 (+) - Chassis ground (-):
(€55) No. 2 1+J - Chassis around (4:

EN(D0HC TURBO)-293
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

CF:DTC PI096 - TUMBLE GENERATOR VALVE CIRCUIT #2 (OPEN CIRCUIT)

-
DTC DETECTING CONDITION:
Immediately at fault recognition
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

TUMBLE
GENERATOR VALVE
ACTUATOR LH

EN1165

EN(D0HC TURBO)-294
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

I CHECK HARNESS BETWEEN ECM AND s the resistance less than 1a? Go to step 2. Repair open circuit
TUMBLE GENERATOR VALVE ACTUATOR between ECM and
CONNECTOR. tumble generator
1)Turn the ignition switch to OFF. valve connector.
2)Disconnect the connector from tumble gen- NOTE:
erator valve and ECM connector. In this case, repaii
3)Measure the resistance between tumble the following:
generator valve actuator and ECM connector. Open circuit in
Connector & terminal harness between
(E5l) NO. 1 - (884)NO. 10: ECM and tumble
(E5l) NO. 2 - (884)NO. 11: generator valve
actuator connec-
tor.
Poor contact in
coupling connec-
tor.
2 CHECK POOR CONTACT. s there poor contact in tumble Repair poor con- Replace the tum-
Check poor contact in tumble generator valve jenerator valve actuator con- tact in tumble gen- ble generator valve
actuator connector. lector. erator valve assembly. <Ref. to
actuator connec- FU(D0HC
tor. TURBO)-40, Tum-
ble Generator
Valve Assembly.>

EN(D0HC TURBO)-295
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

CG:DTC PI097 -TUMBLE GENERATOR VALVE ClRCUlT#2 (OVERCURRENT)

DTC DETECTING CONDITION:

Immediately at fault recognition
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

TUMBLE
GENERATOR VALVE
ACTUATOR LH

EN1165

EN(D0HC TURBO)-296
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

1 CHECK HARNESS BETWEEN ECM AND Is the voltage less than 5V? Replace the tum- Repair battery
TUMBLE GENERATOR VALVE ACTUATOR ble generator valve short circuit
CONNECTOR. assembly. <Ref. to between ECM and
1)Turn the ignition switch to OFF. FU(D0HC tumble generator
2)Disconnect the connector from tumble gen- TURBO)-40, Tum- valve actuator.
erator valve connector. ble Generator
3)Measure the voltage between tumble gener- Valve Assembly.>
ator valve actuator and chassis ground.
Connector & terminal
(€51) No. 1 (+) - Chassis ground (-):
(E51) No. 2 (+) - Chassis ground (-):

CH:DTC PI110 - ATMOSPHERIC PRESSURE SENSOR CIRCUIT LOW INPUT

DTC DETECTING CONDITION:

Two consecutive driving cycles with fault
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-

Step Check Yes No

1 CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Moni- Replace the ECM. It is not necessary
tor or OBD-ll general scan tool <Ref. to FU(D0HC to inspect DTC
indicate DTC P11l o ? TURBO)-47, P1110.
Engine Control
Module.>
NOTE:
Atmospheric pres-
sure sensor is buili
into ECM.

CI: DTC P I 111 - ATMOSPHERIC PRESSURE SENSOR CIRCUIT HIGH INPUT

DTC DETECTING CONDITION:

Two consecutive driving cycles with fault
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.

Step Check Yes No

1 CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Moni- Replace the ECM. It is not necessary
tor or OBD-II general scan tool <Ref. to FU(D0HC to inspect DTC
indicate DTC P111l ? TURBO)-47, P1111.
Engine Control
Module.>
NOTE:
Atmospheric pres-
sure sensor is built
into ECM.

EN(DOHC TURB0)-297
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)
~

-
CJ:DTC P I 112 ATMOSPHERIC PRESSURE SENSOR CIRCUIT RANGWPER-
FORMANCE PROBLEM -
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.

Step Check Yes No

1 CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Moni- Inspect DTC Replace the ECM.
tor or OED-ll general scan tool PO106, PO107, <Ref. to FU(D0HC
indicate DTC PO106, PO107, PO108, P1110 or TURBO)-47,
P0108, P1110 or P111I ? P I 111 using “List Engine Control
of Diagnostic Trou- Module.>
ble Code NOTE:
(DTC)”.<Ref. to Atmospheric pres
EN(D0HC sure sensor is buill
TURBO)-80, List into ECM.
of Diagnostic Trou-
ble Code (DTC).>

EN(D0HC TURBO)-298
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

EN(D0HC TURBO)-299
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

CK: DTC P I 130 - FRONT OXYGEN (NF)SENSOR CIRCUIT MALFUNCTION

(OPEN CIRCUIT) -
DTC DETECTING CONDITION:
Immediately at fault recognition
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:
-

FN1143

EN(D0HC TURBO)-300
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Go to step 2. Repair harness
FRONT OXYGEN ( N F ) SENSOR CONNEC- a? and connector.
TOR. NOTE:
1)Turn the ignition switch to OFF. In this case, repaii
2)Disconnect the connectors from ECM and the following:
front oxygen (NF) sensor connector. Open circuit in
3)Measure the resistance of harness between harness between
ECM and front oxygen (NF) sensor connector. ECM and front
Connector & terminal oxygen (NF)sen-
(8137) NO. 29 - (818) NO. 3: sor connector
(8137) NO. 19 - (818) NO. 4: Poor contact in
front oxygen (NF)
sensor connector
9 Poor contact in
ECM connector
CHECK POOR CONTACT. Is there poor contact in front 3epair poor con- Replace the front
Check poor contact in front oxygen (NF) sen- oxygen (NF) sensor connec- act in front oxygen oxygen (NF) sen-
sor connector. tor? N F ) sensor con- sor. <Ref. to
lector. FU(D0HC
TURBO)-42, Front
Oxygen (NF) Sen,
sor.>

EN(D0HC TURBO)-301
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

CL: DTC P I 131 - FRONT OXYGEN (NF) SENSOR CIRCUIT MALFUNCTION

(SHORT CIRCUIT) -
DTC DETECTING CONDITION:
Immediately at fault recognition
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

MAIN RELAY BATTERY

SBF-5
3 c

EN1143

EN(D0HC TURBO)-302
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK HARNESS BETWEEN ECM AND the resistance more than 10 Go to step 2. Repair ground
FRONT OXYGEN (NF) SENSOR CONNEC- ? short circuit in har
TOR. ness between
1)Turnthe ignition switch to OFF. ECM and front
2)Disconnect the connector from ECM. oxygen (NF) sen-
3)Measure the resistance of harness between sor connector.
ECM connector and chassis ground.
Connector & terminal
(8137) No. 19 - Chassis ground:
CHECK HARNESS BETWEEN ECM AND the resistance more than 10 Go to step 3. Repair ground
FRONT OXYGEN ( A F ) SENSOR CONNEC- ? short circuit in har
TOR. ness between
Measure the resistance of harness between ECM and front
ECM connector and chassis ground. oxygen (NF) sen-
Connector & terminal sor connector.
(8137) No. 29 - Chassis ground:
CHECK OUTPUT SIGNAL FOR ECM. the voltage more than 4.5 V? Go to step 4. Go to step 5.
1)Connect the connector to ECM.
2)Turn the ignition switch to ON.
3)Measure the voltage between ECM connec-
tor and chassis ground.
Connector & terminal
(8137) No. 19 (+) - Chassis ground (-):
CHECK OUTPUT SIGNAL FOR ECM. the voltage more than 10 V? Repair battery Repair poor con-
Measure the voltage between ECM connector short circuit in har- tact in ECM con-
and chassis ground. ness between nector.
Connector & terminal ECM and front
(8137) No. 19 (+) - Chassis ground (-): oxygen (NF) sen-
sor connector.
CHECK OUTPUT SIGNAL FOR ECM. the voltage more than 4.95 Go to step 6. Replace the front
Measure the voltage between ECM connector b
oxygen (NF) sen-
and chassis ground. sor. <Ref. to
Connector & terminal FU(D0HC
(6137) No. 29 (+) - Chassis ground (-): TURBO)-42, Froni
Oxygen (NF) Sen
sor.>
CHECK OUTPUT SIGNAL FOR ECM. the voltage more than 10 V? Repair battery Repair poor con-
Measure the voltage between ECM connector short circuit in har- tact in ECM con-
and chassis ground. nessbetween nector.
Connector & terminal ECM and front
(8137) No. 29 (+) - Chassis ground (-): oxygen (NF) sen-
sor connector.

EN(D0HC TURBO)-303
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

CM:DTC PI134 - FRONT OXYGEN (NF)SENSOR MICRO-COMPUTER PROB-

LEM -
DTC DETECTING CONDITION:
Immediately at fault recognition
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

Step Check Yes No

1 CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Moni- Replace the ECM. I It is not necessarv
’
tor or OBD-II general scan tool <Ref. to FU(DOHC to inspect DTC
indicate DTC P1134? TURBO)-47, P1134.
Engine Control
Module.>

EN(D0HC TURBO)-304
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

EN(D0HC TURBO)-305
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

CN: DTC P I 139 - FRONT OXYGEN (NF) SENSOR #IHEATER CIRCUIT

RANGUPERFORMANCE PROBLEM -
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

w
FRONTOXYGEN

EN(D0HC TURBO)-306
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check
CHECK HARNESS BETWEEN ECM AND s the resistance less than 1
FRONT OXYGEN (NF) SENSOR CONNEC- L? in harness
TOR. between ECM and
1)Start the engine, and warm-up the engine. front oxygen (NF)
2)Turn the ignition switch to OFF. I
sensor connector.
3)Disconnect the connectors from ECM and
front oxygen (NF) sensor.
4)Measure the resistance of harness between
ECM and front oxygen (NF) sensor connector.
Connector & terminal
-
(8137) NO. 5 (818) NO. 1:
-
(8137) NO. 4 (818) NO. 1:
I
CHECK HARNESS BETWEEN ECM AND s the resistance less than 1 30 to step 3. Repair open circuit
FRONT OXYGEN ( N F ) SENSOR CONNEC- 2? in harness
TOR. between ECM and
Measure the resistance of harness between front oxygen (NF)
ECM and front oxygen (NF) sensor connector. sensor connector.
Connector & terminal
(8137) NO. 19 - (818) NO. 4:
(8137) NO. 29 - (818) NO. 3:
I CHECK HARNESS BETWEEN ECM AND s the resistance less than 1 30 to step 4. Repair open circuil
FRONT OXYGEN ( N F ) SENSOR CONNEC- 2? in harness
TOR. between ECM and
Measure the resistance of harness between front oxygen (NF)
main relay and front oxygen (NF) sensor con- sensor connector.
nector.
Connector & terminal
(847) NO. 4 - (818) NO. 2:
I CHECK FRONT OXYGEN (NF)SENSOR. s the resistance less than 5 30 to step 5. Replace the front
Measure the resistance between front oxygen 2? oxygen (NF) sen-
(NF) sensor connector terminals. sor. <Ref. to
Terminals FU(DOHC
NO. 2 -NO. 1: TURBO)-42, Front
Oxygen (NF) Sen
sor.>
i CHECK POOR CONTACT. s there poor contact in ECM or Repair poor con- Replace the front
Check poor contact in ECM and front oxygen ront oxygen (NF) sensor con- tact in ECM or oxygen (NF) sen-
(NF) sensor connector. lector? iront oxygen (NF) sor. <Ref. to
sensor connector. FU(D0HC
TURBO)-42, Fronl
Oxygen (NF) Sen
sor.>

EN(D0HC TURBO)-307
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

C0:DTC P I 141 - MASS AIR FLOW SENSOR CIRCUIT RANGWPERFORMANCE

PROBLEM (LOW INPUT) -
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
Poor driving performance
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

IAlN RELAY

BATTERY
SBF-5

MASS AIR FLOW AND

INTAKE AIR TEMPERATURE

4
ECM

EN(D0HC TU R BO)-308
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK ANY OTHER DTC ON DISPLAY. I Does Subaru select monitor orInspect DTC Replace the mass
OBD-II general scan tool indi- PO102 or PO103 air flow and intake
cate DTC PO1 02 or PO103? using “Diagnos- air temperature
tics Chart with sensor.
Trouble Code”
<Ref. to EN(D0HC
TURBO)-80, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
In this case, it is
not necessary tc
inspect DTC
P I 141.

EN(D0HC TURBO)-309
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

CP:DTC P I 142 - THROTTLE POSITION SENSOR CIRCUIT RANGUPERFOR-

MANCE PROBLEM (LOW INPUT) -
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
Poor driving performance
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

THROTTLE
POSITION
SENSOR

[
1

ml
5 6 7 8
I
I

II

0@ECM

EN1166

EN(D0HC TURBO)-310
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

1 CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Moni- Inspect DTC Replace the throt-
tor or OBD-II general scan tool PO122 or PO123 tle position sen-
indicate DTC PO122 or P0123? using “List of Diag- sor. <Ref. to
nostic Trouble FU(D0HC
Code (DTC)”. TURBO)-33,
<Ref. to EN(D0HC Throttle Position
TURBO)-80, List Sensor.>
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P1142.

EN(D0HC TURBO)-31 1
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENG IN E (DIAGNOSTICS)
~

CQ:DTC P1146 - PRESSURE SENSOR CIRCUIT RANGE/PERFORMANCE

PROBLEM (HIGH INPUT) -
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

THROTTLE BODY

U@ ECM

EN1146

EN(D0HC TURBO)-312
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK ANY OTHER DTC ON DISPLAY. loes the Subaru Select Moni- Inspect DTC 30 to step 2.
NOTE: or or OBD-ll general scan tool PO107, PO108 or
In this case, it is not necessary to inspect DTC ndicate DTC PO107, PO108 or P1112 using “List
PO106. ’1 112? of Diagnostic Trou
ble Code (DTC)”.
<Ref. to EN(D0HC
TURBO)-80, List
of Diagnostic Trou
ble Code (DTC).>
CHECK AIR INTAKE SYSTEM. 4re there holes, loose bolts or Repair air intake 30 to step 3.
lisconnection of hose on air system.
ntake system?
CHECK PRESSURE SENSOR. s the value within the specifi- Go to step 4. 3eplace the pres-
1)Start the engine and warm-up engine until iure sensor. <Ref.
coolant temperature is greater than 60°C o FU(D0HC
(140°F). rURBO)-35, Pres.
2)Place the shift lever in the selector lever in ;ure Sensor.>
“N” or “ P position.
3)Turn the N C switch to OFF.
4)Turn all accessory switches to OFF.
5)Read the data of pressure sensor signal
using Subaru Select Monitor or OBD-ll general
scan tool.
NOTE:
*Subaru Select Monitor
For detailed operation procedure, refer to the
“READ CURRENT DATA FOR ENGINE. <Ref.
to EN(D0HC TURBO)-38, Subaru Select Mom
itor.>
*OBD-II general scan tool
For detailed operation procedure, refer to the
OBD-II General Scan Tool Instruction Manual.
Specification:
*Intake manifold absolute pressure
Ignition ON
73.3 - 106.6 kPa (550 - 800 mmHg,
21.65 - 31.50 inHg)
idling
20.0 - 46.7 kPa (150 - 350 mmHg,
5.91 - 13.78 inHg)
CHECK THROTTLE POSITION. s the throttle positioning ratio Go to step 5. idjust or replace
Read the data of throttle position signal using he throttle posi-
Subaru Select Monitor or OBD-ll general scan ion sensor. <Ref.
tool. o FU(D0HC
NOTE: -URBO)-33,
*Subaru Select Monitor -hrottle Position
For detailed operation procedure, refer to the ;ensor.>
“READ CURRENT DATA FOR ENGINE”. <Ref.
to EN(D0HC TURBO)-38, Subaru Select Mon-
itor.>
*OBD-ll general scan tool
For detailed operation procedure, refer to the
OBD-ll General Scan Tool Instruction Manual.
CHECK THROTTLE POSITION. s the throttle positioning ratio Replace the pres- Ieplace the throt-
?qualto or more than 85% sure sensor. <Ref. le position sen-
vhen throttle is fully open? to FU(D0HC ;or. <Ref. to
TURBO)-35, Pres- ’U(D0HC
sure Sensor.> -URB0)-33,
-hrottle Position
;ensor.>

EN(D0HC TURBO)-313
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

CR:DTC P1230 - FUEL PUMP CONTROLLER MALFUNCTION -

DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

FUEL PUMP
CONTROLLER

ECM

A: @
C :@

EN1141

EN(D0HC TURBO)-314
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK POWER SUPPLY CIRCUIT TO FUEL the voltage more than 1OV? i o to step 2. Repair power sup-
PUMP CONTROLLER. ply circuit.
1)Turnthe ignition switch to OFF. NOTE:
2)Disconnect the connector from fuel pump In this case repair
controller. the following:
3)Turn the ignition switch to ON. Open or ground
4)Measure the voltage between fuel pump short circuit in har-
controller and chassis ground. ness between fuel
Connector & terminal pump relay and
(R122) No. 10 (+)- Chassis ground (-): fuel pump control-
ler.
Poor contact in
fuel pump control-
ler connector.
Poor contact in
fuel pump relay
connector.
CHECK GROUND CIRCUIT OF FUEL PUMP the resistance less than 5 ;o to step 3. Repair harness
CONTROLLER. ? and connector.
1)Turnthe ignition switch to OFF. NOTE:
2)Measure the resistance of harness between In this case, repair
fuel pump controller and chassis ground. the following:
Connector & terminal Open circuit
(R122) No. 5 - Chassis ground: between fuel pump
controller and
chassis ground.
Poor contact in
fuel pump control-
ler connector.
CHECK HARNESS BETWEEN FUEL PUMP the resistance less than 1 i o to step 4. Repair open circuit
CONTROLLER AND FUEL PUMP CONNEC- ? betweenfuel pump
TOR. controller and fuel
1)Disconnect the connector from fuel pump.
2)Measure the resistance of harness between
fuel pump controller and fuel pump connector.
Connector & terminal
(R122) NO. 7 - (R58) NO. 2:
-
(R122) NO. 6 (R58) NO. 1:
CHECK HARNESS BETWEEN FUEL PUMP the resistance more than 1M
CONTROLLER AND FUEL PUMP CONNEC- ? short circuit
TOR. betweenfuel pump
Measure the resistance of harness between controller and fuel
fuel pump controller and chassis ground.
Connector & terminal
(R122) No. 7 - Chassis ground:
(R122) No. 6 - Chassis ground:
CHECK HARNESS BETWEEN FUEL PUMP the resistance less than 1 i o to step 6. Repair harness
CONTROLLER AND ECM CONNECTOR. ? and connector.
1)Turn the ignition switch to OFF. NOTE:
2)Disconnect the connector from ECM. In this case, repair
3)Measure the resistance of harness between the following:
fuel pump controller and ECM connector. Open circuit
. Connector & terminal betweenfuel pump
-
(R122) NO. 9 (8134) NO. 13: controller and
(R122) NO. 8 - (8136) NO. 16: ECM.
Poor contact in
fuel pump control-
ler and ECM con-
nector.

EN(D0HC TURBO)-315
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

5 CHECK HARNESS BETWEEN FUEL PUMP Is the resistance more than 1M Go to step 7. Repair ground
CONTROLLER AND ECM CONNECTOR. R? short circuit
Measure the resistance of harness between betweenfuel pump
fuel pump controller and chassis ground. controller and
Connector & terminal ECM.
(R122) No. 9 - Chassis ground:
(R122) No. 8 - Chassis ground:
7 CHECK POOR CONTACT. Is there poor contact in ECM Repair poor con- Replace the fuel
Check poor contact in ECM and fuel pump and fuel pump controller con- tact in ECM and pump controller.
controller connector. nector. fuel pump control- <Ref. to FU(D0HC
ler. TURBO)-50, Fuel
Pump Controller.>

EN(D0HC TURBO)-316
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

EN(D0HC TURBO)-317
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

CS:DTC PI244 - WASTEGATE CONTROL SOLENOID VALVE RANGWPER-

FORMANCE PROBLEM (LOW INPUT) -
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

MAIN RELAY

BATTERY
SBF-5

I
WASTEGATE
CONTROL SOLENOID
VALVE

EN1150

EN(D0HC TURBO)-318
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

I CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Moni- Inspect DTC Replace the
tor or OBD-ll general scan tool PO245 or PO246 wastegate control
indicate DTC PO245 or P0246? using “List of Diag- solenoid valve.
<Ref. to FU(D0HC
TURBO)-41,
Wastegate Con-
trol Solenoid
Valve.>

EN(D0HC TURBO)-31 9
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

CT:DTC PI245 - WASTEGATE CONTROL SOLENOID VALVE MALFUNCTION

(FAIL-SAFE) -
DTC DETECTING CONDITION:
Immediately at fault recognition
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49,Operation.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspection Mode.>.
WIRING DIAGRAM:

MAIN RELAY

@ ECM
.

WAS TE
CONTRO LENOID
VALVE

EN1150

EN(D0HC TURBO)-320
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE I DIAGNOSTICS)

Step Check Yes No

CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Moni- Inspect DTC Replace the
tor or OBD-II general scan tool P0244, P0245, wastegate control
indicate DTC P0244, P0245, PO246 or P1244 solenoid valve.
PO246 or P1244? using “List of Diag- <Ref. to FU(D0HC
nostic Trouble TURBO)-41,
Code (DTC)”. Wastegate Con-
<Ref. to EN(D0HC trol Solenoid
TURBO)SO, List Valve.>
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P1245.

EN(DOHC TU RB0)-321
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

CU:DTC PI301 - FIRE DUE TO INCREASED EXHAUST TEMPERATURE -

DTC DETECTING CONDITION:
Immediately at fault recognition
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls
Poor driving performance
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

EXHAUSTGAS
TEMPERATURE
SENSOR

@ECM

EN1 161

EN(D0HC TURBO)-322
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

1 CHECK ANY OTHER DTC. Does failure for repair or Repair or replace Contact with SOA
Conduct the troubleshooting for all DTC replacement exist? failure, then (distributor) ser-
P0301, P0302, PO303 and P0304. <Ref. to replace the precat- vice.
EN(D0HC TURBO)-80, List of Diagnostic alytic converter. NOTE:
Trouble Code (DTC).> Inspection by DTM
is required, be-
cause probable
cause is deteriora-
tion of multiple
parts.

EN(D0HC TURBO)-323
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

CV:DTC PI312 - EXHAUST GAS TEMPERATURE CIRCUIT MALFUNCTION -

DTC DETECTING CONDITION:
Immediately at fault recognition
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

EXHAUSTGAS
TEMPERATURE
SENSOR

_I

EN1161

EN(DOHC TURB0)-324
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DlAG NOSTlCS)

Step Check Yes No

1 CHECK ANY OTHER DTC ON DISPLAY. Does the Subaru Select Moni- Inspect DTC Replace the
tor or OBD-ll general scan tool P0545, PO546 or exhaust gas tem-
indicate DTC P0545, PO546 or P1544 using “List perature sensor.
P1544? of Diagnostic Trou- <Ref. to FU(D0HC
ble Code (DTC)”. TURBO)-46,
<Ref. to EN(D0HC Exhaust Tempera-
TURBO)-80, List ture Sensor.>
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
In this case, it is
not necessary tc
inspect DTC
P1312.

EN(D0HC TURBO)-325
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

CW:DTC PI400 - FUEL TANK PRESSURE CONTROL SOLENOID VALVE CIR-

CUIT LOW INPUT -
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

BATTERY
MAIN RELAY SBF-5
3 c

I PRESSURE
I CONTROL
SOLENOID

1 IA:@

D:@
ECM

Step Check Yes No

1 CHECK OUTPUT SIGNAL FROM ECM. Is the voltage more than 10 V? Go to step 2. Go to step 3.
1)Turn the ignition switch to ON.
2)Measure the voltage between ECM and
chassis ground.
Connector & terminal
(8137) No. 22 (+) - Chassis ground (-):

EN(D0HC TURBO)-326
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK POOR CONTACT. s there poor contact in ECM lepair poor con- Contact with SOA
Check poor contact in ECM connector. :onnector? act in ECM con- (distributor) ser-
'ector. vice.
NOTE:
Inspection by DTk
is required, be,
cause probable
cause is deteriora,
tion of multiple
parts.
CHECK HARNESS BETWEEN FUEL TANK s the resistance less than 10 iepair ground Go to step 4.
PRESSURE CONTROL SOLENOID VALVE 2? hort circuit in har-
AND ECM CONNECTOR. less between
1)Turn the ignition switch to OFF. C M and fuel tank
2)Disconnect the connectors from fuel tank lressure control
pressure control solenoid valve and ECM. olenoid valve
3)Measure the resistance of harness between onnector.
fuel tank pressure control solenoid valve con-
nector and chassis ground.
Connector & terminal
(R68) No. 2 - Chassis ground:
CHECK HARNESS BETWEEN FUEL TANK s the voltage less than 1 R? ;o to step 5. Repair harness
PRESSURE CONTROL SOLENOID VALVE and connector.
AND ECM CONNECTOR. NOTE:
Measure the resistance of harness between In this case, repai
ECM and fuel tank pressure control solenoid the following:
valve connector. Open circuit in
Connector & terminal harness between
(8137) NO. 22 - (R68) NO. 2: ECM and fuel tank
pressure control
solenoid valve
connector
Poor contact in
coupling connec-
tors
CHECK FUEL TANK PRESSURE CONTROL s the resistance between 10 i o to step 6. Replace the fuel
SOLENOID VALVE. md 100 R? tank pressure con.
Measure the resistance between fuel tank trol solenoid valve.
pressure control solenoid valve terminals. <Ref. to EC(D0HC
Terminals TURBO)-12, Pres.
NO. 1 -NO. 2: sure Control Sole-
noid Valve.>
CHECK POWER SUPPLY TO FUEL TANK s the voltage more than 10 V? i o to step 7. Repair harness
PRESSURE CONTROL SOLENOID VALVE. and connector.
1)Turn the ignition switch to ON. NOTE:
2)Measure the voltage between fuel tank pres In this case, repai
sure control solenoid valve and chassis the following:
ground. Open circuit in
Connector & terminal harness between
(R68) No. 1 (+) - Chassis ground (-): main relay and fuel
tank pressure con,
trol solenoid valve
connector
Poor contact in
coupling connec-
tors
Poor contact in
main relay connec
tor

EN(D0HC TURBO)-327
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

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 solenoid tact in fuel tank (distributor) ser-
trol solenoid valve connector. valve connector? pressure control vice.
solenoid valve NOTE:
Inspection by DTM
is required, be-
cause probable
cause is deteriora-
tion of multiple
parts.

EN(D0HC TURBO)-328
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

EN(D0HC TURBO)-329
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

CX:DTC PI420 - FUEL TANK PRESSURE CONTROL SOLENOID VALVE CIR-

CUIT HIGH INPUT -
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

BATTERY
MAIN RELAY SBF-5
3 c I

FUEL TANK
I PRESSURE
C0NT R 0L

1
I

SOLENOID
VALVE

EN(D0HC TURBO)-330
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK OUTPUT SIGNAL FROM ECM. )oes voltage change between I Go to step 2. 3 e n if MIL lights
1)Turn the ignition switch to OFF. 1 and 10 V? rp, the circuit has
2)Connect the test mode connector at the eturned to a nor-
lower portion of instrument panel (on the nal condition at
driver’s side), to the side of the center console his time. In this
box. :ase, repair poor
3)Turn the ignition switch to ON. :ontact in ECM
4)While operating the fuel tank pressure con- :onnector.
trol solenoid valve, measure voltage between
ECM and chassis ground.
NOTE:
Fuel tank pressure control solenoid valve oper.
ation can be executed using Subaru Seleci
Monitor. For procedure, refer to “Compulsor)
Valve Operation Check Mode”. <Ref. tc
EN(D0HC TURBO)-50, Compulsory Valve O p
eration Check Mode.>
Connector & terminal
(8137) No. 22 (+) - Chassis ground (-):
! CHECK OUTPUT SIGNAL FROM ECM. s the voltage more than 10 V? So to step 4. 20 to step 3.
1)Turn the ignition switch to ON.
2)Measure the voltage between ECM and
chassis ground.
Connector & terminal
(8137) No. 22 (+) - Chassis ground (-):
1 CHECK POOR CONTACT. 3eplace the ECM.
Check poor contact in ECM connector. onnector? tact in ECM con- :Ref. to FU(D0HC
nector. ruRBO)-47,
Engine Control
dodule.>
CHECK HARNESS BETWEEN FUEL TANK s the voltage more than 10 V? Repair battery 20 to step 5.
PRESSURE CONTROL SOLENOID VALVE short circuit in har.
AND ECM CONNECTOR. ness between
1)Turn the ignition switch to OFF. ECM and fuel tank
2)Disconnect the connector from fuel tank pressure control
pressure control solenoid valve. solenoid valve
3)Turn the ignition switch to ON. connector. After
4)Measure the voltage between ECM and repair, replace the
chassis ground. ECM. <Ref. to
Connector & terminal FU(D0HC
(8137) No. 22 (+) - Chassis ground (-): TURBO)-47,
Engine Control
Module.>
1 CHECK FUEL TANK PRESSURE CONTROL s the resistance less than 1 Replace the fuel 20 to step 6.
SOLENOID VALVE. 2? tank pressure con,
1)Turnthe ignition switch to OFF. trot solenoid valve
2)Measure the resistance between fuel tank <Ref.to EC(D0HC
pressure control solenoid valve terminals. TURBO)-12, Pres
Terminals sure Control Sole-
NO. 1 -NO. 2: noid Valve.> and
ECM <Ref. to
FU(D0HC
TURBO)-47,
Engine Control
Module.>
i CHECK POOR CONTACT. s there poor contact in ECM Repair poor con- 3eplace the ECM.
Check poor contact in ECM connector. :onnector? tact in ECM con- :Ref. to FU(D0HC
nector. TURBO)-47,
Engine Control
I vlodule.>

EN(D0HC TURBO)-331
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

CY:DTC PI443 - EVAPORATIVE EMISSION CONTROL SYSTEM VENT CON-

TROL FUNCTION PROBLEM -
DTC DETECTING CONDITION:
Immediately after fault occurrence
TROUBLE SYMPTOM:
Improper fuel supply
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

BATTERY
MAIN RELAY SBF-5

I --
3 c

I
I I

EN(D0HC TURBO)-332
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

I CHECK ANY OTHER DTC ON DISPLAY. Is there any other DTC on dis- Inspect the rele- 30 to step 2.
play? vant DTC using
“List of Diagnostic
Trouble Code
(DTC)”. <Ref. to
EN(D0HC
TURBO)-80, List
of Diagnostic Trou-
ble Code (DTC).>
! CHECK VENT LINE HOSES. Is there a fault in vent line? Repair or replace 20 to step 3.
Check the following items. the faulty part.
Clogging of vent hoses between canister and
drain valve
Clogging of vent hose between drain valve
and air filter
Clogging of drain filter
b CHECK DRAIN VALVE OPERATION. Does the drain valve produce Contact with SOA 3eplace the drain
1)Turn the ignition switch to OFF. operating sound? (distributor) ser- ialve. <Ref. to
2)Connect the test mode connector at the vice. iC(D0HC
lower portion of instrument panel (on the NOTE: rURBO)-17, Drain
driver’s side), to the side of the center console Inspection by DTM Ja1ve.b
box. is required, be-
Spurn the ignition switch to ON. cause probable
4)Operate the drain valve. cause is deteriora-
NOTE: tion of multiple
Drain valve operation can also be executed us- parts.
ing Subaru Select Monitor. For the procedure,
refer to the “Compulsory Valve Operation
Check Mode”. <Ref. to EN(D0HC TURBO)-50,
Compulsory Valve Operation Check Mode.>

EN(D0HC TURBO)-333
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

EN(D0HC TURBO)-334
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

CZ:DTC PI480 - COOLING FAN RELAY 1 CIRCUIT HIGH INPUT -

DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
TROUBLE SYMPTOM:
Radiator fan does not operate properly.
Overheating
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, Operation.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspection Mode.>.

EN(D0HC TURBO)-335
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICSI

WIRING DIAGRAM:

BATTERY
SBF-l
3 -
e a

I
1
[i

I
-1
cSI
h
4N
IR
MI

EN1157

EN(D0HC TURBO)-336
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

1 CHECK OUTPUT SIGNAL FROM ECM. )oes the voltage change Iven if MIL lights io to step 2.
1)Turnthe ignition switch to OFF. letween 0 and 10 V? ip, the circuit has
2)Connect the test mode connector at the eturned to a nor-
lower portion of instrument panel (on the nal condition at
driver’s side), to the side of the center console his time. In this
box. :ase, repair poor
3)Turn the ignition switch to ON. :ontact in ECM
4)While operating the radiator fan relay, mea- :onnector.
sure voltage between ECM and chassis
ground.
NOTE:
Radiator fan relay operation can be executed
using Subaru Select Monitor. For procedure,
refer to “Compulsory Valve Operation Check
Mode”.<Ref. to EN(D0HC TURBO)-50, Com-
pulsory Valve Operation Check Mode.>
Connector & terminal
(8137) No. 17 (+) - Chassis ground (-):
(8137) No. 28 (+) - Chassis ground (-):
2 CHECK SHORT CIRCUIT IN RADIATOR FAN s the voltage more than 10 V? 3epair battery io to step 3.
RELAY CONTROL CIRCUIT. ;hort circuit in
1)Turn the ignition switch to OFF. adiator fan relay
2)Remove the main fan relay and sub fan relay. :ontrol circuit.
(with A/C models) After repair,
3)Disconnect the test mode connector. eplace the ECM.
4)Turn the ignition switch to ON. :Ref. to FU(D0HC
5)Measure the voltage between ECM and ruRBO)-47,
chassis ground. hgine Control
Connector & terminal dodule.>
(8137) No. 17 (+) - Chassis ground (-):
(8137) No. 28 (+) - Chassis ground (-):
3 CHECK MAIN FAN RELAY. s the resistance less than 1 3eplace the main i o to step 4.
1)Turn the ignition switch to OFF. 2? an relay and
2)Remove the main fan relay I and 2. ICM. <Ref. to
3)Measure the resistance between main fan W(DOHC
relay terminals. rURBO)-47,
Terminal Engine Control
No. 25 - No. 26 (Main fan relay 1) dodule.>
No. 23 - No. 24 (Main fan relay 2)
4 CHECK SUB FAN RELAY. s the resistance less than 1 3eplace the sub i o to step 5.
1)Remove the sub fan relay. 2? an relay and
2)Measure the resistance between sub fan X M . <Ref. to
relay terminals. -U(DOHC
Terminal rURBO)-47,
No. 7 - No. 8 (Sub fan relay 1) Engine Control
No. 17 - No. 18 (Sub fan relay 2) dodule.>
5 CHECK POOR CONTACT. s there poor contact in ECM 3epair poor con- leplace the ECM.
Check poor contact in ECM connector. :onnector? act in ECM con- :Ref. to FU(D0HC
lector. -URBO)-47,
ingine Control
Aodu1e.i

EN(DOHC TU RB0)-337
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

DA:DTC PI507 - IDLE CONTROL SYSTEM MALFUNCTION (FAIL-SAFE) -

DTC DETECTING CONDITION:
Immediately at fault recognition
TROUBLE SYMPTOM:
Engine keeps running at higher revolution than specified idling revolution.
Fuel is cut according to fail-safe function.
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

MAIN RELAY

BATTERY

SBF-5

IDLE
41R CONTROL
SOLENOID
VALVE

@ECM I

EN1160

EN(D0HC TURBO)-338
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGI NE (DIAGNOSTICS)

Step Check Yes No

CHECK ANY OTHER DTC ON DISPLAY. >oesthe Subaru Select Moni- Inspect DTC- Go to step 2.
or or OBD-ll general scan tool P0506, P0507,
ndicate DTC P0506, P0507, P0508, PO509 or
’0508, PO509 or P1142? P1142 using “List
of Diagnostic Trou-
ble Code (DTC)”.
<Ref. to EN(D0HC
TURBO)-80, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P1507.
CHECK AIR INTAKE SYSTEM. s there a fault in air intake sys- Repair air suction Go to step 3.
1)Turnthe ignition switch to ON. em? and leaks.
2)Start the engine, and idle it.
3)Check the following items.
*Loose installation of intake manifold, idle air
control solenoid valve and throttle body
*Cracks of intake manifold gasket, idle air con-
fro1 solenoid valve gasket and throttle body
gasket
*Disconnections of vacuum hoses
CHECK THROlTLE CABLE. >oesthe throttle cable have
)lay for adjustment? cable. <Ref. to
SP-7, INSTALLA-
TION, Accelerator
Control Cable.>
CHECK AIR BV-PASS LINE. ire foreign particles in by-pass Remove foreign Replace the idle
1)Turn the ignition switch to OFF. tir line? particles from by- air control solenoid
2)Remove the idle air control solenoid valve pass air line. valve. <Ref. to
from throttle body. <Ref. to FU(D0HC FU(DOHC
TURBO)-36, Idle Air Control Solenoid Valve.> TURBO)-36, Idle
3)Confirm that there are no foreign particles in Air Control Sole-
bV-DaSS air line. noid Valve.>

EN(D0HC TURBO)-339
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

EN(D0HC TURBO)-340
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

DB:DTC P1518 - STARTER SWITCH CIRCUIT LOW INPUT -

DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
TROUBLE SYMPTOM:
Failure of engine to start
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.

EN(D0HC TURBO)-341
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

WIRING DIAGRAM:

EN1139

EN(D0HC TURBO)-342
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

1 CHECK OPERATION OF STARTER MOTOR, Does the starter motor operate Repair harness Check starter
when ignition switch to “ST”? and connector. motor circuit. <Ref.
NOTE: to EN(D0HC
In this case, repair TURBO)-64,
the following: STARTER
Open or ground MOTOR CIR-
short circuit in har- CUIT, Diagnostics
ness between for Engine Start-
ECM and starter ing Failure.>
motor connector.
Poor contact in
ECM connector.

EN(D0HC TURBO)-343
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

DC:DTC PI544 - HIGH EXHAUST TEMPERATURE DETECTED -

DTC DETECTING CONDITION:
immediately at fault recognition
TROUBLE SYMPTOM:
Erroneous idling
Poor driving performance
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

EXHAUST GAS
TEMPERATURE
SENSOR

IC

F
I @ECM

EN1161

EN(DOHC TURB0)-344
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
FNGINE (DIAGNOSTICS)

Step Check Yes No

CHECK ANY OTHER DTC ON DISPLAY. Ioes the Subaru Select Moni- Inspect DTC ;o to step 2.
or or OBD-ll general scan tool P0335, P0336,
ndicate DTC P0335, P0336, P0340, P0341,
'0340, P0341, P0545, P0546, P0545, P0546,
'1312, P0102, P0103, P0101, P1312, P0102,
'1 141, P0301, P0302, P0303, PO103, P0101,
'0304, P1301, P0171, P0133, P1141, P0301,
'1 134, PO131, P0132, P1130, P0302, P0303,
'1 131, P1139, P0031, P0032, P0304, P1301,
'01 39, PO136, PO039 or PO171, PO133,
'0037? P1134, PO131,
PO132, P1130,
P1131, P1139,
P0031, P0032,
PO139, PO136,
PO039 or PO037
using List of Diag-
nostic Trouble
Code (DTC). <Ref.
to EN(D0HC
TURBO)-80, List
of Diagnostic Trou-
ble Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P1544.
I CHECK EXHAUST SYSTEM. s there a fault in exhaust sys- Repair or replace ;ontact with SOA
Check exhaust system parts. em? failure, then distributor) ser-
NOTE: replace the precat- ice.
Check the following items. alytic converter. JOTE:
*Loose installation of exhaust manifold nspection by DTM
*Cracks or hole of exhaust manifold j required, be-
*Loose installation of front oxygen (NF)senso I
:ause probable
:ause is deteriora-
tion of multiple
Darts.

EN(D0HC TURBO)-345
R!
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

EN(D0HC TURBO)-346
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)
~~~

DD:DTC PI560 - BACK-UP VOLTAGE CIRCUIT MALFUNCTION -

DTC DETECTING CONDITION:
Immediately at fault recognition
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.

EN(DOHC TURB0)-347
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

WIRING DIAGRAM:

EN1171

Step Check Yes No

1 CHECK INPUT SIGNAL FOR ECM. Is the voltage more than 10 V? Repair poor con- Go to step 2.
1)Turn the ignition switch to OFF. tact in ECM con-
2)Measure the voltage between ECM and nector.
chassis ground.
Connector & terminal
(8137) No. 10 (+) - Chassis ground (-):

EN(D0HC TURBO)-348
I
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

! CHECK HARNESS BETWEEN ECM AND Is the resistance less than 10 Repair ground Go to step 3.
MAIN FUSE BOX CONNECTOR. R? short circuit in har-
1)Disconnect the connector from ECM. ness between
2)Measure the resistance of harness between ECM connector
ECM and chassis ground. and battery termi-
Connector & terminal nal.
(8137) No. 10 - Chassis ground:
I CHECK FUSE SBFQ. Is fuse blown? Replace the fuse. Repair harness
and connector.
NOTE:
In this case, repai
the following:
Open circuit in
harness between
ECM and battery
Poor contact in
ECM connector
Poor contact in
battery terminal

EN(D0HC TURBO)-349
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)

DE:DTC P1590 - NEUTRAL POSITION SWITCH CIRCUIT HIGH INPUT -

DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

10

INHIBKOR SWKCH

@a a

I STAFiTER MOTOF

B2M437(

EN(DOHC TURBO)-350
 -
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

step Check Yes No

I CHECK DTC PO705 ON DISPLAY. 3oes the Subaru Select Moni- Inspect DTC Go to step 2.
:or or OBD-II general scan tool PO705 using “List
ndicate DTC P0705? of Diagnostic Trou-
ble Code (DTC)”.
<Ref. to EN(D0HC
TURBO)-80, List
of Diagnostic Trou-
ble Code (DTC).>
! CHECK INPUT SIGNAL FOR ECM. s the voltage less than 1 V? Go to step 3. Go to step 5.
1)Turnthe ignition switch to ON.
2)Measure the voltage between ECM and
chassis ground in selector lever “ N and “ P
positions.
Connector & terminal
i
(8134) No. 8 (+) - Chassis ground (-):
1 CHECK INPUT SIGNAL FOR ECM. s the voltage between 4.5 and Go to step 4. Go to step 5.
Measure the voltage between ECM and chas- 5.5 V?
sis ground in selector lever except for “N” and
“ P positions.
Connector L? terminal
(8134) No. 8 (+) - Chassis ground (-):
I CHECK POOR CONTACT. s there poor contact in ECM Repair poor con- Contact with SOA
Check poor contact in ECM connector. :onnector? tact in ECM con- (distributor)ser-
nector. vice.
NOTE:
Inspection by DTM
is required, be-
cause probable
cause is deteriora-
tion of multiple
parts.
i CHECK INPUT SIGNAL FOR ECM. s the voltage more than 10 V? Repair battery Go to step 6.
Measure the voltage between ECM and chas- short circuit in har-
sis ground. ness between
Connector & terminal ECM and inhibitor
(8134) No. 8 (+) - Chassis ground (-): switch connector.
i CHECK HARNESS BETWEEN ECM AND IN- s the resistance less than 1 Go to step 7. Repair harness
HIBITOR SWITCH CONNECTOR. 2? and connector.
1)Turnthe ignition switch to OFF. NOTE:
2)Disconnect the connectors from ECM and In this case, repaii
inhibitor switch. the following:
3)Measure the resistance of harness between b Open circuit in

ECM and inhibitor switch connector. harness between

Connector & terminal ECM and inhibitor
(8134) NO. 8 - (T7) NO. 12: switch connector
b Poor contact in
zoupling connector
Poor contact in
inhibitor switch
Zonnector
b Poor contact in
ECM connector

EN(D0HC TURBO)-351
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK INHIBITOR SWITCH GROUND LINE. s the resistance less than 5 20 to step 8. Repair open circuit
Measure the resistance of harness between 2? in harness
inhibitor switch connector and engine ground. between inhibitor
Connector & terminal switch connector
(T7) No. 7 - Engine ground: and starter motor
ground line.
NOTE:
In this case, repai,
the following:
Open circuit in
harness between
inhibitor switch
connector and
starter motor
ground line
Poor contact in
starter motor con-
nector
Poor contact in
starter motor
ground
Starter motor
CHECK INHIBITOR SWITCH. s the resistance less than 1 30 to step 9. Replace the inhibi,
Measure the resistance between inhibitor 2? tor switch. <Ref. to
switch connector receptacle’sterminals in AT-28, Inhibitor
selector lever “N” and “ P positions. Switch.>
Terminals
NO. 7 - NO. 12:
CHECK SELECTOR CABLE CONNECTION. s there any fault in selector 3epair selector Contact with SOA
:able connection to inhibitor :able connection. (distributor) ser-
;witch? <Ref.to CS-27, vice.
INSPECTION, NOTE:
Select Cable.> Inspection by DTL
is required, be
cause probablc
cause is deteriora
tion of multiplf
parts.

EN(D0HC TURBO)-352
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

EN(D0HC TURBO)-353
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

DF:DTC PI591 - NEUTRAL POSITION SWITCH CIRCUIT LOW INPUT -

DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

B2M437(

EN(DOHC TURB0)-354
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK DTC PO705 ON DISPLAY. Does the Subaru Select Moni- Inspect DTC 20 to step 2.
tor or OBD-ll general scan tool PO705 using “List
indicate DTC P0705? of Diagnostic Trou-
ble Code (DTC)”.
<Ref. to EN(D0HC
TURBO)-80, List
of Diagnostic Trou-
ble Code (DTC).>
CHECK INPUT SIGNAL FOR ECM. Is the voltage between 4.5 and Even if MIL lights so to step 3.
1)Turn the ignition switch to ON. 5.5 V at except “ N and “ P up, the circuit has
2)Measure the voltage between ECM and positions? returned to a nor-
chassis ground. mal condition at
Connector & terminal this time.
(6134) No. 8 (+) - Chassis ground (-):
CHECK HARNESS BETWEEN ECM AND Is the resistance less than 10 Repair ground i o to step 4.
TRANSMISSION HARNESS CONNECTOR. R? short circuit in har-
1)Turn the ignition switch to OFF. ness between
2)Disconnect the connectors from ECM and ECM and trans-
transmission harness connector (T3). mission harness
3)Measure the resistance of harness between connector.
ECM connector and chassis ground.
Connector & terminal
(6134) No. 8 - Chassis ground:
CHECK TRANSMISSION HARNESS CON- Is the resistance less than 10 Repair ground $0to step 5.
NECTOR. R? short circuit in har-
1)Disconnect the connector from inhibitor ness between
switch. transmission har-
2)Measure the resistance of harness between ness and inhibitor
transmission harness connector and engine switch connector.
ground.
Connector & terminal
(T3) No. 12 - Engine ground:
CHECK INHIBITOR SWITCH. Is the resistance more than 1 Go to step 6. Ieplace the inhibi.
Measure the resistance between inhibitor M a at except “N” and “ P posi- or switch. <Ref. to
switch connector receptacle’sterminals in tions? 4l-28, Inhibitor
selector lever except for “N” position. ;witch.>
Terminals
NO. 7 - no. 12:
CHECK SELECTOR CABLE CONNECTION. Is there any fault in selector Repair selector :ontact with SOA
cable connection to inhibitor cable connection. distributor) ser-
switch? <Ref. to CS-27, ice.
INSPECTION, JOTE:
Select Cable.> nspection by DTk
; required, be
:ause probablc
:ause is deteriora
ion of multiplc
,arts.

EN(DOHC TURB0)-355
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

DG:DTC P I 594 - AUTOMATIC TRANSMISSION DIAGNOSIS INPUT SIGNAL

CIRCUIT MALFUNCTION -
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

r @ TCM

02M4371

Step Check Yes No

1 CHECK DRIVING CONDITION. Is the AT shift control function- Go to step 2. Replace the TCM.
1)Start and warm-up the engine until the radia- ing properly? <Ref. to AT-45,
tor fan makes one complete rotation. Transmission Con-
2)Drive the vehicle. trol Module
(TCM).>

EN(D0HC TURBO)-356
 Step Check Yes No
2 CHECK ACCESSORY. Are car phone and/or CB Repair grounding Replace the TCM.
I installed on vehicle? line of car phone <Ref. to AT-45,
or CB system. Transmission Con-
trol Module
(TCM).>

EN(D0HC TURB0)957
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

DH:DTC P I 595 - AUTOMATIC TRANSMISSION DIAGNOSIS INPUT SIGNAL

CIRCUIT LOW INPUT -
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

n@TCM

IC 71

F7

B2M4371

EN(D0HC TURBO)-358
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAG NOSTlCS)

Step Check Yes No

CHECK HARNESS BETWEEN ECM AND Is the voltage less than 1 V? 30 to step 2. Even if MIL lights
TCM CONNECTOR. ~ pthe, circuit has
1)Turnthe ignition switch to ON. eturned to a nor-
2)Measure the voltage between ECM and nal condition at
chassis ground. his time.
Connector & terminal \IOTE:
(6135) No. 20 (+) - Chassis ground (-): n this case, repaii
he following:
' Poor contact in
X M connector
' Poor contact in
TCM connector
! CHECK HARNESS BETWEEN ECM AND Is the resistance less than 10 3epair ground 30 to step 3.
TCM CONNECTOR. R? ;hort circuit in har-
1)Turn the ignition switch to OFF. less between
2)Disconnect the connector from ECM and ICM and TCM
TCM. :onnector.
3)Measure the resistance of harness between
ECM and chassis ground.
Connector & terminal
(6135) No. 20 - Chassis ground:
I CHECK OUTPUT SIGNAL FOR ECM. Is the voltage more than 5 V? i o to step 4. 3epair poor con-
1)Connect the connector to ECM. act in ECM con-
2)Turn the ignition switch to ON. lector.
3)Measure the voltage between ECM and
chassis ground.
Connector & terminal
(6135) No. 20 (+) - Chassis ground (-):
I CHECK TROUBLE CODE FOR AUTOMATIC Does the trouble code appear nspect trouble 3eplace the TCM.
TRANSMISSION. for automatic transmission? :ode for automatic :Ref. to AT-45,
Read the trouble code for automatic transmis- ransmission. rransmission Con-
sion. <Ref. to AT-24, Read Diagnostic Trouble :Ref. to AT-44, rol Module
Code (DTC).> liagnostic Proce- TCM).>
jure with Diagnos-
ic Trouble Code
DTC).>

EN(D0HC TURBO)-359
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

-
DI: DTC P I 596 AUTOMATIC TRANSMISSION DIAGNOSIS INPUT SIGNAL
CIRCUIT HIGH INPUT -
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

n
IC
@TCY

82M4371

EN(D0HC TURBO)-360
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK HARNESS BETWEEN ECM AND s the voltage more than 10 V? Repair battery Go to step 2.
TCM CONNECTOR. short circuit in har-
1)Turn the ignition switch to ON. less between
2)Measure the voltage between ECM and ECM and TCM
chassis ground. zonnector. After
Connector & terminal repair, replace the
(8135) No. 20 (+) - Chassis ground (-): ECM. <Ref. to
FU(D0HC
TURBO)-47,
Engine Control
Module.>
! CHECK HARNESS BETWEEN ECM AND s the voltage more than 4 V? Go to step 5. Go to step 3.
TCM CONNECTOR.
Measure the voltage between ECM connector
and chassis ground.
Connector & terminal
(8135) No. 20 (+) - Chassis ground (-):
CHECK HARNESS BETWEEN ECM AND s the voltage less than 1 V? Repair poor con- Go to step 4.
TCM CONNECTOR. tact in ECM con-
Measure the voltage between ECM connector nector.
and chassis ground.
Connector & terminal
(8135) No. 20 (+) - Chassis ground (-):
a

I CHECK OUTPUT SIGNAL FROM ECM. Ioes the voltage change from Even if MIL lights Contact with SOA
Measure the voltage between ECM and chas- V to 4 V while monitoring the up, the circuit has (distributor) ser-
sis ground. falue with voltage meter? returned to a nor- vice.
Connector & terminal mal condition at NOTE:
(8135) No. 20 (+) - Chassis ground (-): this time. Inspection by DTN
NOTE: is required, b e
In this case, repaii cause probable
the following: cause is deteriora.
Poor contact in tion of multiple
ECM connector parts.
Poor contact in
TCM connector
i CHECK HARNESS BETWEEN ECM AND s the voltage more than 4 V? Go to step 6. Repair open circuit
TCM CONNECTOR. in harness
Measure the voltage between TCM and chas- between ECM and
sis ground. TCM connector.
Connector & terminal
(B54) No, 20 (+) - Chassis ground (-):
i CHECK POOR CONTACT. s there poor contact in TCM Repair poor con- Check TCM power
Check poor contact in TCM connector. :onnector? tact in TCM con- supply line and
nector. aroundina line.

EN(D0HC TURBO)-361
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE lDlAGNOSTlCSl

DJ:DTC PI698 - ENGINE TORQUE CONTROL CUT SIGNAL CIRCUIT LOW IN-
PUT -
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
CAUTION:
After repair or replacement of faulty parts, condut Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

IC i

c II

I @ .

EN(D0HC TURBO)-362
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK OUTPUT SIGNAL FROM ECM. Is the voltage more than 3 V? Repair poor con- So to step 2.
1)Start the engine, and warm-up the engine. tact in ECM con-
2)Turn the ignition switch to OFF. nector.
3)Turn the ignition switch to ON.
4)Measure the voltage between ECM and
chassis ground.
Connector & terminal
(B 136) No. 14 (+) - Chassis ground (-):
CHECK HARNESS BETWEEN ECM AND Is the resistance less than 10 Repair ground Go to step 3.
TCM CONNECTOR. R? short circuit in har-
1)Turn the ignition switch to OFF. nessbetween
2)Disconnect the connectors from ECM and ECM and TCM
TCM. connector.
3)Measure the resistance of harness between
ECM and chassis ground.
Connector & terminal
-
(8136) No. 14 Chassis ground:
CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Repair poor con- Repair open circuit
TCM CONNECTOR. R? tact in ECM or in harness
Measure the resistance of harness between TCM connector. between ECM and
ECM and TCM connector. TCM connector.
Connector & terminal
-
(8136) NO. 14 (BSS) NO. 20:

EN(D0HC TURBO)-363
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

DK:DTC P1699 - ENGINE TORQUE CONTROL CUT SIGNAL CIRCUIT HIGH IN-
PUT -
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

F
IC
@TCM

EN(D0HC TURBO)-364
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

I CHECK OUTPUT SIGNAL FROM ECM. Is the voltage less than 3 V? 30 to step 2. Repair battery
1)Start the engine, and warm-up the engine. short circuit in har-
2)Turn the ignition switch to OFF. ness between
3)Disconnect the connector from TCM. ECM and TCM
4)Turn the ignition switch to ON. connector. After
5)Measure the voltage between ECM and repair, replace the
chassis ground. ECM. <Ref. to
Connector & terminal FU(D0HC
(B 136) No. 14 (+)- Chassis ground (-): TURBO)-47,
Engine Control
Module.>
2 CHECK HARNESS BETWEEN ECM AND Does the voltage change more qepair battery Contact with SOA
TCM CONNECTOR. than 10 V by shaking harness short circuit in har- (distributor) ser-
1)Turnthe ignition switch to OFF. and connector of ECM while less between vice.
2)Measure the voltage between ECM and monitoring the value with volt- ECM and TCM NOTE:
chassis ground. age meter? :onnector. After Inspection by DTM
Connector & terminal ,epair, replace the is required, be-
(B 136) No. 14 (+) - Chassis ground (-): ECM. <Ref. to cause probable
FU(D0HC cause is deteriora.
TURBO)-47, tion of multiple
Engine Control parts.
Module.>

EN(D0HC TURBO)-365
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
-
ENGINE IDIAGNOSTICS)
~

-
DL:DTC PI 701 CRUISE CONTROL SET SIGNAL CIRCUIT MALFUNCTION
FOR AUTOMATIC TRANSMISSION -
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

D 71

EN1170

EN(D0HC TURBO)-366
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

I CHECK HARNESS BETWEEN TCM AND Is the resistance less than 1 20 to step 2. Repair open circuit
CCM CONNECTOR. R? in harness
1)Turn the ignition switch to OFF. between TCM and
2)Disconnect the connectors from TCM and CCM connector.
CCM.
3)Measure the resistance of harness between
TCM and CCM connector.
Connector & terminal
(655)NO. 22 - (694) NO.3 :
! CHECK HARNESS BETWEEN TCM AND Is the resistance less than 10 3epair short circuit Go to step 3.
CCM CONNECTOR. n? n harness
Measure the resistance of harness between letween TCM and
TCM and chassis ground. X M connector.
Connector & terminal
(655) No. 22 - Chassis ground:
CHECK INPUT SIGNAL FOR TCM. Is the resistance less than 1 V’ 20 to step 4. Check cruise con-
1)Connect the connector to TCM and CCM. trol command
2)Lift-up the vehicle or set the vehicle on free switch circuit.
rollers. <Ref. to CC-7,
CAUTION: INSPECTION,
On AWD models, raise all wheels off Cruise Control
ground. Command
3)Start the engine. Switch.>
4)Turn the cruise control main switch to ON.
5)Move selector lever to “ D and slowly
increase vehicle speed to 50 km/h (31 MPH).
6)Turn the cruise control command switch to
ON.
7)Measure the voltage between TCM and
chassis ground.
Connector & terminal
(655) No. 11 (+) - Chassis ground (-):
I CHECK POOR CONTACT. I S there
poor contact in TCM 3epair poor con- Replace the TCM.
Check poor contact in TCM connector. Zonnector? act in TCM con- <Ref. to AT-45,
lector. Transmission Con-
trol Module
I
(TCM).>

EN(D0HC TURBO)-367
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

DM:DTC PI711 - ENGINE TORQUE CONTROL SIGNAL 1 CIRCUIT MALFUNC-

TION -
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
TROUBLE SYMPTOM:
Excessive shift shock
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

El@ TCM

71

B2M4374

EN(D0HC TURBO)-368
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK INPUT SIGNAL FOR ECM. ;the voltage more than 4.5 V? ;o to step 2. Go to step 4.
1)Turn the ignition switch to ON.
2)Measure the voltage between ECM and
chassis ground.
Connector & terminal
(8135) No. 19 (+) - Chassis ground (-):
! CHECK INPUT SIGNAL FOR ECM. ;the voltage more than 10 V? qepair battery Go to step 3.
Measure the voltage between ECM and chas- ;hort circuit in har-
sis ground. less between
Connector & terminal X M and TCM
(8135) No. 19 (+) - Chassis ground (-): :onnector.
1 CHECK POOR CONTACT. s there poor contact in ECM 3epair poor con- Replace the ECM.
Check poor contact in ECM connector. :onnector? act in ECM con- <Ref. to FU(D0HC
lector. TURBO)-47,
Engine Control
Module.>
I CHECK HARNESS BETWEEN ECM AND s the resistance less than 1 30 to step 5. Repair open circuit
TCM CONNECTOR. 2? in harness
1)Turn the ignition switch to OFF. between ECM and
2)Disconnect the connectors from ECM and TCM connector.
TCM.
3)Measure the resistance of harness between
ECM and TCM connector.
Connector & terminal
-
(8135) NO. 19 (854) NO. 13:
i CHECK HARNESS BETWEEN ECM AND s the resistance less than 10 3epair ground Go to step 6.
TCM CONNECTOR. 2? short circuit in har-
Measure the resistance of harness between less between
ECM and chassis ground. :CM and TCM
Connector & terminal :onnector.
(8135) No. 19 - Chassis ground:
i CHECK POOR CONTACT. s there poor contact in TCM 3epair poor con- Replace the TCM.
Check poor contact in TCM connector. :onnector? :act in TCM con- <Ref. to AT-45,
lector. Transmission Con.
trol Module
(TCM).>

EN(DOHC TU RB0)-369
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

DN:DTC PI712 - ENGINE TORQUE CONTROL SIGNAL 2 CIRCUIT MALFUNC-

TION -
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
TROUBLE SYMPTOM:
Excessive shift shock
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(D0HC TURBO)-
49, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(D0HC TURBO)-46, Inspec-
tion Mode.>.
WIRING DIAGRAM:

B2M437E

EN(D0HC TURBO)-370
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
ENGINE (DIAGNOSTICS)

Step Check Yes No

CHECK INPUT SIGNAL FOR ECM. Is the voltage more than 4.5 V? Go to step 2. 30 to step 4.
1)Turnthe ignition switch to ON.
2)Measure the voltage between ECM and
chassis ground.
Connector & terminal
(8134) No. 18 (+) - Chassis ground (-):
CHECK INPUT SIGNAL FOR ECM. Is the voltage more than 10 V? Repair battery 30 to step 3.
Measure the voltage between ECM and chas- short circuit in har-
sis ground. ness between
Connector & terminal ECM and TCM
(8134) No. 18 (+) - Chassis ground (-): connector.
CHECK POOR CONTACT. Is there poor contact in ECM Repair poor con- 3eplace the ECM.
Check poor contact in ECM connector. Zonnector? tact in ECM con- :Ref. to FU(D0HC
nector. rURBO)-47,
Engine Control
Module.>
CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Go to step 5. 3epair open circuii
TCM CONNECTOR. n? n harness
1)Turnthe ignition switch to OFF. ietween ECM and
2)Disconnect the connectors from ECM and TCM connector.
TCM.
3)Measure the resistance of harness between
ECM and TCM connector.
Connector & terminal
i
( 8 134) NO. 18 - (856) NO. 4:
CHECK HARNESS BETWEEN ECM AND Is the resistance less than 10 Repair ground 30 to step 6.
TCM CONNECTOR. n? short circuit in har-
Measure the resistance of harness between ness between
ECM and chassis ground. ECM and TCM
Connector & terminal connector.
(8134) No. 18 - Chassis ground:
CHECK POOR CONTACT. Is there poor contact in TCM Repair poor con- 3eplace the TCM.
Check poor contact in TCM connector. connector? tact in TCM con- :Ref. to AT-45,
nector. rransmission Con-
:rol Module
:TCM).>

EN(D0HC TURBO)-371
 GENERAL DIAGNOSTIC TABLE
ENGINE (DIAGNOSTICS)

19.General Diagnostic Table

A: INSPECTION
1. ENGINE
NOTE:
Malfunction of parts other than those listed is also possible. <Ref. to ME(D0HC TURBO)-91, Engine Trouble
in General.>

SvmDtom Problem parts

1. Engine stalls during idling.
2. Rough idling
3. Engine does not return to idle.
4. Poor acceleration
5. Engine stalls or engine sags or hesitates at
acceleration.
1) Idle air control solenoid valve
2) Pressure sensor
3) Mass air flow and intake temperature sensor
4) Ignition parts (*I)
5) Engine coolant temperature sensor (*2)
6) Crankshaft position sensor ('3)
7) Camshaft position sensor (*3)
8) Fuel injection parts (*4)
1) Idle air control solenoid valve
2) Pressure sensor
3) Mass air flow and intake temperature sensor
4) Engine coolant temperature sensor (*2)
5) Ignition parts (*I)
6) Air intake system (*5)
7) Fuel injection parts (*4)
8) Throttle position sensor
9) Crankshaft position sensor (*3)
IO) Camshaft position sensor (*3)
11) Oxygen sensor
12) Fuel pump and fuel pump relay
1) Idle air control solenoid valve
2) Engine coolant temperature sensor
3) Accelerator cable ("6)
4) Throttle position sensor
5) Pressure sensor
6) Mass air flow sensor
1) Pressure sensor
2) Mass air flow and intake temperature sensor
3) Throttle position sensor
4) Fuel injection parts (*4)
5 ) Fuel pump and fuel pump relay
6) Engine coolant temperature sensor (*2)
7) Crankshaft position sensor (*3)
8) Camshaft position sensor (*3)
9) A/C switch and A/C cut relay
10) Engine torque control signal circuit
11) Ignition parts (*I)
1) Pressure sensor
2) Mass air flow and intake temperature sensor
3) Engine coolant temperature sensor (*2)
4) Crankshaft position sensor (*3)
5 ) Camshaft position sensor (*3)
6) Purge control solenoid valve
7) Fuel injection parts ('4)
8) Throttle position sensor
9) Fuel pump and fuel pump relay

EN(D0HC TURBO)-372
 GENERAL DIAGNOSTIC TABLE
ENGINE IDIAGNOSTICS)

SvmDtom Problem parts

1) Pressure sensor
2) Mass air flow and intake temperature sensor
3) Engine coolant temperature sensor (*2)
4) Crankshaft position sensor (*3)
6. Surge
5 ) Camshaft position sensor (*3)
6) Fuel injection parts (*4)
7) Throttle position sensor
8) Fuel pump and fuel pump relay
1) Pressure sensor
2) Mass air flow and intake temperature sensor
3) Engine coolant temperature sensor
7. Spark knock
4) Knock sensor
5 ) Fuel injection parts (*4)
6) Fuel pump and fuel pump relay
1) Pressure sensor
2) Mass air flow and intake temperature sensor
8. After burning in exhaust system 3) Engine coolant temperature sensor (*2)
4) Fuel injection parts (*4)
5 ) Fuel pump and fuel pump relay
*1: Check ignition coil & ignitor assembly and spark plug.
*2: Indicate the symptom occurring only in cold temperatures.
*3:Ensure the secure installation.
*4: Check fuel injector, fuel pressure regulator and fuel filter.
*5:Inspect air leak in air intake system.
*6: Adjust accelerator cable.

EN(DOHC TURB0)-373
 GENERAL DIAGNOSTIC TABLE
ENGINE (DIAGNOSTICS)

EN(D0HC TURBO)-374
 I
2002 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX
~

TRANSMISSION SECTION

This service manual has been prepared

to provide SUBARU service personnel
with the necessary information and data
for the correct maintenance and repair
of SUBARU vehicles.
This manual includes the procedures
c- - for maintenance, disassembling, reas-
sembling, inspection and adjustment of
components and diagnostics for guid-
ance of experienced mechanics.
Please peruse and utilize this manual
fully to ensure complete repair work for
satisfying our customers by keeping
their vehicle in optimum condition.
When replacement of parts during
repair work is needed, be sure to use
SUBARU genuine parts.

All information, illustration and specifi-

cations contained in this manual are
based on the latest product information
available at the time of publication
approval.

FUJI HEAVY INDUSTRIES LTD. G1830BE4

 1

CONTROL SYSTEMS

CSr
Page
1. General Description .................................................................................... 2
2. Electrical Component .................................................................................. 6
3. AT Shift Lock System .................................................................................. 8
4. Select Lever .............................................................................................. 23
5. Select Cable .............................................................................................. 26
6. AT Shift Lock Solenoid and “P” Position Switch ........................................ 29
7. Integrated Module ..................................................................................... 31
8. MT Gear Shift Lever .................................................................................. 32
9. General Diagostic...................................................................................... 38
c- .
 GENERAL DESCRIPTION
I
CONTROL SYSTEMS

1. General Description
A: SPECIFICATIONS
I Item I Specification -1
I Vibration torque of rod against lever N.m (kgf-m, ft-lb) I 0.7 (0.07, 0.5) or less

cs-2
 GENERAL DESCRIPTION
I
CONTROL SYSTEMS

B: COMPONENT
1. AT SELECT LEVER

.‘
‘-
.‘
‘ I
I
. .‘ ‘-A ‘

TR054t

Indicator light bulb Cushion (25) Slider

Detent arm Guide plate (26) Clip
Detent spring Snap pin (27) “P” position switch
Select lever Outer cable (28) Spring
Spring pin Inner cable (29) Button
Arm Nut B
Pin Nut A Tightening torque: N.m (kgf-m, fi-lb)
Plate Clip T1: 7.5 (0.76, 5.5)
Grommet Lock plate T2: 13 (1.3, 9.4)
Packing Shift lock solenoid T3: l S ( 1 . 8 , 13.0)
Grip Clamp T4: 33 (3.4,25)
Indicator cover Cover

cs-3
I CONTROL SYSTEMS
GENERAL DESCRIPTION

2. MT GEAR SHIFT LEVER

TI30594

(1) Gear shift knob (IO) O-ring A (19) Stay

(2) Console boot (11) O-ring B (20) Spacer
(3) Plate complete (12) BushA
(4) Lever (13) Cushion rubber Tightening torque: N-m (kgf-m, ft-lb)
(5) Bush (14) Bush6 T1: 7.5 (0.76, 5.5)
(6) Bush (15 ) Joint T2: 12 (1.2, 8.7)
(7) Locking wire (16) Rod T3: lS(1.8, 13.0)
(8) Boot (17) Bracket
(9) Snap ring (18) Washer

cs-4
 GENERAL DESCRIPTION I
CONTROL SYSTEMS

C: CAUTION
Wear working clothing, including a cap, protec-
tive goggles, and protective shoes during opera-
tion.
Remove contamination including dirt and corro-
sion before removal, installation or disassembly.
Keep the disassembled parts in order and pro-
tect them from dust or dirt.
Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary re-
moval, installation, disassembly, and replacement.
Use SUBARU genuine grease etc. or the equiv-
alent. Do not mix grease etc. with that of another
grade or from other manufacturers.
Be sure to tighten fasteners including bolts and
nuts to the specified torque.
Place shop jacks or safety stands at the specified
points.
Apply grease onto sliding or revolution surfaces
before installation.
c. Before installing O-rings or snap rings, apply suf-
ficient amount of grease to avoid damage and de-
formation.
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.
Before disconnecting electrical connectors, be
sure to disconnect the negative terminal from bat-
tery.

cs-5
I ELECTRICAL COMPONENT
CONTROL SYSTEMS

2. Electrical Component
A: LOCATION

(1) Inhibitor switch (4) Key warning switch (7) Key lock solenoid
(2) Integrated module (5) Shift lock solenoid
(3) Stop light switch (6) “P” position switch

CS-6
 ELECTRICAL COMPONENT
I
CONTROL SYSTEMS

(2)

\ \o\ ' B2M2246E TR0548

TR0549

cs-7
 I
AT SHIFT LOCK SYSTEM
CONTROL SYSTEMS

3. AT Shift Lock System

A: ELECTRICAL SPECIFICATION

10 9 8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9 20 19 18 17 16 15 14 13 12 11

I BO031 1

InpuVOutput signal
Contents Connector No. Terminal No.
Measured value and measuring conditions
Battery power supply 8281 2 9-16V
Ignition power supply B280 19 10 - 15 V when ignition switch is at ON or START.
Ignition power supply 8280 10 10 - 15 V when ignition switch is at ACC.
0 V when select lever is in “ P position.
Inhibitor Switch (“P” position) 8280 5 9 - 16 V when select lever is in other positions than “ P
oosition.

Stop light switch I B280 I 9

9 - 16 V when stop light switch is ON.
0 V when stop light switch is OFF.

I “P” position switch I B280

Shift lock solenoid signal
0 V when select lever is in “ P position.
9 - 16 V when select lever is in other positions than “P”
position.
8.5 - 16 V when shift lock is released.
8281 9
0 V when shift lock is oPeratina.
I

9 - 16 V when key is inserted.

Key warning switch signal 6280 20
0 V when key is removed.
7.5 - 16 V when turning ignition switch to ON, select
Key lock solenoid signal 8281 3 lever is in “P” position and brake switch is ON.
0 V at other conditions than above. .
Ground B281 4 -
Ground B281 13 -

CS-8
 AT SHIFT LOCK SYSTEM
I
CONTROL SYSTEMS

B: SCHEMATIC

OQ

(2)
0
0 c----
L
(4)

(1) Ignition switch (4) integrated module (7) Shift lock solenoid
(2) Stop light switch (5) Inhibitor switch (8) “P” position switch
(3) Key warning switch (6) Key lock solenoid (9) Battery

cs-9
 AT SHIFT LOCK SYSTEM
CONTROL SYSTEMS

C: INSPECTION
Step Check Yes NO
CHECK SHIFT LOCK. While brake pedal is Go to step 2. Inspect “SELECT
1)Turn the ignition switch ON. depressed, can select lever LEVER CANNOT
2)Move the select lever to “P” position. move from “ P range to other BE SHIFT
positions? LOCKED. <Ref.
to CS-I4, SELECT
LEVER CANNOT
BE SHIFT
LOCKED,
INSPECTION, AT
Shift Lock Sys-
tem.>
! CHECK SHIFT LOCK. While brake pedal is not Inspect “SELECT Go to step 3.
depressed, can select lever LEVER SHIFT
move from “P” range to other LOCK CANNOT
positions? BE RELEASED.
<Ref. to CS-16,
SELECT LEVER
SHIFT LOCK
CANNOT BE
RELEASED,
INSPECTION, AT
Shift Lock Sys-
tem.>
I CHECK KEY INTERLOCK. When select lever is in other Inspect “KEY 4T shift lock sys-
than “P” position, does ignition INTERLOCK em is normal.
switch turn to “LOCK position? DOES NOT BE
Or when select lever is in “ P LOCKED OR
position, does ignition switch RELEASED. <Ref.
turn to “LOCK position? to CS-20, KEY
INTERLOCK
DOES NOT LOCK
OR RELEASE,
INSPECTION, AT
Shift Lock Sys-
tem.>

cs-10
AT SHIFT LOCK SYSTEM
CONTROL SYSTEMS

cs-11
 AT SHIFT LOCK SYSTEM
CONTROL SYSTEMS

1. INTEGRATED MODULE POWER SUPPLY AND GROUND LINE

WIRING DIAGRAM:

r 0

P 0
z

I
A: @
I I
-
-

TR0551

cs-12
 AT SHIFT LOCK SYSTEM 1
CONTROL SYSTEMS
~

Step Check Yes No

CHECK FUSE (No. 3 , 4 and 11). s the fuse (No. 3,4 or 11) 3eplace the fuse So to step 2.
1)Aemove the fuse (No. 3 , 4 and 11). )lawn out? :No. 3, 4 or 11). If
he replaced fuse
:No. 3,4 or 11)
ias blown out eas
ly, repair short cir-
:uit in harness
letween fuse and
ntegrated module.
! CHECK HARNESS CONNECTOR BETWEEN s the resistance less than 1 30 to step 3. Repair open circuit
INTEGRATED MODULE AND BODY 2? in harness
GROUND. between inte-
1)Turn the ignition switch to OFF. grated module and
2)Measure the resistance of harness between body ground.
integrated module and chassis ground.
Connector & terminal
(8281) No. 4 - Chassis ground:
-
(8281) No. 13 Chassis ground:
I CHECK BATTERY POWER SUPPLY. s the voltage more than 9 V? 30 to step 4. Repair open circuit
1)Turn the ignition switch to ON (engine OFF). harness between
2)Measure the voltages between integrated battery and inte-
module and chassis ground. grated module,
Connector & terminal and poor contact
(8281) No. 1 (+) - Chassis ground (-): in coupling con-
nector.
I CHECK IGNITION POWER SUPPLY CIR- s the voltage more than 9 V? So to step 5. Repair open circuit
CUIT. harness between
1)Tufn the ignition switch to ACC. battery and inte-
2)Measure the voltage between integrated grated module,
module and chassis ground. and poor contact
Connector & terminal in coupling con-
(8280) No. 10 (+) - Chassis ground (-): nector.
> CHECK IGNITION POWER SUPPLY CIR- s the voltage more than 9 V? Go to step 6. Repair open circuit
CUIT. harness between
1)Turn the ignition switch to ON (engine OFF). battery and inte-
2)Measure the voltage between integrated grated module,
module and chassis ground. and poor contact
Connector & terminal in coupling con-
(8281) No. 19 (+) - Chassis ground (-): nector.
i CHECK POOR CONTACT. s there poor contact in power Repair poor con- Replace the inte-
;upply and ground line circuit? tact. grated module.

CS-13
 AT SHIFT LOCK SYSTEM
CONTROL SYSTEMS

2. SELECT LEVER CANNOT BE SHIFT LOCKED

WIRING DIAGRAM:

SBF-1

STOP LIGHT

A: @
B: @ INTEGRATED MODULE

I la1
I
1I SHIFT LOCK

I SOLENOID

Is
OC :WITHOUT CRUISE CONTROL MODEL
WC :WITH CRUISE CONTROL MODEL

TR0552

cs-14
 AT SHIFT LOCK SYSTEM
CONTROL SYSTEMS

Step Check Yes No

I CHECK STOP LIGHT SWITCH. Does the stop light turn ON? Go to step 2. Inspect the stop
Depress the brake pedal. light system.
2 CHECK HARNESS BETWEEN STOP LIGHT Is the resistance more than 1 Repair open circuit So to step 3.
SWITCH AND INTEGRATED MODULE. MR? in harness
1)Turn the ignition switch to OFF. between inte-
2)Disconnect the integrated and stoplight grated module and
switch connector. stop light switch.
3)Measure the resistance of harness between
stop light switch and integrated module.
Connector & terminal
Without cruise control model
(864) NO. 1 - (B280) NO. 9:
Without cruise control model
(B65) NO. 3 - (8280) NO. 9:
3 CHECK HARNESS BETWEEN STOP LIGHT Is the resistance less than 1 Repair short circuit Go to step 4.
SWITCH AND INTEGRATED MODULE. n? in harness
Measure the resistance of harness between between inte-
stop light switch and chassis ground. grated module and
Connector & terminal stop light switch.
Without cruise control model
(B64) No. 1 - Chassis ground:
Without cruise control model
(B65) No. 3 - Chassis ground:
4 CHECK HARNESS BETWEENINTEGRATED Is the resistance more than 1 Repair open circuit Go to step 5.
MODULE AND SHIFT LOCK SOLENOID. MR? in harness
1)Disconnect the shift lock solenoid connector between inte-
2)Measure the resistance of harness between grated module and
integrated module and shift lock solenoid.. shift lock solenoid.
Connector & terminal
(B116) NO. 4 - (8281) NO. 9:
5 CHECK HARNESSBETWEENINTEGRATED Is the resistance less than 1 Repair short circuit Go to step 6.
MODULE AND SHIFT LOCK SOLENOID. Q? in harness
Measure the resistance of harness between between inte-
shift lock solenoid and chassis ground. grated module and
Connector & terminal shift lock solenoid.
( B l l 6 ) No. 4 - Chassis ground:
6 CHECK HARNESS BETWEEN SHIFT LOCK Is the resistance more than 1 Repair open circuit Go to step 7.
SOLENOID AND CHASSIS GROUND. MR? in harness
Measure the resistance of harness between between shift lock
shift lock solenoid and chassis ground. solenoid and body
Connector & terminal ground.
(6116) No. 5 - Chassis ground:
7 CHECK SHIFT LOCK SOLENOID. Is the resistance between 10 Go to step 8. Replace the shift
Measure the resistance of shift lock solenoid and 20 R? lock solenoid.
connector terminals.
Terminal
NO. 4 -NO. 5:
8 CHECK SHIFT LOCK SOLENOID. Does the shift lock solenoid Go to step 9. Replace the shift
Connect the battery with shift lock solenoid operate properly? lock solenoid.
connector terminal and operate solenoid.
Terminal
-
NO. 4 (+) NO. 5 (--)I
9 CHECK POOR CONTACT. Is there poor contact in key Repair poor con- Replace the inte-
lock circuit? tact. grated module.

CS-15
 AT SHIFT LOCK SYSTEM
CONTROL SYSTEMS

3. SELECT LEVER SHIFT LOCK CANNOT BE RELEASED

WIRING DIAGRAM:

INHIBITOR STOP LIGHT

SWITCH SWITCH

I
A: @
B: @ INTEGRATED MODULE

I SHIFT LOCK
~

I SOLENOID

B
m n
11213]4]516171819110
11~12~13~14]15]16~17~18~19~20
9 10 11 12

TR0553

CS-16
 AT SHIFT LOCK SYSTEM I
CONTROL SYSTEMS
~ ~

Step Check Yes No

CHECK INHIBITOR SWITCH. ;ombination meter indicator Go to step 2. 4djust inhibitor
1)Turn the ignition switch to ON (engine OFF). amp and select lever “ P , “R”, ;witch and select
2)Move the select lever from “P”to “1” range. IN”, “ 3 , “ 2 and “1” are cor- :able.
.ectly matched?
CHECK HARNESS BETWEEN INHIBITOR s the resistance less than 1 Repair short circuit 30 to step 3.
SWITCH AND INTEGRATED MODULE. n? in harness
1)Turn the ignition switch to OFF. between inte-
2)Disconnect the connector transmission har- grated module and
ness and intgrated module. transmission con-
3)Measure the resistance of harness between nector.
integrated module and chassis ground.
Connector & terminal
(6280) No. 5 - Chassis ground:
CHECK HARNESS BETWEEN INHIBITOR s the resistance more than 1 Repair open circuit 30 to step 4.
SWITCH AND INTEGRATED MODULE. WR? in harness
Measure the resistance of harness between between inte-
integrated module and inhibitor switch. grated module and
Connector & terminal transmission con-
(612) NO. 3 - (6280) NO. 5: nector
CHECK HARNESS BETWEEN INHIBITOR s the resistance less than 1 Go to step 5. Sepair open circuii
SWITCH AND CHASSIS GROUND. n? n harness
Measure the resistance of harness between 2etween inte-
integrated module and chassis ground. Jrated module and
Connector & terminal :hassis ground.
(612) No. 4- Chassis ground:
CHECK INHIBITOR SWITCH. s the resistance more than 1 Repair or replace 30 to step 6.
1)Move the select lever to “ P position. wn? inhibitor switch.
2)Measure the resistance of transmission har-
ness connector terminals.
Connector & terminal
(T3) NO. 3 - NO. 4:
CHECK OUTPUT SIGNAL FOR INTEGRAT- Is the voltage between 9 and Go to step 7. 30 to step 15.
ED MODULE. 16 V?
1)Connect all connectors.
2)Turn the ignition switch to ON.
3)Measure the voltage between integrated
module and chassis ground.
Connector & terminal
(6280) No. 5 (+) - Chassis ground (-):
CHECK STOP LIGHT SWITCH. Does the stop light turn on? Go to step 8. Inspect stop light
Depress the brake pedal. iystem.
CHECK HARNESS BETWEEN STOP LIGHT Is the voltage more than 9 V? Go to step 9. Repair open or
SWITCH AND AT SHIFT LOCK CONTROL short circuit in har,
MODULE. ness between inte
1)Depress the brake pedal. grated module ana
2)Measure the voltage between integrated itop light switch.
module and chassis ground.
Connector & terminal
(6280) No. 9 (+) - Chassis ground (-):
CHECK HARNESS BETWEENINTEGRATED Is the resistance more than 1 Repair open circuit Go to step 10.
MODULE AND SHIFT LOCK SOLENOID. MR? in harness
1)Turn the ignition switch to OFF. between inte-
2)Disconnect the connector from shift lock grated module and
solenoid and integrated module. shift lock solenoid.
3)Measure the resistance of harness between
integrated module and shift lock solenoid.
Connector & terminal
(6281) NO. 9 - (61161 NO. 4:

CS-17
I AT SHIFT LOCK SYSTEM
CONTROL SYSTEMS

Step Check Yes No

IO CHECK HARNESS BETWEENINTEGRATEC Is the resistance less than 10 Go to step 11. Repair short circui
MODULE AND SHIFT LOCK SOLENOID. R? in harness
Measure the resistance of harness between between inte-
shift lock solenoid and chassis ground. grated module an(
Connector & terminal shift lock solenoid
(6281) No. 9 - Chassis ground:
I1 CHECK HARNESS BETWEEN SHIFT LOCK Is the resistance less than 1 Go to step 12. Repair open circui
SOLENOID AND CHASSIS GROUND. n? in harness
Measure the resistance of harness between between shift lock
shift lock solenoid and chassis ground. solenoid and chas
Connector & terminal sis ground.
( 6 1 16) No. 5 - Chassis ground:
12 CHECK SHIFT LOCK SOLENOID. Is the resistance between 10 Go to step 13. Replace the shift
Measure the resistance of shift lock solenoid and 20 R? lock solenoid.
connector terminals.
Terminal
NO. 4 - NO. 5:
13 CHECK SHIFT LOCK SOLENOID. Is shift lock solenoid operating So to step 14. Replace the shift
Connect the battery with shift lock solenoid properly? lock solenoid.
connector terminal and operate solenoid.
Terminal
-... . NO. 4 (+) - NO. 5I)-(
14 CHECK OUTPUT SIGNAL FOR AT SHIFT Is the voltage more than 8.5 V? 30 to step 15. Replace the inte-
LOCK CONTROL MODULE. grated module.
1)Turnthe ignition switch to ON (engine OFF).
2)Measure the voltage between integrated
module and chassis ground.
Connector & terminal
(6281) No. 9 (+) - Chassis groundI)-(
5 CHECK POOR CONTACT. Is there poor contact in key 3epair poor con- Replace the inte-
lock circuit? act. grated module.

CS-18
AT SHIFT LOCK SYSTEM I
CONTROL SYSTEMS

cs-19
 AT SHIFT LOCK SYSTEM
CONTROL SYSTEMS

4. KEY INTERLOCK DOES NOT LOCK OR RELEASE

WIRING DIAGRAM:

(D
>
a
si E
$ 0

c.

TR0554

cs-20
I AT SHIFT LOCK SYSTEM
I
CONTROL SYSTEMS

Step Check Yes No

CHECK HARNESS BETWEEN BATTERY s the voltage between 9 and 30 to step 2. 3epair open or
AND KEY WARNING SWITCH. I6 V? short circuit in har-
1)Disconnectthe connector key warning less between bat-
switch. :ery and key
2)Measure the voltage of harness between key Narning switch.
warning switch and chassis ground.
Connector & terminal
(874) No. 2 - Chassis ground:
CHECK KEY WARNING SWITCH. Is the resistance more than 1 3eplace key warn- 30 to step 4.
Measure the resistance of stop light switch WR? ng switch.
connector terminals.
Terminal
NO. 1 - NO. 2:
CHECK KEY WARNING SWITCH. Is the resistance more than 1 30 to step 4. Replace key warn-
1)Remove the key. MR? ing switch.
2)Measure the resistance of stop light switch
connector terminals.
Terminal
NO. 1 - NO. 2:
CHECK HARNESS BETWEEN AT SHIFT Is the resistance more than 9 30 to step 5. Repair open circuit
LOCK CONTROL MODULE AND KEY V? in harness
WARNING SWITCH. between inte-
1)Disconnectthe integrated module connector. grated module and
2)Measure the voltage of harness integrated key warning
module and chassis ground. switch.
Connector & terminal
(8280) No. 20 - Chassis ground:
CHECK HARNESS BETWEENINTEGRATED Is the resistance more than 1 Repair open circuit Go to step 6.
MODULE AND KEY LOCK SOLENOID. MR? n harness
1)Disconnectthe connector key lock solenoid. setween inte-
2)Measure the resistance of harness between grated module and
integrated module and key lock solenoid. cey lock solenoid.
Connector & terminal
(873) NO. 2 - (8281) NO. 3:
CHECK HARNESS BETWEEN INTEGRATED Is the resistance more than 1 Go to step 7. Repair short circuit
MODULE AND KEY LOCK SOLENOID. R? in harness
Measure the resistance of harness between between inte-
integrated module and chassis ground. grated module and
Connector & terminal key lock solenoid.
(B281) No. 3 - Chassis ground:
CHECK HARNESS BETWEEN KEY LOCK Is the resistance less than 10 Go to step 8. Repair open circuit
SOLENOID AND CHASSIS GROUND. a? in harness
Measure the resistance of harness between between key lock
key lock solenoid and chassis ground. solenoid and chas
Connector & terminal sis ground.
(873) No. 1 - Chassis ground:
CHECK KEY LOCK SOLENOID. Is the resistance between 4 Go to step 14. Replace the key
Measure the resistance of key lock solenoid and 8 R? lock solenoid.
connector terminals.
Connector & terminal
(873) NO. 1 -NO. 2:
CHECK HARNESS BETWEEN “P” POSI- Is the resistance less than 1 Go to step 10. Repair short circuil
TION SWITCH AND CHASSIS GROUND. R? in harness
Measure the resistance of harness between between “P” posi-
“ P position switch and chassis ground. tion switch and
Connector & terminal integrated module
(8116) No. 2 - Chassis ground:

cs-21
 AT SHIFT LOCK SYSTEM
CONTROL SYSTEMS

Step Check Yes No

IO CHECK HARNESS BETWEEN AT SHIFT s the resistance more than 1 Repair open circuit Go to step 11.
LOCK CONTROL MODULE AND “P” POSI- AQ? in harness
TION SWITCH. between inte-
1)Disconnectthe connector from “ P position grated module and
switch. “P” position switch.
2)Measure the resistance of harness between
integrated module and “ P position switch.
Connector & terminal
(B116) NO. 2 - (8280) NO. 6:
I1 CHECK HARNESS BETWEEN “P” POSI- s the resistance more than 1 IGo to step 12. Repair open circuit
TlON SWITCH AND CHASSIS GROUND. JIR? in harness
Measure the resistance of harness “P”position between “P” posi-
switch and chassis ground. tion switch and
Connector & terminal shassis ground.
( B l l 6 ) No. 6 - Chassis ground:
I2 CHECK “P” POSITION SWITCH. s the resistance less than 1 Go to step 13. Replace the “P”
1)Move the select lever to “P” position. 2? aosition switch.
2)Measure resistance between “ P position
switch connector terminals.
Terminal
NO. 2 - NO. 6:
k . CHECK “P” POSITION SWITCH. s the resistance more than 1 Go to step 14. Replace the “P”
1)Move the select lever to other than “P” posi- JIQ? position switch.
tion.
2)Measure resistance between “ P position
switch connector terminals.
Terminal
NO. 2 - NO. 6:
4 CHECK OUTPUT SIGNAL FOR INTEGRAT- s the voltage 7.5 and 16 V? 30 to step 15. Replace the inte-
ED MODULE. grated module.
1)Connect all connectors.
2)Turn the ignition switch to ON (engine OFF).
3)Move the select lever to “P” position.
4)Press the brake pedal.
5)Measure the voltage between integrated
module connector and chassis ground.
Connector & terminal
(8281) No. 3 (+) - Chassis ground (-):
I5 CHECK POOR CONTACT. s there poor contact in AT shift Repair poor con- Replace the inte-
x k circuit? tact. grated module.

cs-22
 SELECT LEVER
I
CONTROL SYSTEMS

4. Select Lever B: INSTALLATION

1) Mount the select lever onto the vehicle body.
A: REMOVAL 2) Tighten the four bolts to install the select lever to
1) Set the vehicle on the lift. the vehicle body, then connect the connector.
2) Disconnect the ground terminal from battery.
Tightening torque:
3) Move the select lever to the “N” position.
13 N.m (1.3 kgf-m, 9.4 ft-lb)
4) Lift-up the vehicle.
5) Remove the rear exhaust pipe and muffler.
6) Remove the heat shield cover. (If equipped)
7) Disconnect the cable from select lever and then
remove the cable bracket.

3) Install the console box. <Ref. to El-39, INSTAL-

LATION, Glove Box.>
4) Set the location of select lever at ‘IN” position.
5) Lift-up the vehicle.
6) Set the location of range select lever to “N” posi-
(A) Adjusting nuts tion.
(B) Cable bracket 7) Insert the thread portion of the other inner cable
and into the connector hole of the select lever, and
8) Lower the vehicle. fix the other outer cable end to the bracket.
9) Remove the console box. <Ref. to El-41, RE- 8) Adjust the select cable position. <Ref. to CS-27,
MOVAL, Console Box.> ADJUSTMENT, Select Cable.>
10) Disconnect the connectors, then remove the 9) After completion of fitting, make sure that the se-
four bolts to take out the select lever assembly from lect lever operates smoothly all across the operat-
the body. ing range.
10) Inspect the following items. If the following in-
spection reveals problems, adjust the select cable
and inhibitor switch. <Ref. to CS-27, ADJUST-
MENT, Select Cable.> and <Ref. to AT-28, AD-
JUSTMENT, Inhibitor Switch.>
(1) The engine starts operating when select le-
ver is in position “P”,but not in other positions.
(2) The back-up light is lit when the select lever
is in position ‘W, but not in other positions.
(3) Select lever and indicator positions are
I1510
matched.
11) Check the shift-lock system.
(1) Ensure the ignition switch rotates from
“ACC” to “LOCK when the select lever is set at
“P”. Also check that ignition key can be removed
only from the “LOCK position.
(2) Ensure the select lever moves from “P” to
any other position when the brake pedal is de-
pressed with ignition key set at “ON” or
“START.
12) Install heat shield cover. (If equipped)
13) Install rear exhaust pipe and muffler.

CS-23
 SELECT LEVER
I
CONTROL SYSTEMS

C: DISASSEMBLY 6) Remove the lock plate.

1) Remove the grip.
2) Remove the indicator light and then remove the n
indicator cover.
NOTE:
Be careful not to break the indicator light during re-
moval.

v
TR0556

7) Remove the pattern plate.

B3M1511A

(A) Grip
c. ~ (B) Indicator cover
(C) indicator light

3) Remove the slider. TR0557

4) Remove the clips and then remove the guide
8) Remove the clip and remove the “P” position
plate. switch.
I

I B3M2177A

(A) Clips
(A) Clip
(B) Guide plate
(B) “P” position switch
5) Remove the clamp, and shift lock solenoid. 9) Remove the cap and then extract straight pin.

I TR0555
B3M1797A

(A) Clamp
(A) Straight pin
(B) Shift lock solenoid
(B) Select lever lower

CS-24
 I
SELECT LEVER
CONTROL SYSTEMS

10)Remove the select lever lower then take away

the select lever upper from plate.

dA’ B3M1848A

(A) Select lever lower

(B) Select lever upper
(C) Plate

1 1 ) Remove the spring and remove the detent arm.

(A) Detent arm

(B) Spring

12)Remove the cushion.

D: ASSEMBLY
1) Clean all parts before assembly.
2) Apply grease [NIGTIGHT LYW No. 2 or equiva-
lent] to each parts. <Ref. to CS-3, AT Select Le-
ver.>
3) Assembly is in the reverse order of disassembly.
4) After completion of fitting, transfer the select le-
ver to range “P” - “l”, then check whether the in-
dicator and select lever agree, whether the pointer
and position mark agree and what the operating
force is.
E: INSPECTION
1) Inspect the removed parts by comparing with
new ones for deformation, damage and wear. Cor-
rect or replace if defective.
2) Confirm the following parts for operating condi-
tion before assembly. Moving condition of the se-
lector lever upper, it should move smoothly.

CS-25
I I
SELECT CABLE
CONTROL SYSTEMS

5. Select Cable 10) Disconnect the cable from select lever and then
remove the cable bracket.
A: REMOVAL
1) Set the vehicle on the lift.
2) Disconnect the ground terminal from battery.
3) Prior to removal, set the lever to “N” position.
4) Lift-up the vehicle.
5) Remove the front and center exhaust pipe. (Non-
turbo model) <Ref. to EX(S0HC)-5, REMOVAL,
Front Exhaust Pipe.>
CAUTION:
When removing the exhaust pipes, be careful
each exhaust pipe does not drop out.
6) Remove the center exhaust pipe. (Turbo model) (A) Adjusting nuts
<Ref. to EX(D0HC TURBO)-8, REMOVAL, Center (B) Cable bracket
Exhaust Pipe.>
7) Remove’ the heat shield cover. (If equipped) 11) Remove the select cable from plate assembly.
8) Remove the snap pin from range select lever.

(A) Range select lever

(B) Snap pin
(C) Select cable
(D) Clamp
9) Remove the plate assembly from transmission
case

(A) Select cable

(B) Plate ASSY
(C) Clamp

CS-26
I SELECT CABLE
I
CONTROL SYSTEMS

B: INSTALLATION C: INSPECTION
1) Install the select cable to plate assembly. Check the removed cable and replace if damaged,
rusty, or malfunctioning.
Tightening torque:
1) Check for smooth operation of the cable.
32 N.m (3.3 kgf-m, 24 fi-lb)
2) Check the inner cable for damage and rust.
2) Install the select cable to range select lever. 3) Check the outer cable for damage, bends, and
3) Install the plate assembly to transmission. cracks.
Tightening torque: 4) Check the boot for damage, cracks, and deterio-
T: 24.5 N-m (2.5 kgf-m, 18.1 ft-lb) ration.
5) Move the select lever from “P” position to “1” po-
sition. You should be able to feel the detentes in
each position. If the detentes cannot be felt or the
position pointer is improperly aligned, adjust the ca-
ble.
D: ADJUSTMENT
1) Set the vehicle on the lift.
2) Disconnect the ground terminal from battery.
3) Set the lever to “N” position.
4) Lift-up the vehicle.
c.
5) Remove the rear exhaust pipe and muffler.
(A) Select cable 6) Remove the heat shield cover. (If equipped)
(B) Plate ASSY 7) Loosen the adjusting nut on each side.

4) Install the snap pin to range select lever

I / 03M1792A

(A) Adjusting nut A

(B) Adjusting nut B
(A) Range select lever
(B) Snap pin
(C) Select cable
(D) Clamp

5) Move the select lever to the “N” position, then ad-

just the select cable position. <Ref. to CS-27, AD-
JUSTMENT, Select Cable.>
6) Install the heat shield cover. (If equipped)
7) Install the front and center exhaust pipe. (Non-
turbo model) <Ref. to EX(S0HC)-6, INSTALLA-
TION, Front Exhaust Pipe.>
8) Install the center exhaust pipe. (Turbo model)
<Ref. to EX(D0HC TURBO)-9, INSTALLATION,
Center Exhaust Pipe.>

CS-27
I SELECT CABLE
CONTROL SYSTEMS

8) Turn the adjusting nut B until it lightly touches the

connector.

(A) Front side

(B) Select lever
(C) Connector
(D) Adjusting nut B
(E) Contact point
(F) Adjusting nut A

S).While preventing the adjusting nut B from mov-

ing with a wrench, tighten adjusting nut A.
Tightening torque:
7.5 N.m (0.76 kgf-m, 5.5 ft-lb)

(A) Adjusting nut A

(B) Adjusting nut B

10) After completion of fitting, make sure that the

select lever operates smoothly all across the oper-
ating range.
11) Install in the reverse order of removal.

CS-28
 AT SHIFT LOCK SOLENOID AND “P” POSITION SWITCH I
CONTROL SYSTEMS

6. AT Shift Lock Solenoid and 6 : INSTALLATION

“P” Position Switch Install in the reverse order of removal.

A: REMOVAL
1) Disconnect the ground terminal from battery.
2) Remove the console box. <Ref. to El-41, RE-
MOVAL, Console Box.>
3) Disconnect the connector.
4) Remove the grip.
5 ) Remove the indicator cover.

6) Remove the slider.

7) Remove the cushion.
8) Remove the clip and remove the “P” position
switch.

(A) Clip
(B) “ P position switch

9) Remove the clamp and remove the shift lock so-

lenoid.

(A) Clamp
(B) Shift lock solenoid

CS-29
I AT SHIFT LOCK SOLENOID AND “P” POSITION SWITCH
CONTROL SYSTEMS

C: INSPECTION
Step Check
1 CHECK SHIFT LOCK SOLENOID.
Measure the resistance of shift lock solenoid and 20 R? lock solenoid and
connector terminals. “ P position switch
Terminal assembly.
NO. 4 - NO. 5
2 CHECK SHIFT LOCK SOLENOID. Is the shift lock solenoid oper- Go to step 3. Replace the shift
Connect the battery with shift lock solenoid ating properly? lock solenoid and
connector terminal, operate solenoid. “ P position switch
Terminal assembly.
NO. 4 (+) - NO. 5 (-)
3 CHECK “P” POSITION SWITCH. Is the resistance less than 1 Go to step 4. Replace the “ P
1)Move the select lever to “ Pposition. n? position switch.
2)Measure resistance between “ P position
switch connector terminals.
4 CHECK “P” POSITION SWITCH. Is the resistance more than 1 Normal Replace the “P”
1)Move the select lever to other than “P” posi- MR? position switch.
tion.
2)Measure resistance between “P” position
switch connector terminals.

CS-30
 INTEGRATED MODULE
I
CONTROL SYSTEMS

7. Integrated Module B: INSTALLATION

Install in the reverse order of removal.
A: REMOVAL
1 ) Disconnect the ground terminal from battery.

2 ) Remove the lower cover.

3) Remove the knee bolster.

4) Disconnect the connector from integrated mod-

ule.
5) Remove the integrated module.

CS-31
I MT GEAR SHIFT LEVER
I
CONTROL SYSTEMS

8. MT Gear Shift Lever 11) Remove the cushion rubber from body.

A: REMOVAL
1) Set the vehicle on the lift.
2) Remove the gear shift knob.
3) Disconnect the ground terminal from battery.
4) Remove the console box. <Ref. to El-41, RE-
MOVAL, Console Box.>
5) Remove the boot plate from body.

(A) Stay
(B) Cushion rubber
12) Remove the joint and then extract the spring
pin.

@.Lift-up the vehicle.

7) Remove the rear exhaust pipe and muffler.
8) Remove the heat shield cover. (If equipped)
9) Remove the stay from transmission bracket.

(A) Joint
(B) Spring pin

13) Lower the vehicle.

14) Remove the gear shift lever

(A) Stay
(B) Transmission bracket
10) Remove the rod from joint.

CS-32
 MT GEAR SHIFT LEVER
I
CONTROL SYSTEMS

B: INSTALLATION 7) Connect the rod to the joint.

1) Install the joint to the transmission and secure Tightening torque:
with the straight pin. 18 N.m (1.8 kgf-m, 73.0 ff-lb)
2) Insert the gear shift lever from room side.
NOTE:
After inserting the rod and stay, temporarily put
them onto transmission mount.

(A) Stay
(B) Rod

8) Connect the stay to transmission bracket.

3) Lift-up the vehicle. Tightening torque:
c4) Install the joint to shifter arm.
.
18 N-m (1.8 kgf-m, 13.0 ff-lb)
5) Insert the spring pin.

(A) Stay
(A) Joint
(B) Transmission bracket
(B) Spring pin
9) Install the heat shield cover. (If equipped)
6) Mount the cushion rubber on the body. IO) Install the rear exhaust pipe and muffler.
Tightening torque: 1 1 ) Lower the vehicle.
18 N-m (1.8 kgf-m, 13.0 ff-lb) 12) Install the boot plate to body.
Tightening torque:
7.5 N.m (0.76 kgf-m, 5.5 ff-lb)
13) Install the consol box. <Ref. to El-41, INSTAL-
LATION, Console Box.>

(A) Stay
(B) Cushion rubber

cs-33
I MT GEAR SHIFT LEVER
I
CONTROL SYSTEMS

C: DISASSEMBLY 5) Remove the bush and cushion rubber from stay.

1) Disassemble the locking wire.

B3M08300

' ' B3M0617C

(A) Bushing
(A) Locking wire (B) Stay
(B) Stay (C) Cushion rubber

2) Remove the rod from gear shift lever. 6) Remove the O-ring, then disconnect the bush D.

- B3M1828A

(A) Rod (A) O-ring B

(B) Gear shift lever (B) O-ring A
(C) Stay (C) Bushing B

3) Remove the snap ring from bush B, then discon- 7) Draw out the spring pin, then remove the bush C
nect the stay. from gear shift lever.

B3M0619B 83M0621B

(A) Snap ring (A) Spring pin

(B) Bushing B (B) BushingA
(C) Boot

4) Remove the boot from gear shift lever.

cs-34
 MT GEAR SHIFT LEVER
I
CONTROL SYSTEMS

D: ASSEMBLY 4) Insert the gear shift lever into the boot hole.
1) Clean all parts before assembly. 5) Install the snap ring and stay to the bushing B.
2) Mount the bushing B and cushion rubber on the
stay.

B3M0619C

B3M0830C
(A) Snap ring
(6) Bushing B
(A) Bushing
6) Tighten with locking wire to the extent that the
(6) Cushion rubber boot will not come off.
3) Mount each part; boot, O-ring, bush, spacer, CAUTION:
bush A, bush B and straight pin on the gear shift le- Always use new locking wire.
..-
-
ver.
CAUTION:
Always use new O-rings.
Apply grease [DNIGTIGHT LYW No. 2 or
equivalent] to the inner and side surfaces of the
bushing when installing the spacer.

L(A)
(6)
(C)
(D)
(E)
(F)
Boot
O-ring B
Bushing
Spacer
BushingA
Bushing E3
B3M0623C
(A) Locking wire
(6) Stay

7) Insert the rod into the boot hole.

8) Connect the rod to gear shift lever.
Tightening torque:
11.8 N.m (1.2 kgf-m, 8.7 fi-lb)

n
(G) Spring pin
(H) O-ring A

(A) Rod
(6) Shift lever
(C) Stay

cs-35
I MT GEAR SHIFT LEVER
CONTROL SYSTEMS

9) Check the swing torque of the rod in relation to E: INSPECTION

the gear shift lever. 1) Check each part (bushing, cushion rubber, spac-
If the torque exceeds the specification, replace the er, boot, stay and rod, etc.) for deformation, dam-
bushing or retighten nuts. age and wear. Repair or replace any defective part.
Rocking torque: Determine defective parts by comparing with new
0.7 N.m (0.07 kgf-m, 0.5 ft-lb) or less parts.

(A) Center of rotation

(6) Swing torque

70) Check that there is no excessive play and that

parts move smoothly.

B3M7 765A

(A) Bushing
(6) Cushion rubber
(C) Spacer
(D) Boot
(E) Stay
(F) Rod

CS-36
 MT GEAR SHIFT LEVER 3
CONTROL SYSTEMS

2) Check the swing torque of the rod in relation of

the gear shift lever.
If the torque exceeds the specification, replace the
bushing or retighten nuts.
Rocking torque:
0.7 N-m (0.07 kgf-m, 0.5 ff-lb) or less

(6)

B3M1829C

(A) Center of rotation

(B) Swing torque

cs-37
 GENERAL DlAGOSTlC
CONTROL SYSTEMS

9. General Diagostic
A: INSPECTION
Symptom Problem Darts
Stop light switch
Shift lock does not function. Shift lock solenoid
Integrated module
Stop light switch
Shift lock solenoid
Shift lock cannot be released.
Integrated module
Inhibitor switch
Key warning switch
“ P position switch
Key interlock does not function.
Key lock solenoid
Integrated module
Key warning switch
“ P position switch
Key interlock cannot be released.
Key lock solenoid
Integrated module
Inhibitor switch
Starter does not run. Select cable
Starter circuit
Inhibitor switch
Back-up light does not light up. Select cable
Back-up light circuit

CS-38
 I

AUTOMATIC TRANSMISSION

AT
1.
Page
General Description .................................................................................... 2
a
2. Automatic Transmission Fluid ..................................................................... 9
3. Differential Gear Oil ................................................................................... 11
4. Road Test .................................................................................................. 12
5. Stall Test ................................................................................................... 13
6. Time Lag Test ........................................................................................... 15
7. Line Pressure Test .................................................................................... 16
8. Transfer Clutch Pressure Test .................................................................. 18
9. Automatic Transmission Assembly ........................................................... 19
C. . 10. Transmission Mounting System ................................................................ 25
11. Extension Case Oil Seal ........................................................................... 27
12. Inhibitor Switch .......................................................................................... 28
13. Front Vehicle Speed Sensor ..................................................................... 32
14. Rear Vehicle Speed Sensor ...................................................................... 35
15. Torque Converter Turbine Speed Sensor ................................................. 36
16. Control Vatve Body ................................................................................... 37
17. Shift Solenoids. Duty Solenoids and ATF Temperature Sensor ...............39
18. ATF Filter .................................................................................................. 44
19. Transmission Control Module (TCM) ........................................................ 45
20 . Dropping Resistor ..................................................................................... 46
21. ATF Cooler Pipe and Hose ....................................................................... 47
I GENERAL DESCRIPTION
I
AUTOMATIC TRANSMISSION

1. General Description 4. TRANSMISSION GEAR RATIO

A: SPECIFICATIONS Model I Sedan non-turbo

I Except sedan
non-turbo I
1. TORQUE CONVERTER CLUTCH 1st I 3.027 I 2.785 I
Model Non-turbo Turbo
2nd I 1.619 I 1.545 I
3rd 1.ooo
Symmetric, 3 element, single stage, 2 phase
Type 4th 0.694
torwe converter

ratio torque I 1.9 - 2.1 I 1.85-2.15

5. PLANETARY GEAR AND PLATE
Nominal
diameter I 246 mm (9.69 in)

1-1
speed
(at sea level)
2,100 - 2,600 rpm 1 2,600 - 3,300 rpm
Model
I “ 1
Turbo

One-way
clutch
1 Sprague type one-way clutch
Front sun gear number of
teeth
33

Front pinion number of teeth I 21

2. OILPUMP Front internal gear number
75
of teeth
I Type I Pracoid constant-displacementpump I Rear sun gear number of
37 42
LDriving method I Driven by engine teeth
Inner rotor 9 Rear pinion number of teeth I 19 I 17

3. TRANSMISSION CONTROL ELEMENT Drive & driven plate number

4 5
of high clutch
4-forward, 1-reverse, double-row plane- Drive & driven plate number
Type 6 7
tary gears of low clutch

I I
Multi-Dlate clutch 3 sets
I Multi-plate brake I
One-way clutch
(sprague type)
2 sets
1 sets
I
Drive & driven plate number
of 2-4 brake
Drive & driven plate number
of low & reverse brake
1

AT-2
 GENERAL DESCRIPTION I
AUTOMATIC TRANSMISSION

6. SELECTOR POSITION 8. COOLING AND HARNESS

P (Park)
Transmission in neutral, output member immov.
able, and engine start possible
Cooling system
I Liquid-cooledcooler incorpo-
rated in radiator I
Transmission in reverse for backing
(Reverse) I Transmission harness I 20 poles I
tral) 9. TRANSFER
Automatic gear change 1st e + 2nd +_) 3rd
D (Drive) Model Non-turbo Turbo
+ 4th

Multi-plate Variable torque

Automatic gear change 1st e + 2nd +_)3rd t Transfer type transfer distribution
4th (MPT) (VTD)
2nd gear locked (Deceleration possible 2nd t Drive & driven plate
2 (2nd)
3rd c 4th)

1 (1st)
1 1st gear locked (Deceleration possible 1st t
2nd c 3rd t 4th)
number of transfer
clutch
5

I Electronic, hydraulic type

3

Control method I
Control
method I Hydraulic remote control
Lubricant
The same Automatic transmission
fluid used in automatic transmis-
sion
7. HYDRAULIC CONTROL AND LUBRICA- Ist reduction Clear ratio I I.OOO ( 5 ~ 5 3 ) I
JlON

forward speed changes by electri-

cal signals of vehicle speed and
accelerator (throttle) opening]

Fluid
mission fluid
9.3 - 9.6 8 (9.8 - 10.1 US qt,
Fluid capacity
7.4 - 7.7 Imp qt)
Forced feed lubricationwith oil
Lubrication system
,DUmD
,
Automatic transmission fluid
Oil
(above mentioned)

10.FlNAL REDUCTION

I Model Sedan non-turbo Except sedan non-turbo

Front final gear ratio 4.444 (4019) 4.1 11 (37/91

ITEM
Front differential gear oil
API Classification
GL - 5
SAE Viscosity No. and Applicable Temperature
Lubricationoil ("C) -30 -26 -15 -5 0 15 2530

H3M1235A
Front differential oil capacity 1.2 8 (1.3 US qt, 1.1 Imp qt)

AT-3
 GENERAL DESCRIPTION
I
AUTOMATIC TRANSMISSION

B: COMPONENT
NOTE:
For information about other transmission mounting components, refer to “AUTOMATIC TRANSMISSION”
<Pub. No. G0853ZE> a separate publication.
1. TRANSMISSION MOUNTING

’1I
P
t

(1) Pitching stopper Tightening torque: N.m (kgf-m, ft-lb)

(2) Rear cushion rubber T1: 35 (3.6, 26)
(3) Crossmember T2: 39 (4.0,29)
(4) Stopper T3: 50 (5.1, 37)
T4: 58 (5.9, 43)
T5: 70 (7.1, 51)

AT-4
 GENERAL DESCRIPTION I
AUTOMATIC TRANSMISSION

C: CAUTION Use SUBARU genuine gear oil, grease etc. or

Wear working clothing, including a cap, protec-
tive goggles, and protective shoes during opera-
tion.
Remove contamination including dirt and corro-
sion before removal, installation, and disassembly.
Keep the disassembled parts in order and pro-
tect them from dust or dirt.
Until the oil pan is removed, do not place with the
oil pan side facing up to prevent foreign matter from
entering the valve body.
Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary re-
moval, installation, disassembly and replacement.
When disassembling the-case and other light al-
loy parts, use a plastic hammer to force it apart. Do
not pry it apart with a screwdriver or other tool.
Be careful not to burn your hands, because each
part on the vehicle is hot after running.
~ . ..
the equivalent. Do not mix gear oil, grease etc. with
that of another grade or from other manufacturers.
Be sure to tighten fasteners including bolts and
nuts to the specified torque.
Place shop jacks or safety stands at the specified
points.
Apply gear oil onto sliding or revolution surfaces
before installation.
Replace deformed or otherwise damaged snap
rings with new ones.
Before installing O-rings or oil seals, apply suffi-
cient amount of ATF fluid to avoid damage and de-
formation.
Be careful not to incorrectly install or fail to install
O-rings, snap rings and other such parts.
Before securing a part on a vice, place cushion-
ing material such as wood blocks, aluminum plate,
or shop cloth between the part and the vice.
Avoid damaging the mating surface of the case.
Before applying sealant, completely remove the
old seal.

D: PREPARATION TOOL
1. SPECIAL TOOLS
~

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

398527700 PULLER ASSY Used for removing and installing extension case
roller bearing.

Used for installing extension oil seal.

AT-5
I GENERAL DESCRIPTION
3
AUTOMATIC TRANSMISSION

I---
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
498575400 OIL PRESSURE Used for measuring oil pressure.
GAUGE ASSY

I B3M204C
498897200 4DAPTER Used for oil pump housing when measuring
reverse clutch pressure and line pressure.

I B3M2041
498545400 -ILTER WRENCH Jsed for removing and installing ATF filter.

498277200 ;TOPPER SET Jsed for removing and installing automatic trans.
nission assembly to engine.

I B3M2043

AT-6
 GENERAL DESCRIPTION I
AUTOMATIC TRANSMISSION

ILLUSTRATION I TOOLNUMBER DESCRIPTION REMARKS

41099AA020 NGINE SUPPORT Used for supporting engine.

B3M1976 ~

I 41099AA010 INGINE SUPPORT Jsed for supporting engine.

3RACKET

B3M1975
Turbo model :RANK PULLEY Used for removing and installing bolts which hold
499977300 WRENCH torque converter clutch and drive plate.
Non-turbo model
499977100

B2M4157

I 24082AA150
(Newly adopted tool
CARTRIDGE Troubleshooting for electrical systems.

B2M3876

AT-7
 GENERAL DESCRIPTION
I
AUTOMATIC TRANSMISSION

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

22771AA030 SELECT MONITOR Troubleshooting for electrical systems.
KIT English:
22771AA030 (Without printer)
German:
22771AA070 (Without printer)
French:
22771AA080 (Without printer)
Spanish:
22771AA090 (Without printer)

B2M3877
499267300 STOPPER PIN Used for installing and adjusting inhibitor switch.

B3M2008

2. GENERAL PURPOSE TOOLS

TOOL NAME REMARKS

AT-8
 AUTOMATIC TRANSMISSION FLUID I
AUTOMATIC TRANSMISSION

2. Automatic Transmission (4) Fluid temperature rising speed:

Fluid
A: INSPECTION
1) Check the level of the ATF.
(1) Raise the ATF temperature to 60 to 80°C
(140 to 176°F) from 40 to 60°C (104 to 140°F)
(when cold) by driving a distance of 5 to 10 km (3
to 6 miles).
NOTE:
The level of ATF varies with fluid temperature. Pay
attention to the fluid temperature when checking oil
level.
B3M1020B
(A) ATF level gauge
(B) Upper level
(C) Lower level
(2) Make sure the vehicle is level. After select-
ing all positions (P, R, N, D, 3, 2, l ) , set the se-
lect leveler in “P” range. Measure fluid level with
the engine idling.
NOTE:
After running, idle the engine for one or two min-
utes before measurement.
(3) If the fluid level is below the center between
upper and lower marks, add the recommended
ATF until the fluid level is found within the spec-
ified range (above the center between upper
and lower marks). When the transmission is hot,
the level should be above the center of upper
and lower marks, and when it is cold, the level
should be found below the center of these two
marks.
CAUTION:
Use care not to exceed the upper limit level.
ATF level varies with temperature. Remem-
ber that the addition of fluid to the upper limit
mark when the transmission is cold will result
in overfilling of fluid.
By idling the engine
Time for temperature rise to 60°C (140°F) with at-
mospheric temperature of 0°C (32°F): More than
25 minutes
<Reference>
Time for temperature rise to 30°C (86°F) with atmo-
spheric temperature of 0°C (32°F): Approx. 8 min-
utes
By running the vehicle
Time for temperature rise to 60°C (140°F) with at-
mospheric temperature of 0°C (32°F): More than
10 minutes
(5) Method for checking fluid level upon delivery
or at periodic inspection:
Check fluid level after a warm-up run of approx.
10 minutes. During the warm-up period, the au-
tomatic transmission functions can also be
checked.
2) Check the fluid for leaks.
Check for leaks in the transmission. If there are
leaks, it is necessary to repair or replace gasket, oil
seals, plugs or other parts.
B: REPLACEMENT
1) Lift-up the vehicle.
2) Drain the ATF completely.
CAUTION:
Directly after the engine has been running, the
ATF is hot. Be careful not to burn yourself.
NOTE:
Tighten the ATF drain plug after draining the ATF.
Tightening torque:
25 N-m (2.5 kgf-m, 18.1 ft-lb)
(A) Oil pan
(B) Drain plug
(C) Differential oil drain plug
3) Lower the vehicle.

AT-9
I AUTOMATIC TRANSMISSION FLUID
I
AUTOMATIC TRANSMISSION

4) Pour ATF into the oil charge pipe.

Recommended fluid:
Dexron Ill type automatic transmission fluid
Capacity:
Fill the same amount of fluid drained from the
drain plug hole.
Capacity when transmission is overhauled:
9.3-9.6 8 (9.8- 10.1 USqt, 8.2-8.4Imp
qt)
5) Check the level and leaks of the ATF.
<Ref. to AT-9, INSPECTION, Automatic Transmis-
sion Fluid.>

AT-I 0
 DIFFERENTIAL GEAR OIL I
AUTOMATIC TRANSMISSION

3. Differential Gear Oil B: REPLACEMENT

1) Lift-up the vehicle.
A: INSPECTION 2) Drain the differential gear oil completely.
1) Park the vehicle on a level surface. CAUTION:
2) Remove the oil level gauge and wipe it clean. Directly after the engine has been running, the
3) Reinsert the level gauge all the way. Be sure that differential gear oil is hot. Be careful not to burn
the level gauge is correctly inserted and in the yourself.
proper orientation.
4) Remove it again and note the reading. If the dif- NOTE:
ferential gear oil level is below the “L” line, add oil to Tighten the differential gear oil drain plug after
bring the level up to the “F’ line. draining the differential gear oil.
5) To prevent overfilling the differential gear oil, do Tightening torque:
not add oil above the ‘IF line. 44 N.m (4.5 kgf-m, 32.5 ff-16)

c. .

I s3M0478A

(A) Upper level (A) Oil pan

(B) Lower level (B) Drain plug
(C) Differential oil drain plug

3) Lower the vehicle.

4) Pour gear oil into the gauge hole.
Recommended fluid:
Use GL-5 or equivalent.
Gear oil capacity:
1.2 8 (1.3 US qt, 1.1 Imp qt)
5) Check the level of the differential gear oil.
<Ref. to AT-1 1, INSPECTION, Differential Gear
Oil.>

AT-I 1
 ROAD TEST
AUTOMATIC TRANSMISSION

4. RoadTest
A: INSPECTION
1. GENERAL PRECAUTION
Road tests should be conducted to properly diag-
nose the condition of the automatic transmission.
CAUTION:
When performing the test, do not exceed post-
ed speed limit.
2. D RANGE SHIFT FUNCTION
Check shifting between 1st a 2nd w 3rd a 4th
while driving on normal city streets.
3. D RANGE SHIFT SHOCK
Check the shock level when shifting up during nor-
mal driving.
4. KICK-DOWN FUNCTION
Check kick-down for each gear. Also check the
krick-down shock level.

between D -
5. ENGINE BRAKE OPERATION
Check the 3rd gear engine brake when shifting
3rd range while driving in 4th gear of
D range [50 to 60 km/h (31 to 37 MPH)].
Check the 2nd gear engine brake when shifting
between 3 2 range while driving in the 3 range
3rd gear [40 to 50 km/h (25 to 31 MPH)].
Check the 1st gear engine brake when shifting
between 2 -1 range while driving in the 2 range
2nd gear [20 to 30 km/h (12 to 19 MPH)].
6. LOCK-UP FUNCTION
Check that rpm does not change sharply when the
axle pedal is lightly depressed when driving on flat
roads at normal speed in the lock-up range.
7. P RANGE OPERATION
Stop the vehicle on an uphill grade of 5% or more
and shift to “P” range. Check that the vehicle does
not move when the parking brake is released.
8. UNUSUAL SOUNDS AND VIBRATION
Check for unusual sounds and vibration while driv-
ing and during shifting.
9. CLIMBING CONTROL FUNCTION
Check that the gear remains in 3rd when going
up a grade.
Check that the gear remains in 3rd when apply-
ing the brakes while going down a grade.
10.01L LEAKS
After the driving test, inspect for oil leaks.

AT-I 2
I STALL TEST
5. Stall Test
A: INSPECTION
1. GENERAL INFORMATION
The stall test is of extreme importance in diagnos-
ing the condition of the automatic transmission and
the engine. It should be conducted to measure the
engine stall speeds in “R” and “2” ranges.
Purposes of the stall test:
1) To check the operation of the automatic trans-
mission clutch.
2) To check the operation of the torque converter
clutch.
3) To check engine performance.
2. TEST METHODS
1) Preparations before test:
(1) Check that the throttle valve opens fully.
(2) Check that the engine oil level is correct.
c _ . (3) Check that the coolant level is correct.
(4) Check that the ATF level is correct.
(5) Check that the differential gear oil level is
correct.
(6) Increase ATF temperature to 50 to 80°C
(122 to 176°F) by idling the engine for approxi-
mately 30 minutes (with select lever set to “N” or
lip”).
2) Install an engine tachometer at a location visible
from the driver’s compartment and mark the stall
speed range on the tachometer scale.
3) Place the wheel chocks at the front and rear of all
wheels and engage the parking brake.
4) Move the manual linkage to ensure it operates
properly, and shift the select lever to the “2” range.
5) While forcibly depressing the foot brake pedal,
gradually depress the accelerator pedal until the
engine operates at full throttle.
03M1589E
(A) Brake pedal
(B) Accelerator pedal
6) When the engine speed is stabilized, read that
speed quickly and release the accelerator pedal.
AT-1 3
I
AUTOMATIC TRANSMISSION
7) Shift the select lever to Neutral, and cool down
the engine by idling it for more than one minute.
8) Record the stall speed.
9) If the stall speed in “2” range is higher than spec-
ifications, low clutch slipping and “2-4 brake slip-
ping” may occur. To identify it, conduct the same
test as above in D range.
10) Perform the stall tests with the select lever in
the R range.
NOTE:
Do not continue the stall test for MORE THAN
FIVE SECONDS at a time (from closed throttle, ful-
ly open throttle to stall speed reading). Failure to
follow this instruction causes the engine oil and
ATF to deteriorate and the clutch and brake to be
adversely affected.
Be sure to cool down the engine for at least one
minute after each stall test with the select lever set
in the “P’ or ‘IN” range and with the idle speed lower
than 1,200 rpm.
If the stall speed is higher than the specified
range, attempt to finish the stall test in as short a
time as possible, in order to prevent the automatic
transmission from sustaining damage.
Stall speed (at sea level):
Non-turbo model: 2,100 -2,600 rpm
Turbo model: 2,600 - 3,300 rpm

AUTOMATIC TRANSMISSION
3. EVALUATION
Stall speed (at sea level)
Less than specifications
Greater than specifications
I
STALL TEST
Position Cause
Erroneous engine operation
Torque converter clutch's one-way clutch slipping
Line pressure too low
Low clutch slipping
~
One-wav clutch malfunctionim -
Line pressure too low
R Reverse clutch slipping
Low & reverse brake slipping
Line pressure too low
2 Low clutch slipping
I 2-4 brake slipping
AT-I 4
 TIME LAG TEST
I
AUTOMATIC TRANSMISSION

6. Time Lag Test

A: INSPECTION
1. GENERAL INFORMATION
If the select lever is shifted while the engine is
idling, there will be a certain time elapse or lag be-
fore the shock can be felt. This is used for checking
the condition of the low clutch, reverse clutch, low &
reverse brake and one-way clutch.
CAUTION:
Perform the test at normal operation fluid
temperature 60 to 80°C (140 to 176°F).
Be sure to allow a one minute interval be-
tween tests.
Make three measurements and take the aver-
age value.
2. TEST METHODS
1) Fully apply the parking brake.
-2.)Start the engine.
3) Check the idling speed (NC OFF).
4) Shift the select lever from “N” to “D” range.
Using a stop watch, measure the time it takes from
shifting the lever until the shock is felt.
Time lag: Less than 1.2 seconds
5 ) In the same manner, measure the time lag for
“N” + “R”.
Time lag: Less than 1.5 seconds
3. EVALUATION
1) If “N” + ‘ID time lag is longer than specified:
Line pressure too low
Low clutch worn
One-way clutch not operating properly
2) If “N” + “R” time lag is longer than specified:
Line pressure too low
Reverse clutch worn
Low & reverse brake worn

AT-I 5
I LINE PRESSURE TEST
AUTOMATIC TRANSMISSION

7. Line Pressure Test 2. TEST METHODS

1) Temporarily attach the ST to a suitable place in
A: MEASUREMENT the driver’s compartment, remove the blind plug lo-
1. GENERAL INFORMATION cated in front of the toe board and pass the hose of
the ST to the engine compartment.
If the clutch or the brake shows a sign of slippage or ST 498575400 OIL PRESSURE GAUGE
shifting sensation is not correct, the line pressure ASSY
should be checked.
Excessive shocks during upshifting or shifting
takes place at a higher point than under normal cir-
cumstances, may be due to the line pressure being
too high.
Slippage or inability to operate the vehicle may,
in most cases, be due to loss of oil pressure for the
operation of the clutch, brake or control valve.
1) Line pressure measurement (under no load):
CAUTION:
Before measuring line pressure, jack-up all
wheels.
Maintain temperature of ATF at approximate- (A) Pressure gauge hose
ly 50°C (122°F) during measurement. (B) Hole in toe board (blind plug hole)
(ATF will reach the above temperature after (C) Brake pedal
idling the engine for approximately 30 minutes
with select lever in “N” or “P”.) 2) Remove the test plug and install the ST instead.
2) Line pressure measurement (under heavy load):
ST 498897200 OIL PRESSURE GAUGE
ADAPTER
CAUTION:
Before measuring line pressure, apply both
foot and parking brakes with all wheels
chocked (Same as for “stall” test conditions).
Measure the line pressure when the select le-
ver is in “R”, “2” with engine under stall condi-
tions.
Measure the line pressure within 5 the sec-
onds after shifting the select lever to each posi-
tion. (If the line pressure needs to be measured
again, allow the engine to idle and then stop.
Wait for at least one minute before measure-
ment.) (A) Test plug
Maintain the temperature of ATF at approxi-
mately 50°C (122°F) during measurement. (ATF 3) Connect ST1 with ST2.
will reach the above temperature after idling the ST1 498897200 OIL PRESSURE GAUGE
engine for approximately 30 minutes with the ADAPTER
select lever in “N” or “P”.) ST2 498575400 OIL PRESSURE GAUGE
ASSY

AT-16
 LINE PRESSURE TEST
I
AUTOMATIC TRANSMISSION

4) Check for duty ratio changes by opening and

closing the throttle valve using the Subaru Select
Monitor.
(1) Insert the cartridge to the Subaru Select
Monitor. <Ref. to AT-5, PREPARATION TOOL,
General Description.>

(2) Connect the Subaru Select Monitor to data

link connector.
5 ) Check the line pressure in accordance with the
following chart.
3. EVALUATION
Standard line Dressure 1
Range Line pres- Throttle Line pressure
posi- sure duty position kPa (kgkm’, psi)
tion ratio (Yo)
1,128-1,304
Full open (11.5 - 13.3,
164- 189)
1,520 - 1,716
Full open (15.5 - 17.5,
220 - 249)
304 - 412
D 100 Full closed
(3.1 - 4.2, 44 - 60)

AT-I 7
I TRANSFERCLUTCHPRESSURETEST
AUTOMATIC TRANSMISSION

8. Transfer Clutch Pressure 2. EVALUATION

Test MTP model

A: INSPECTION NOTE:
If the oil pressure is not produced or if it does not
1. TEST METHODS change in the AWD mode, the transfer duty sole-
noid or transfer valve assembly may be malfunc-
MPT model tioning. If the oil pressure is produced in the FWD
Check the transfer clutch pressure in accordance mode, the problem is similar to that in the AWD
with the following chart in the same manner as with mode.
line pressure. <Ref. to AT-16, Line Pressure Test.>
ST 498897700 OIL PRESSURE ADAPTER Standard transfer clutch Dressure kPa (ka/cm2. Dsi)
SET Duty ratio Throttle
AWD mode
FWD
ST 498575400 OIL PRESSURE GAUGE (%) position mode
ASSY 932 - 1,089
AWD mode: “D” range (9.5-11.1,
closed
FWD mode: “P”range, engine speed 2,000 rpm
2/3 t hrot- 216 - 294
CAUTION: tle (2.2 - 3.0, 31 - 43)
Before setting in FWD mode, install the spare
fuse on FWD mode switch.
c. ~ t 1

Duty ratio Throttle Standard transfer clutch pressure

(Yo) position kPa (kg/cm2,psi)
Full 932 - 1,089
5
closed (9.5-11.1, 135-158)
2/3 throt- 216-294
60
tle (2.2 - 3.0, 31 - 43)

(A) Test plug

VTD model
Check the transfer clutch pressure in accordance
with the following chart in the same manner as with
line pressure.
ST 498897700 OIL PRESSURE ADAPTER
SET
ST 498575400 OIL PRESSURE GAUGE
ASSY

7
H3M18408

(A) Test plug

AT-I 8
 AUTOMATIC TRANSMISSION ASSEMBLY
I
AUTOMATIC TRANSMISSION

9. Automatic Transmission As- 10) Disconnect the following connectors:

(1) Transmission harness connector
sembly
A: REMOVAL
1) Set the vehicle on the lift.
2) Open the front hood fully, and support it with
stay.
3) Disconnect the ground terminal from battery.
4) Remove the air intake duct. (Non-turbo model)
<Ref. to IN(S0HC)-7, REMOVAL, Air Intake Duct.>
5 ) Remove the air cleaner case. (Non-turbo model)
<Ref. to IN(S0HC)-6, REMOVAL, Air Cleaner
Case.>
6) Remove the air cleaner case stay. (Non-turbo (2) Transmission ground terminal
model) 11) Remove the starter. <Ref. to SC-6, REMOVAL,
Starter.>
12) Install the ST to torque converter clutch case.
ST 498277200 STOPPER SET

7) Remove the intercooler. (Turbo model) <Ref. to

IN(D0HC TURBO)-10, REMOVAL, Intercooler.>
8) Remove the front, center, rear exhaust pipe and
muffler. (Non-turbo model) 13) Remove the pitching stopper.
<Ref. to EX(S0HC)-5, REMOVAL, Front Exhaust
Pipe.>, <Ref. to EX(S0HC)-9, REMOVAL, Rear
Exhaust Pipe.> and <Ref. to EX(S0HC)-1 1, RE-
MOVAL, Muffler.>
9) Remove the center, rear exhaust pipe and
muffer. (Turbo model) <Ref. to EX(D0HC TUR-
BO)-8, REMOVAL, Center Exhaust Pipe.>, <Ref.
to EX(D0HC TURBO)-13, REMOVAL, Rear Ex-
haust Pipe.> and <Ref. to EX(D0HC TURBO)-14,
REMOVAL, Muffler.>

14) Separate the torque converter clutch from drive

plate.
(1) Remove the service hole plug.
(2) Remove the bolts which hold torque con-
verter clutch to drive plate.
(3) While rotating the engine, remove the other
bolts using ST.
CAUTION:
Be careful not to drop bolts into the torque con-
verter clutch housing.

AT-I 9
 AUTOMATIC TRANSMISSION ASSEMBLY
I
AUTOMATIC TRANSMISSION

Turbo model 17) Remove the bolt which holds right upper side of
ST 499977300 CRANK PULLEY WRENCH transmission to engine.
Non-turbo model
ST 499977100 CRANK PULLEY WRENCH

B3M2044

18) Lift-up the vehicle.

15) Remove the ATF level gauge.
CAUTION:
Plug the opening to prevent entry of foreign
particles into transmission fluid.
19) Remove the under cover.
20) Remove the heat shield cover. (If equipped)
21) Drain the ATF to remove the ATF drain plug.

(A) Oil pan

(6) Drain plug
16) Set the ST.
22) Disconnect the ATF cooler hoses from pipes of
NOTE: transmission side, and remove the ATF level gauge
Also is available Part No. 41099AA010. guide.
ST 41 099AA020 ENGINE SUPPORT ASSY

23) Remove the propeller shaft.

<Ref. to DS-14, REMOVAL, Propeller Shaft.>
24) Remove the shift select cable. <Ref. to CS-26,
REMOVAL, Select Cable.>
25) Disconnect the stabilizer link from transverse
link.

AT-20
 AUTOMATIC TRANSMISSION ASSEMBLY
I
AUTOMATIC TRANSMISSION

26) Remove the bolt securing ball joint of trans- 30) Remove the transmission rear crossmember
verse link to housing. from vehicle.

S4M0090

27) Remove the spring pins and separate front 31) Remove the transmission.
drive shafts from each side of the transmission. CAUTION:
Move the transmission and torque converter as
a unit away from engine.

Remove the nuts which hold lower side of

transmission to engine.
I 32) Separate transmission assembly and rear
cushion rubber.

v
B3M2047

29) Place the transmission jack under transmis-

sion.
CAUTION:
Make sure that the support plates of trans-
mission jack don't touch the oil pan.

AT-2 1
I AUTOMATIC TRANSMISSION ASSEMBLY
I
AUTOMATIC TRANSMISSION

B: INSTALLATION 6) Tighten the nuts and bolts which hold lower side
1) Install the rear cushion rubber to transmission of transmission to engine.
assembly. Tightening torque:
Tightening torque: 50 N-m (5.1 kgf-m, 36.9 ft-lb)
39 N.m (4.0 kgf-m, 29 ft-lb)
2) Install the ST to torque converter clutch case.
ST 498277200 STOPPER SET

7) Lower the vehicle.

8) Connect the engine and transmission.
(1) Remove the ST from torque converter clutch
3) Install the transmission onto engine. case.
-_. (1) Gradually raise the transmission with trans- NOTE:
Be careful not to drop the ST into the torque con-
mission jack.
verter clutch case when removing the ST.
ST 498277200 STOPPER SET
(2) Install the starter.
<Ref. to SC-7, INSTALLATION, Starter.>
(3) Tighten the bolt which holds right upper side
of transmission to engine.
Tightening torque:
50 N.m (5.1 kgf-m, 36.9 ft-lb)

(2) Engage them at splines.

4) Install the transmission rear crossmember.
Tightening torque:
T1: 35 N-m (3.6 kgf-m, 26 ft-lb)
T2: 70 Nom(7.1 kgf-m, 51.4 ft-lb)

03M2044

5) Take off the transmission jack.

AT-22
I AUTOMATIC TRANSMISSION ASSEMBLY
1
AUTOMATIC TRANSMISSION

9) Install the torque converter clutch to drive plate. 12) Lift-up the vehicle.
(1) Tighten the bolts which hold torque convert- Install the front drive shafts into transmission.
er clutch to drive plate. (1) Lift-up the vehicle.
(2) Tighten the other bolts while rotating the en- (2) Install the front drive shaft into transmission.
gine by using ST. (3) Drive the spring pin into chamfered hole of
CAUTION: drive shaft.
Be careful not to drop bolts into the torque con- CAUTION:
verter clutch housing. Always use a new spring pin.
Turbo model
ST 499977300 CRANK PULLEY WRENCH
Non-turbo model
ST 499977100 CRANK PULLEY WRENCH
Tightening torque:
25 N.m (2.5 kgf-m, 18.1 ft-lb)

13) Install the ball joint into housing.

14) Connect the stabilizer link to transverse link,
and temporarily tighten the bolts.
CAUTION:
Discard the loosened self-locking nut and re-
place with a new one.
(3) Clog the service hole with a plug. Tightening torque:
10) Remove the ST. T1: 30 N.m (3.1 kgf-m, 22.4 ft-lb)
T2: 50 N-m (5.1 kgf-m, 37 ft-lb)

11) Install the pitching stopper.

Tightening torque: 15) Install the shift select cable onto select lever.
T1: 50 N.m (5.1 kgf-m, 37 ft-lb) <Ref. to CS-27, INSTALLATION, Select Cable.>
T2: 58 N.m (5.9 kgf-m, 43 ft-lb) 16) Install the ATF level gauge guide, and connect
the ATF cooler hoses to pipe.

AT-23
I AUTOMATIC TRANSMISSION ASSEMBLY
1
AUTOMATIC TRANSMISSION
17) Install the propeller shaft. 32) Check the select lever operation.
<Ref. to DS-15, INSTALLATION, Propeller Shaft.> <Ref. to AT-28, INSPECTION, Inhibitor Switch.>
18) Install the heat shield cover. (If equipped) 33) Check the ATF level. <Ref. to AT-9, Automatic
19) Install the front, center, rear exhaust pipes and Transmission Fluid.>
muffler. (Non-turbo model) 34) Check the vehicle on the road tester.
<Ref. to EX(S0HC)-6, INSTALLATION, Front Ex- <Ref. to AT-12, Road Test.>
haust Pipe.>, <Ref. to EX(S0HC)-9, INSTALLA-
TION, Rear Exhaust Pipe.> and <Ref. to
EX(S0HC)-11, INSTALLATION, Muffler.>
20) Install the center, rear exhaust pipes and muf-
fler. (Turbo model) <Ref. to EX(D0HC TURBO)-9,
INSTALLATION, Center Exhaust Pipe.>, <Ref. to
EX(D0HC TURBO)-13, INSTALLATION, Rear Ex-
haust Pipe.>, <Ref. to EX(D0HC TURBO)-14, IN-
STALLATION, Muff ler.>
21) Install the under cover.
22) Lower the vehicle.
23) Install the ATF level gauge.

c. .

24) Connect the following connectors:

(1) Transmission harness connectors
(2) Transmission ground terminal
25) Install the air cleaner case stay. (Non-turbo
model)
Tightening torque:
16 N.m (1.6 kgf-m, 11.6 ft-16)
26) Install the air cleaner case. (Non-turbo model)
<Ref. to IN(S0HC)-6, INSTALLATION, Air Cleaner
Case.>
27) Install the air intake duct. (Non-turbo model)
<Ref. to IN(S0HC)-7, INSTALLATION, Air Intake
Duct.>
28) Install the intercooler. (Turbo model) <Ref. to
IN(D0HC TURBO)-1 1, INSTALLATION, Intercool-
er.>
29) Connect the battery ground terminal.
30) Fill ATF up to the middle of the “COLD” side on
level gauge by using the gauge hole.
Recommended fluid:
Dexron Ill type automatic transmission fluid
Fluid capacity:
9.3-9.6 0 (9.8-10.1 USqt, 7.4-7.7lmp
qt)
31) Take off the vehicle from lift arms.

AT-24
 TRANSMISSION MOUNTING SYSTEM
I
AUTOMATIC TRANSMISSION

1O.Transmission Mounting Sys- 6) Set the transmission jack under the transmis-
sion.
tem CAUTION:
A: REMOVAL Make sure that the support plates of trans-
mission jack don't touch the oil pan.
1. PITCHING STOPPER 7) Remove the crossmember.
1) Disconnect the ground terminal from battery.
2) Remove the air intake duct. (Non-turbo model)
<Ref. to IN(S0HC)-7, REMOVAL, Air Intake Duct.>
3) Remove the air cleaner case. (Non-turbo model)
<Ref. to IN(S0HC)-6, REMOVAL, Air Cleaner
Case.>
4) Remove the intercooler. (Turbo model) <Ref. to
IN(D0HC TURBO)-10, REMOVAL, Intercooler.>
5) Remove the pitching stopper.

8) Remove the rear cushion rubber.

B: INSTALLATION
1. PITCHING STOPPER
1) Install the pitching stopper.
Tightening torque:
T I : 50 N.m (5.1 kgf-m, 37 ff-lb)
T2: 58 N.m (5.9 kgf-m, 43 ft-lb)
2. CROSSMEMBER AND CUSHION RUB-
BER
1) Disconnect the ground terminal from battery.
2) Jack-up the vehicle and support it with sturdy
racks.
3) Remove the front, center, rear exhaust pipes
and muffler. (Non-turbo model)
<Ref. to EX(S0HC)-5, REMOVAL, Front Exhaust
Pipe.>, <Ref. to EX(S0HC)-9, REMOVAL, Rear
Exhaust Pipe.> and <Ref. to EX(S0HC)-11, RE-
MOVAL, Muffler.>
4) Remove the center, rear exhaust pipes and muf- 2) Install the air intake duct and cleaner case. (Non-
fler. (Turbo model) <Ref. to EX(D0HC TURBO)-8, turbo model) <Ref. to IN(S0HC)-7, REMOVAL, Air
REMOVAL, Center Exhaust Pipe.>, <Ref. to Intake Duct.>, <Ref. to IN(S0HC)-6, REMOVAL,
EX(D0HC TURBO)-13, REMOVAL, Rear Exhaust Air Cleaner Case.>
Pipe.>, <Ref. to EX(D0HC TURBO)-14, REMOV- 3) Install the intercooler. (Turbo model) <Ref. to
AL, Muffler.> IN(D0HC TURBO)-10, REMOVAL, Intercooler.>
CAUTION:
When removing the exhaust pipes, be careful
each exhaust pipe does not drop out.
5) Remove the heat shield cover. (If equipped)

AT-25
I TRANSMISSION MOUNTING SYSTEM
AUTOMATIC TRANSMISSION

2. CROSSMEMBER AND CUSHION RUB- C: INSPECTION

BER Repair or replace parts if the results of the inspec-
1) Install the rear cushion rubber. tion below are not satisfactory.
Tightening torque: 1. PITCHING STOPPER
39 N.m (4.0 kgf-m, 29 ff-lb) Make sure that the pitching stopper is not bent or
2 ) Install the crossmember. damaged. Make sure that the rubber is not stiff,
cracked, or otherwise damaged.
Tightening torque:
T I : 35 N-m (3.6 kgf-m, 26 ft-lb) 2. CROSSMEMBER AND CUSHION RUB-
T2: 70 N.m (7.1 kgf-m, 51.4 ff-lb) BER
Make sure that the crossmember is not bent or
damaged. Make sure that the cushion rubber is not
stiff, cracked, or otherwise damaged.

c.

3) Remove the transmission jack.

4) Install the heat shield cover. (If equipped)
5 ) Install the front, center, rear exhaust pipes and
the muffler. (Non-turbo model)
<Ref. to EX(S0HC)-6, INSTALLATION, Front Ex-
haust Pipe.>, <Ref. to EX(S0HC)-9, INSTALLA-
TION, Rear Exhaust Pipe.> and <Ref. to
EX(S0HC)-11, INSTALLATION, Muffler.>
6) Install the center, rear exhaust pipes and muffler.
(Turbo model) <Ref. to EX(D0HC TURBO)-14, IN-
STALLATION, Muffler.>, <Ref. to EX(D0HC TUR-
BO)-13, INSTALLATION, Rear Exhaust Pipe.>,
<Ref. to EX(D0HC TURBO)-9, INSTALLATION,
Center Exhaust Pipe.>

AT-26
 EXTENSION CASE OIL SEAL
AUTOMATIC TRANSMISSION

11.Extension Case Oil Seal
A: INSPECTION
Make sure that the ATF does not leak from the joint
of the transmission and propeller shaft. If so, re-
place the oil seal. <Ref. to AT-27, REPLACE-
MENT, Extension Case Oil Seal.>
B: REPLACEMENT
1) Set the vehicle on the lift.
2) Disconnect the ground terminal from battery.
3) Lift up the vehicle.
4) Clean the transmission exterior.
5 ) Drain the ATF completely.
NOTE:
Tighten the ATF drain plug after draining the ATF.
Tightening torque:
25 N-m (2.5 kgf-m, 18.1 ft-lb)
13) Install the rear exhaust pipe and muffler.
Non-turbo model
<Ref. to EX(S0HC)-9, INSTALLATION, Rear Ex-
haust Pipe.> and <Ref. to EX(S0HC)-11, INSTAL-
LATION, Muffler.>
Turbo model
<Ref. to EX(D0HC TURBO)-14, INSTALLATION,
Muffler.>, <Ref. to EX(D0HC TURBO)-13, IN-
STALLATION, Rear Exhaust Pipe.>
14) Pour ATF and check the ATF level. <Ref. to AT-
9, Automatic Transmission Fluid.>

(A) Oil pan

(B) Drain plug
(C) Differentialoil drain plug

6) Remove the rear exhaust pipe and muffler.

Non-turbo model
<Ref. to EX(S0HC)-9, REMOVAL, Rear Exhaust
Pipe.> and <Ref. to EX(S0HC)-11, REMOVAL,
Muffler.>
Turbo model
<Ref. to EX(D0HC TURBO)-13, REMOVAL, Rear
Exhaust Pipe.>, <Ref. to EX(D0HC TURBO)-14,
REMOVAL, Muffler.>
7) Remove the heat shield cover. (If equipped)
8) Remove the propeller shaft. <Ref. to DS-14, RE-
MOVAL, Propeller Shaft.>
9) Using the ST, remove the oil seal.
ST 398527700 PULLER ASSY
10) Using the ST, install the oil seal.
ST 498057300 INSTALLER
11) Install the propeller shaft. <Ref. to DS-15, IN-
STALLATION, Prope1ler Shaft.>
12) Install the heat shield cover. (If equipped)

AT-27
I INHIBITOR SWITCH
AUTOMATIC TRANSMISSION
3) Check if there is continuity at equal points when
the select lever is turned 1.5" in both directions
from the N range.
If there is continuity in one direction and the conti-
nuity in the other or if there is continuity at unequal
points, adjust the inhibitor switch.<Ref. to AT-28,
ADJUSTMENT, Inhibitor Switch.>

I f-----3

Position Pin No. (A) Continuity does not exist.

P 4-3 (B) Continuity exists.
-. R 4-2 (C) 1.5"
I
N 4-1
Signal sent to TCM
D 4-8 4) Repeat the above checks. If there are abnormal-
3 4-7 ities, adjust the select cable. <Ref. to CS-27, AD-
2 4-6 JUSTMENT, Select Cable.>
I 1 I 4-5 I B: ADJUSTMENT
Starter circuit PIN 12-11 1) Shift the select lever to the N range.
Back-up light circuit R 10-9 2) Loosen the three inhibitor switch securing bolts.
3) Insert the ST as vertical as possible into the
holes in the inhibitor switch lever and switch body.
Inhibitor switch side connector ST 499267300 STOPPER PIN

B3H0016e

4) Tighten the three inhibitor switch bolts.

Tightening torque:
3.4 N.m (0.35 kgf-m, 2.5 ft-lb)
5 ) Repeat the above checks. If the inhibitor switch
is determined to be "faulty", replace it.

AT-28
 INHI BI T 0R SWITCH
I
AUTOMATIC TRANSMISSION

C: REMOVAL 11) Remove the plate assembly from transmission

1) Set up the vehicle on the lift. case.
2) Move the select lever to neutral position.
3) Remove the air cleaner case. (Non-turbo model)
<Ref. to IN(S0HC)-6, REMOVAL, Air Cleaner
Case.>
4) Remove the intercooler. (Turbo model) <Ref. to
IN(D0HC TURBO)-10, REMOVAL, Intercooler.>
5) Disconnect the inhibitor switch connector.

(A) Select cable

(B) Plate ASSY

12) Remove the bolts.

c-

(A) Inhibitor switch

6) Remove the inhibitor switch connector from stay.

7) Lift-up the vehicle.
8) Remove the front exhaust pipe with center ex-
haust pipe. (Non-turbo model)
<Ref. to EX(S0HC)-5, REMOVAL, Front Exhaust
Pipe.>
9) Remove the center exhaust pipe. (Turbo model)
(A) Inhibitor switch
<Ref. to EX(D0HC TURBO)-8, REMOVAL, Center
Exhaust Pipe.> 13) Move the range select lever to parking position
10) Remove the snap pin from range select lever. (left side).

(A) Snap pin (A) Range select lever

(B) Select cable
(C) Range select lever

AT-29
I INHIBITOR SWITCH
AUTOMATIC TRANSMISSION
14) Remove the inhibitor switch from transmission. 6) Install the plate assembly to transmission.
Tightening torque:
T: 24.5 N.m (2.50 kgf-m, 18.1 ff-16)

(A) Inhibitor switch

15) Disconnect the inhibitor switch harness from in-

hibitor switch. (A) Select cable
(B) Plate ASSY
D: INSTALLATION
1) Connect the inhibitor switch harness to inhibitor 7 ) Install the snap pin to range select lever
switch.
2) Install the inhibitor switch to transmission case.
c.

(A) Snap ring

(B) Select cable
(A) Inhibitor switch (C) Range select lever

3) Move the range select lever to neutral position. 8) Install the front exhaust pipe with center exhaust
4) Using the ST, tighten bolts of inhibitor switch. pipe. (Non-turbo model)
ST 499267300 STOPPER PIN <Ref. to EX(S0HC)-6, INSTALLATION, Front Ex-
haust Pipe.>
Tightening torque:
9) Install the center exhaust pipe. (Turbo model)
3.4 N-m (0.35 kgf-m, 2.5 ff-16)
<Ref. to EX(D0HC TURBO)-9, INSTALLATION,
Center Exhaust Pipe.>
10) Lower the vehicle.
11) Install the inhibitor switch connector from stay.

(A) Inhibitor switch

(B) Range select lever

5) Install the select cable to range select lever.

AT-30
 INHIBITOR SWITCH
1
AUTOMATIC TRANSMISSION

12) Connect the inhibitor switch connector.

(A) Inhibitor switch

13) Install the air cleaner case. (Non-turbo model)

<Ref. to IN(S0HC)-6, INSTALLATION,Air Cleaner
Case.>
14) Install the intercooler. (Turbo model)
<Ref. to IN(D0HC TURBO)-11, INSTALLATION,
Intercooler.>
1 5 ) Inspect the inhibitor switch. <Ref. to AT-28, IN-
SPECTION, Inhibitor Switch.>

AT-31
I FRONT VEHICLE SPEED SENSOR
AUTOMATIC TRANSM ISSlON
13.Front Vehicle Speed Sensor
A: REMOVAL
1) Set up the vehicle on the lift.
2) Disconnect the ground terminal from battery.
3) Remove the air cleaner case. (Non-turbo model)
<Ref. to IN(SOHC)-6, REMOVAL, Air Cleaner
Case.>
4) Remove the intercooler. (Turbo model) <Ref. to
W(DOHC TURBO)-10, REMOVAL, Intercooler.>
5) Disconnect the transmission connector.
(A) Transmission connector
6) Remove the transmission connector from stay.
7) Lift-up the vehicle.
8) Clean the transmission exterior.
AT-32
9) Drain the ATF completely.
NOTE:
Tighten the ATF drain plug after draining the ATF.
Tightening torque:
25 N-m (2.5 kgf-m, 18.1 ft-lb)
(A) Oil pan
(B) Drain plug
(C) Differential oil drain plug
IO) Remove the front, center, rear, exhaust pipes
and muffler.
<Ref. to EX(S0HC)-5, REMOVAL, Front Exhaust
Pipe.>, <Ref. to EX(S0HC)-9, REMOVAL, Rear
Exhaust Pipe.> and <Ref. to EX(S0HC)-11, RE-
MOVAL, Muffler.>
11) Remove the center, rear exhaust pipes and
muffler. (Turbo model) <Ref. to EX(D0HC TUR-
BO)-8, REMOVAL, Center Exhaust Pipe.>, <Ref.
to EX(D0HC TURBO)-13, REMOVAL, Rear Ex-
haust Pipe.>, <Ref. to EX(D0HC TURBO)-14, RE-
MOVAL, Muffler.>
12) Remove the shield cover.
13) Remove the propeller shaft. <Ref. to DS-14,
REMOVAL, Propeller Shaft.>
14) Place the transmission jack under crossmem-
ber.
NOTE:
Place a shop cloth or equivalent between the
crossmember and transmission.
15) Remove the transmission rear crossmember
bolts.
 FRONT VEHICLE SPEED SENSOR I
AUTOMATIC TRANSMISSION

16) Lower the AT jack. 20) Disconnect the duty solenoids and ATF tem-
NOTE: perature sensor connectors. Remove the connec-
Do not separate the AT jack and transmission. tors from clip and disconnect the connectors.
17) Remove the oil cooler outlet pipe.
CAUTION:
When removing the outlet pipe, be careful not
to lose the balls and springs used with retain-
ing screws.
18) Remove the front and rear vehicle speed sen-
sor and torque converter turbine speed sensor.
Front vehicle speed sensor and torque
converter turbine speed sensor

(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)
(F) 2-4 brake timing solenoid (Black)
(G) 2-4 brake duty solenoid (Red)
(H) ATF temperature sensor
(I) Transfer duty solenoid (Brown)
(J) Transmission ground
(A) Front vehicle speed sensor
(B) Torque converter turbine speed sensor 21) Remove the harness assembly.
Rear vehicle speed sensor B: INSTALLATION
1) Pass the harness assembly through the hole in
the transmission case.

(A) Rear vehicle speed sensor

(B) Front vehicle speed sensor

19) Remove the oil pan.

AT-33
I FRONT VEHICLE SPEED SENSOR
AUTOMATIC TRANSMISSION
2) Connect the harness connectors. 6) Install the oil cooler outlet pipe.
Connect the connectors of same color, and secure CAUTION:
the connectors to valve body sing clips. Be sure to use a new aluminum washer.
Tightening torque (Transmission ground termi- Tightening torque:
nal): 25 N-m (2.5 kgf-m, 18.1 ft-lb)
8 N-m (0.8 kgf-m, 5.8 ft-lb) 7) Install the transmission rear crossmember bolts.
Tightening torque:
75 Nom(7.6 kgf-m, 55 ft-lb)
8 ) Install the propeller shaft. <Ref. to DS-15, IN-
STALLATION, PropeIler Shaft.>
9) Install the shield cover. (If equipped)
10) Install the front, center, rear exhaust pipes and
muffler. (Non-turbo model)
<Ref. to EX(S0HC)-6, INSTALLATION, Front Ex-
haust Pipe.> and <Ref. to EX(S0HC)-9, INSTAL-
B2M22631 LATION, Rear Exhaust Pipe.> and <Ref. to
EX(S0HC)-11, INSTALLATION, Muffler.>
(A) Lock-up duty solenoid (Blue) 11) Install the center, rear exhaust pipes and muf-
(B) Low clutch timing solenoid (Gray) fler. (Turbo model) <Ref. to EX(D0HC TURBO)-
Line pressure duty solenoid (Red) 14, INSTALLATION, Muffler.>, <Ref. to EX(D0HC
Shift solenoid 2 (Yellow) TURBO)-13, INSTALLATION, Rear Exhaust
Shift solenoid 1 (Green) Pipe.>, <Ref. to EX(D0HC TURBO)-9, INSTALLA-
2-4 brake timing solenoid (Black) TION, Center Exhaust Pipe.>
2-4 brake duty solenoid (Red) 12) Lower the vehicle.
ATF temperature sensor 13) Install the transmission connector to the stay.
Transfer duty solenoid (Brown) 14) Install the air cleaner case. (Non-turbo model)
Transmission ground
<Ref. to IN(S0HC)-6, INSTALLATION, Air Cleaner
Case.>
3) Apply proper amount of liquid gasket to the en- 15) Install the intercooler. (Turbo model). <Ref. to
tire oil pan mating surface. IN(D0HC TURBO)-11, INSTALLATION, Intercool-
Fluid packing: er.>
Three Bond 12176

I B3M1040

4) Install the oil pan.

Tightening torque:
25 N-m (2.5 kgf-m, 18.1 ff-lb)
5) Install the front and rear vehicle speed sensor,
and also the torque converter turbine speed sen-
sor, and then fasten the harness.
Tightening torque:
7 N-m (0.7 kgf-m, 5. 1 ft-lb)

AT-34
 REAR VEHICLE SPEED SENSOR
AUTOMATIC TRANSMISSION

14.Rear Vehicle Speed Sensor

A: REMOVAL
When removing the rear vehicle speed sensor, re-
fer to “Front Vehicle Speed Sensor.” <Ref. to AT-
32, REMOVAL, Front Vehicle Speed Sensor.>
B: INSTALLATION
When installing the rear vehicle speed sensor, refer
to “Front Vehicle Speed Sensor.” <Ref. to AT-33,
INSTALLATION, Front Vehicle Speed Sensor.>

AT-35
I TORQUE CONVERTER TURBINE SPEED SENSOR
I
AUTOMATIC TRANSMISSION

15.Torque Converter Turbine

Speed Sensor
A: REMOVAL
When removing the torque converter turbine speed
sensor, refer to “Front Vehicle Speed Sensor.’’
<Ref. to AT-32, REMOVAL, Front Vehicle Speed
Sensor.>
B: INSTALLATION
When installing the torque converter turbine speed
sensor, refer to “Front Vehicle Speed Sensor.”
<Ref. to AT-33, INSTALLATION, Front Vehicle
Speed Sensor.>

AT-36
 CONTROL VALVE BODY
I
AUTOMATIC TRANSMISSION

5) Disconnect the duty solenoids and ATF temper-

16.Control Valve Body ature sensor connectors. Remove the connectors
A: REMOVAL from clip and disconnect the connectors.
1) Lift-up the vehicle.
2) Clean the transmission exterior.
3) Drain the ATF completely.
NOTE:
Tighten the ATF drain plug after draining the ATF.
Tightening torque:
25 N.m (2.5 kgf-m, 18.7 ff-16)

B2M2269

(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)
(F) 2-4 brake timing solenoid (Black)
(G) 2-4 brake duty solenoid (Red)
(H) ATF temperature sensor
(A) Oil pan (I) Transfer duty solenoid (Brown)
(B) Drain plug
(C) Differential oil drain plug 6) Remove the control valve. When removing the
control valve body, be careful not to interfere with
4) Remove the oil pan. transfer duty solenoid wiring.
NOTE:
Remove and clean the magnet.
Remove the old gasket on the oil pan and trans-
mission case completely.

I103;

AT-37
I CONTROL VALVE BODY
I
AUTOMATIC TRANSMISSION

B: INSTALLATION 5) Apply proper amount of liquid gasket to the en-

1) Set the range select lever in ‘IN” position. tire oil pan mating surface.
2) Install the control valve and ground earth con- Fluid packing:
nectors. Tree Bond 12178
Tightening torque:
8 N.m (0.8 kgf-m, 5.8 ft-lb)

B3M1040

6) Install the oil pan.

(A) Short bolts
(B) Long bolts
ij Connect all connector.
Lock-up duty solenoid (Blue)
Low clutch timing solenoid (Gray)
Line pressure duty solenoid (Red)
Shift solenoid 2 (Yellow)
Shift solenoid 1 (Green)
2-4 brake timing solenoid (Black)
2-4 brake duty solenoid (Red)
ATF temperature sensor
Transfer duty solenoid (Brown)
Tightening torque:
4.9 N-m (0.5 kgf-m, 3.6 ft-16)
7 ) Pour ATF into the oil charge pipe. <Ref. to AT-9,
Automatic Transmission Fluid.>
8) Check the level of the ATF.
<Ref. to AT-9, Automatic Transmission Fluid.>
C: DISASSEMBLY
Refer to “AUTOMATIC TRANSMISSION” <Pub.
No. G0853ZE> a separate publication.
D: ASSEMBLY
Refer to “AUTOMATIC TRANSMISSION” <Pub.
No. G0853ZE> a separate publication.
E: INSPECTION
Refer to “AUTOMATIC TRANSMISSION” <Pub.
No. G0853ZE> a separate publication.

4) Attach the magnet at the specified position.

AT-38
 SHIFT SOLENOIDS, DUTY SOLENOIDS AND ATF TEMPERATURE SENSOR I
AUTOMATIC TRANSMISSION

17.Shift Solenoids, Duty Sole- 8) Remove the solenoids, duty solenoids and ATF
temperature sensor.
noids and ATF Temperature
Sensor
A: REMOVAL
1) Set the vehicle on the lift.
2) Disconnect the ground terminal from battery.
3) Lift-up the vehicle.
4) Clean the transmission exterior.
5) Drain the ATF completely.
NOTE:
Tighten the ATF drain plug after draining the ATF.
Tightening torque: (A) Lock-up duty solenoid (Blue)
25 Nom(2.5 kgf-m, 18.1 ff-lb) (B) Low clutch timing solenoid (Gray)
(C) Line pressure duty solenoid (Red)
(D) Shift solenoid 2 (Yellow)
(E) Shift solenoid 1 (Green)
(F) 2-4 brake timing solenoid (Black)
c- . (G) 2-4 brake duty solenoid (Red)
(H) ATF temperature sensor

1. TRANSFER DUTY SOLENOID AND

TRANSFER VALVE BODY
1) Set up the vehicle on the lift.
2) Disconnect the ground terminal from battery.
(A) Oil pan 3) Remove the air intake duct. <Ref. to IN(S0HC)-
(B) Drain plug 7, REMOVAL, Air Intake Duct.>
4) Remove the air cleaner case. <Ref. to IN(S0-
6) Remove the oil pan. HC)-6, REMOVAL, Air Cleaner Case.>
7) Disconnect the solenoid and sensor connectors. 5 ) Remove the intercooler. (Turbo model) <Ref. to
Remove the connectors from clip and disconnect IN(D0HC TURBO)-10, REMOVAL, Intercooler.>
the connectors. 6) Remove the pitching stopper.
I

(G) (F) B2M2263J

Lock-up duty solenoid (Blue)
Low clutch timing solenoid (Gray)
Line pressure duty solenoid (Red)
Shift solenoid 2 (Yellow)
Shift solenoid 1 (Green)
2-4 brake timing solenoid (Black)
2-4 brake duty solenoid (Red)
ATF temperature sensor
Transfer duty solenoid (Brown)
7) Remove the front exhaust pipe with center ex-
haust pipe. (Non-turbo model)
With OBD
<Ref. to EX(S0HC)-5, REMOVAL, Front Exhaust
Pipe.>
8) Remove the center exhaust pipe. (Turbo model)
<Ref. to EX(D0HC TURBO)-8, REMOVAL, Center
Exhaust Pipe.>

AT-39
I SHIFT SOLENOIDS, DUTY SOLENOIDS AND ATF TEMPERATURE SENSOR I
AUTOMATIC TRANSMISSION
9) Raise the vehicle and drain the ATF 14) Remove the select cable nut.

G3M0308

(A) Oil pan

15) Move the gear select cable so that extension
bolts can be removed.
(B) Drain plug
16) Remove the bolts.
(C) Defferential oil drain plug
17) Remove the extension case.
10) Remove the heat shield cover. (If equipped) NOTE:
11) Remove the propeller shaft. <Ref. to DS-14, Use a container to catch oil flowing from extension.
REMOVAL, Propeller Shaft.>
12) Remove the rear crossmember.
-_.(1) Support the transmission using a transmis-
sion jack and raise slightly.
(2) Remove the bolts and nuts as shown in the
figure.

18) Disconnect the transfer duty solenoid connec-

tor.
19) Remove the transfer duty solenoid and transfer
valve body.

13) Remove the rear vehicle speed sensor

B3M1045F

(A) Transfer valve body

(B) Transfer duty solenoid connector
(C) Transfer duty solenoid

AT-40
 SHIFT SOLENOIDS, DUTY SOLENOIDS AND ATF TEMPERATURE SENSOR
AUTOMATIC TRANSMISSION

B: INSTALLATION 3) Apply proper amount of liquid gasket to the en-

1) Install the solenoids and ATF temperature sen- tire oil pan mating surface.
sor. Fluid packing:
Tree Bond 12178
Tightening torque:
T: 8 N-m (0.8 kgf-m, 5.8 ft-lb)
I

B3M 1040

4) Install the oil pan.

Tightening torque:
(A) Lock-up duty solenoid (Blue) 4.9 N.m (0.50 kgf-m, 3.6 ft-lb)
(B) Low clutch timing solenoid (Gray)
(C) Line pressure duty solenoid (Red)
c- - (D) Shift solenoid 2 (Yellow)
(E) Shift solenoid 1 (Green)
(F) 2-4 brake timing solenoid (Black)
(G) 2-4 brake duty solenoid (Red)
(H) ATF temperature sensor

2) Connect the harness connectors.

Connect the connectors of same color, and secure
the connectors to valve body using clips.

(A) Oil pan

(B) Drain plug

5 ) Fill ATF up to the middle of the “COLD” side on

level gauge by using the gauge hole. <Ref. to AT-9,
Automatic Transmission Fluid.>
6) Check the ATF level. <Ref. to AT-9, Automatic
Transmission Fluid.>

(G, CF, B2M2263J

Lock-up duty solenoid (Blue)

Low clutch timing solenoid (Gray)
Line pressure duty solenoid (Red)
Shift solenoid 2 (Yellow)
Shift solenoid 1 (Green)
2-4 brake timing solenoid (Black)
2-4 brake duty solenoid (Red)
ATF temperature sensor
Transfer duty solenoid (Brown)

AT-4 1
I SHIFT SOLENOIDS, DUTY SOLENOIDS AND ATF TEMPERATURE SENSOR
e
AUTOMATIC TRANSMISSION

1. TRANSFER DUTY SOLENOID AND 4) Install the rear crossmember.

TRANSFER VALVE BODY (1) Tighten the bolts.
1) Install the transfer duty solenoid and transfer Tightening torque:
valve body. T I : 35 N-m (3.6 kgf-m, 26 ft-lb)
(1) Install the transfer duty solenoid and trans- T2: 70 N.m (7.1 kgf-m, 51.4 ft-lb)
fer valve body.
Tightening torque:
T: 8 N-m (0.8 kgf-m, 5.8 ft-lb)
(2) Connect the transfer duty solenoid connec-
tor.

(2) Lower and remove the transmission jack.

c.
(A) Transfer valve body
(B) Transfer duty solenoid connector
(C) Transfer duty solenoid
5) Install the propeller shaft. <Ref. to DS-15, IN-
STALLATION, Propeller Shaft.>
6) Install the front exhaust pipe and center exhaust
pipe.
7) Lower and remove the jack.
8) Connect the transmission harness connector.

2) Install the extension case to transmission case.

(1) Tighten eleven bolts.
Tightening torque:
25 N-m (2.5 kgf-m, 18.1 ft-lb)
(2) Adjust the select cable. <Ref. to CS-27, AD-
JUSTMENT, Select Cable.>
3) Install the rear vehicle speed sensor.
Tightening torque: 9) Install the pitching stopper.
T: 7 N.m (0.7 kgf-m, 5. t ft-lb)
Tightening torque:
T1: 50 N.m (5.1 kgf-m, 37 ft-lb)
T2: 58 N.m (5.9 kgf-m, 43 ft-lb)

IO) Install the air cleaner case and duct.

AT-42
I SHIFT SOLENOIDS, DUTY SOLENOIDS AND ATF TEMPERATURE SENSOR
I
AUTOMATIC TRANSMISSION

11) Fill ATF up to the middle of the "COLD" side on

level gauge by using the gauge hole. <Ref. to AT-9,
Automatic Transmission Fluid.>
12) Check the ATF level. <Ref. to AT-9, Automatic
Transmission Fluid.>

AT-43
 ATF FILTER
AUTOMATIC TRANSMISSION

18.ATF Filter C: INSPECTION

Replace the part if any defect is found from the in-
A: REMOVAL spection.
NOTE: Check for rust, hole, ATF leaks, and other damage.
The ATF filter is maintenance free.
1) Lift-up the vehicle.
2) Using the ST, remove the ATF filter.
ST 498545400 OIL FILTER WRENCH

Torque wrench length Tightening torque

mm (in) N.m (kgf-m, ft-lb)
100 (3.94) 6 (0.6, 4.3)
150 (5.91) 5 (0.5, 3.6)
200 (7.87) 4 (0.4, 2.9)
250 (9.841 3 (0.3. 2.2)

CAUTION:
Align the ST with torque wrench while tighten-
ing the ATF filter.
ST 498545400 OIL FILTER WRENCH
3) Add ATF.
4) Inspect the level of ATF. <Ref. to AT-9, Automat-
ic Transmission Fluid.>

AT-44
 TRANSMISSION CONTROL MODULE (TCM)
I
AUTOMATIC TRANSMISSION

19.Transmission Control Mod- B: INSTALLATION

1) Install the transmission control module.
ule (TCM)
Tightening torque:
A: REMOVAL 7.5 N-m (0.76 kgf-m, 5.5 ft-lb)
1) Disconnect the ground terminal from battery.

(A) Transmission control module

2) Remove the lower cover and then disconnect the
connector. (B) Brake pedal bracket

2) Connect the connectors to transmission control

c- . module.
3) Install in the reverse order of removal.

3) Disconnect the connectors from transmission

control module.

(A) Transmission control module

(B) Brake pedal bracket

4) Remove the transmission control module.

AT-45
 DROPPING RESISTOR
AUTOMATIC TRANSMISSION

20.Dropping Resistor B: INSTALLATION

1) Install in the reverse order of removal.
A: REMOVAL
Tightening torque:
NOTE: 6.4 N.m (0.65 kgf-m, 4.7 fWb)
The dropping resister is only equipped to Non-turbo
models.
1) Disconnect the ground terminal from battery.

(A

03M2170A

(A) Dropping resistor

2) Remove the air intake duct. <Ref. to IN(S0HC)-

6, REMOVAL, Air Cleaner Case.>
3)Disconnect the connector from dropping resistor.
4) Remove the dropping resistor.

J/

\
i::
I '

(A) Dropping resistor

C: INSPECTION
~~
B3M2170A

Step Check Yes No

1 CHECK RESISTOR. Is the resistance between 9 Go to step 2. Replace the drop-
1)Turn the ignition switch to OFF. and 15 a? ping resistor. <Ref.
2)Disconnect the connector from dropping to AT-46, Dropping
resistor.
3)Measure the resistance between dropping
resistor terminal.
Terminals
NO. 1 - NO. 2:
2 CHECK RESISTOR. Is the resistance between 9 Dropping resistor Replace the drop-
Measure the resistance between dropping and 15 a? is normal. ping resistor.
resistor terminal. <Ref. to AT-46,
Terminals Dropping Resis-
NO. 3 - NO. 4: tor.>

AT-46
 ATF COOLER PIPE AND HOSE I
AUTOMATIC TRANSMISSION

21 .ATF Cooler Pipe and Hose 6) Remove the ATF cooler pipe from cylinder head.

A: REMOVAL
1. NON-TURBO MODEL
1) Set the vehicle on the lift.
2) Lift-up the vehicle.
3) Remove the under cover.
4) Disconnect the ATF cooler hose from radiator.
NOTE:
Do not remove with a screwdriver or other point-
ed tools.
When the hose is difficult to remove, wrap a shop 7) Remove the oil cooler inlet and outlet pipes.
cloth around the hose to protect it. Turn it with pli- CAUTION:
ers, and then pull directly out with your hand. When removing the outlet pipe, be careful not
to lose the ball and spring used with retaining
screw.

c-

S2M0895

5) Disconnect the ATF cooler hoses from pipes.

NOTE:
Do not remove with a screwdriver or other point- (A) Inlet pipe
ed tools. (B) Outlet pipe
When the hose is difficult to remove, wrap a shop
cloth around the hose to protect it. Turn it with pli-
ers, and then pull directly out with your hand.

AT-47
I ATF COOLER PIPE AND HOSE
I
AUTOMATIC TRANSMISSION

2. TURBO MODEL 8) Remove the ATF cooler pipe from frame.

1) Set the vehicle on the lift.
2) Remove the battery and washer tank.
3) Lift-up the vehicle.
4) Remove the under cover.
5) Remove the radiator under cover.

EN1063

sconnect the ATF cooler hose from radiator

NOTE:
:- Do not remove with a screwdriver or other point-
ed tools. I'
When the hose is difficult to remove, wrap a shop TR0331
cloth around the hose to protect it. Turn it with pli-
9) Remove the oil cooler inlet and outlet pipes.
ers, and then pull directly out with your hand.
CAUTION:
When removing the outlet pipe, be careful not
to lose the ball and spring used with retaining
screw.

-I TR0329

7) Disconnect the ATF cooler hoses from pipes.

NOTE:
Do not remove with a screwdriver or other point-
ed tools.
When the hose is difficult to remove, wrap a shop (A) Inlet pipe
cloth around the hose to protect it. Turn it with pli- (B) Outlet pipe
ers, and then pull directly out with your hand.

AT-48
 ATF COOLER PIPE AND HOSE
I
AUTOMATIC TRANSMISSION

B: INSTALLATION 3) Connect the ATF cooler hose to pipe transmis-

sion side.
1. NON-TURBO MODEL NOTE:
1) Install the oil cooler outlet and inlet pipes. Install so that the hose is not folded over, exces-
CAUTION: sively bent, or twisted.
Be sure to use a new aluminum washer. Be careful to insert the hose to the specified po-
sition.
Tightening torque:
T1: 44 N-m (4.5 kgf-m, 32.5 ff-lb)
T2: 25 N-m (2.5 kgf-m, 18.1 ff-lb)

4) Connect the ATF cooler hose to pipe of radiator

side.
NOTE:
(A) Inlet pipe Install so that the hose is not folded over, exces-
(B) Outlet pipe sively bent, or twisted.
Be careful to insert the hose to the specified po-
2) Install the ATF cooler pipe to cylinder head. sition.
Tightening torque:
7.35 N-m (0.75 kgf-m, 5.42 ft-lb)

S2M0895

5) istall the under cover.

6) Fill ATF. <Ref. to AT-9, Automatic Transmission
Fluid.>
NOTE:
Make sure there are no ATF leaks in joints between
the transmission, radiator, pipes, and hoses.

AT-49
I ATF COOLER PIPE AND HOSE
I
AUTOMATIC TRANSMISSION

2. TURBO MODEL 3) Connect the ATF cooler hose to pipe transmis-

sion side.
1) Install the oil cooler outlet and inlet pipes.
NOTE:
CAUTION: Install so that the hose is not folded over, exces-
Be sure to use a new aluminum washer. sively bent, or twisted.
Tightening torque: Be careful to insert the hose to the specified po-
T l : 44 N.m (4.5 kgf-m, 32.5 ft-lb) sition.
T2: 25 N-m (2.5 kgf-m, 18.1 ft-lb)

4) Connect the ATF cooler hose to pipe of radiator

-- . (A) Inlet pipe
side.
NOTE:
(B) Outlet pipe
Install so that the hose is not folded over, exces-
2) Install the ATF cooler pipe to frame. sively bent, or twisted.
Be careful to insert the hose to the specified po-
sition.

L
TR0329

5) Install the radiator under cover.

Tightening torque:
4.9 N.m (0.5 kgf-m, 3.6 ft-lb)

TR0331

EN106:

6) Install the under cover.

7) Install the battery and washer tank.

AT-50
 ATF COOLER PIPE AND HOSE
I
AUTOMATIC TRANSMISSION

8) Fill ATF. <Ref. to AT-9, Automatic Transmission C: INSPECTION

Fluid.> Repair or replace any defective hoses, pipes,
NOTE: clamps, and washers found from the inspection be-
Make sure there are no ATF leaks in joints between low.
the transmission, radiator, pipes, and hoses. 1) Check for ATF leaks in joints between the trans-
mission, radiator, pipes, and hoses.
2) Check for deformed clamps.
3) Lightly bend the hose and check for cracks in the
surface and other damage.
4) Pinch the hose with your fingers and check for
poor elasticity. Also check for poor elasticity in the
parts where the clamp was installed by pressing
with your fingernail.
5 ) Check for peeling, cracks, and deformation at
the tip of the hose.

c- .

AT-51
 ATF COOLER PIPE AND HOSE
I
AUTOMATIC TRANSMISSION

AT-52
AUTOMATIC TRANSMISSION
(DIAGNOSTICS)

Page
1. Basic Diagnostic Procedure ........................................................................ 2
2. Check List for Interview ............................................................................... 4
3. General Description .................................................................................... 5
4. Electrical Components Location.................................................................. 7
5. Transmission Control Module (TCM) I/O Signal ....................................... 11
6. Subaru Select Monitor............................................................................... 22
7. Read Diagnostic Trouble Code (DTC) ...................................................... 24
8. Inspection Mode ........................................................................................ 26
9. Clear Memory Mode.................................................................................. 27
c- . 10. AT OIL TEMP Warning Light Display ........................................................ 28
11. List of Diagnostic Trouble Code (DTC) ..................................................... 29
12. Diagnostic Procedure for AT OIL TEMP Warning Light ............................ 31
13. Diagnostic Procedure for Select Monitor Communication......................... 39
14. Diagnostic Procedure with Diagnostic Trouble Code (DTC) ..................... 44
15. Diagnostic Procedure for No-Diagnostic Trouble Code (DTC) ...............108
16. Symptom Related Diagnostic .................................................................. 127
I BASIC DIAGNOSTIC PROCEDURE
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

1. Basic Diagnostic Procedure

A: PROCEDURE
Step Check Yes No
CHECK PRE-INSPECTION. j the unit that might influence ;o to step 2. 3epair or replace
1)Ask the customer when and how the trouble l e AT problem normal? ?achitem.
occurred using the interview checklist. <Ref. to
AT-4, Check List for Interview.>
2)Before performing diagnosis, inspect the fol-
lowing items which might influence the AT
problems.
*General inspection <Ref. to AT-5, INSPEC-
TION, General Description.>
*Oil leak
*Stall speed test <Ref. to AT-I 3, Stall Test.>
*Line pressure test <Ref. to AT-16, Line Pres-
sure Test.>
*Transfer clutch pressure test <Ref. to AT-I 8,
Transfer Clutch Pressure Test.>
*Time lag test <Ref. to AT-15, Time Lag Test.>
*Road test <Ref. to AT-12, Road Test.>
*Inhibitor switch <Ref. to AT-28, Inhibitor
Switch.>
CHECK AT OIL TEMP WARNING LIGHT. )oes not the AT OIL TEMP $0 to step 3. 30 to step 4.
Turn the ignition switch to ON. iarning light light up?
CHECK AT OIL TEMP WARNING LIGHT. j the AT OIL TEMP warning $0 to step 4. 30 to step 5.
1)Turn the ignition switch to OFF. ght flashing?
2)Repair the AT OIL TEMP warning light circuit
or power supply and ground line circuit.
<Ref. to AT-31, Diagnostic Procedure for AT
OIL TEMP Warning Light.>
3)Turn the ignition switch to ON.
CHECK INDICATION OF DTC. j the diagnostic trouble code 20 to step 6. 30 to step 5.
Calling up the diagnostic trouble code (DTC). DTC) displayed? JOTE:
Without SUBARU SELECT MONITOR 3ecord all diag
<Ref. to AT-24, WITHOUT SUBARU SELECT iostic trouble code
MONITOR, Read Diagnostic Trouble Code DTC).
(DTC).>
With SUBARU SELECT MONITOR
<Ref. to AT-25, WITH SUBARU SELECT
MONITOR, Read Diagnostic Trouble Code
(DTC).>
NOTE:
If the communication function of the selec
monitor cannot be executed normally, check
the communication circuit. <Ref. to AT-39
COMMUNICATION FOR INITIALIZING IM.
POSSIBLE, Diagnostic Procedure for Selec
Monitor Communication.>

AT-2
 BASIC DIAGNOSTIC PROCEDURE
I
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

Step Check Yes No

5 PERFORM THE GENERAL DIAGNOSTICS. Is the diagnostic trouble code io to step 6. iomplete the
1NnsDect usina the “Diaqnostic Procedure for (DTC) displayed? iagnosis.
No-Diagnostictrouble Code”.<Ref. to AT-108,
Diagnostic Procedure for No-Diagnostic Trou-
ble Code (DTC).>
2)lnspect using the “Symptom Related Diag-
nostic’’. <Ref. to AT-127, Symptom Related
Diagnostic.>
3)Perform the clear memory mode.
With SUBARU SELECT MONITOR
<Ref. to AT-27, WITH SUBARU SELECT
MONITOR, Clear Memory Mode.>
Without SUBARU SELECT MONITOR
<Ref. to AT-27, WITHOUT SUBARU SELECT
MONITOR, Clear Memory Mode.>
4)Perform the inspection mode. <Ref. to AT-26,
Inspection Mode.>
Calling up the diagnostic trouble code (DTC).
Without SUBARU SELECT MONITOR
<Ref. to AT-24, WITHOUT SUBARU SELECT
MONITOR, Read Diagnostic Trouble Code
(DTC).>
With SUBARU SELECT MONITOR
<Ref. to AT-25, WITH SUBARU SELECT
MONITOR, OPERATION, Read Diagnostic
Trouble Code (DTC).>
6 PERFORM THE DIAGNOSIS. 5 the diagnostic trouble code nspect using the :omplete the
1)lnspect using the “Diagnostics Chart with DTC) displayed? Diagnostics Chart hagnosis.
Diahnostic Trouble Code”.<Ref. to AT-44, Diag- vith Diagnostic
nostic Procedure with Diagnostic Trouble Code 2onnector”. <Ref.
(DTC).> o AT-44, Diagnos-
NOTE: ic Procedure with
For trouble code table, refer to the “List of Diag. liagnostic Trou-
nostic Trouble Code”.<Ref. to AT-29, List of Di. ,le Code (DTC).>
agnostic Trouble Code (DTC).>
2)Repair the trouble cause.
3)Perform the clear memory mode.
With SUBARU SELECT MONITOR
<Ref. to AT-27, WITH SUBARU SELECT
MONITOR, OPERATION, Clear Memory
Mode.>
Without SUBARU SELECT MONITOR
<Ref. to AT-27, WITHOUT SUBARU SELECT
MONITOR, Clear Memory Mode.>
4)Perform the inspection mode. <Ref. to AT-26,
Inspection Mode.>
5)Calling up the diagnostic trouble code (DTC)
Without SUBARU SELECT MONITOR
<Ref. to AT-24, WITHOUT SUBARU SELECT
MONITOR, OPERATION, Read Diagnostic
Trouble Code (DTC).>
With SUBARU SELECT MONITOR
<Ref. to AT-25, WITH SUBARU SELECT
MONITOR, OPERATION, Read Diagnostic
Trouble Code ( D T C b

AT-3
 CHECK LIST FOR INTERVIEW
I
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

2. Check List for Interview NOTE:

Use copies of this page for interviewing customers.
A: CHECK
Check the following items when problem has oc-
curred.
Customer's name I
Data vehicle brought in
Data of repair
Trans. model TRANSMISSION I VIN
Odometer reading km/h or mile
Freauencv D Continuous U Intermittent ( times a day)
~~

Weather CI Fine CI Cloudy U Rainy U Snowy

CI Various/Others
( 1
Place U High 0 Suburbs U Inner city CI Uphill U Rough road
U Others
( 1
Outdoor temperature 0 Hot U Warm c3 Cool U Cold
Vehicle speed km/h (MPH:
Malfunction indicator lamp (MIL) U Continuously lit ] U Not lit
Select lever Dosition CIP UR UN UD C13 U 2 U1
Driving condition U Not affected U At starting CI While idling
U At racing U While accelerating U While cruising
0 While decelerating U While turning (URH/CI
I LH)
SvmDtoms
, * I U No up-shift
I Q No down-shift
CI No kick down
CI Vehicle does not move (UAny position U Particular position)
CI Lock-uD malfunction
I U Noise or vibration
I 0 Shift shock or sliD
I U Select lever does not move

AT-4
 GENERAL DESCRIPTION
I
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

3. General Description 3. ATFLEVEL

Make sure the ATF level is in the specification.
A: CAUTION
Supplemental Restraint System “Airbag”
The airbag system wiring harness is routed near
the transmission control module (TCM).
CAUTION:
All airbag system wiring harness and con-
nectors are colored yellow. Do not use electri-
cal test equipment on these circuit.
Be careful not to damage the airbag system
wiring harness when performing diagnostics
and servicing the TCM. B3M0173B

Measurement
When measuring the voltage and resistance of the (A) Upper level
ECM, TCM or each sensor, use a tapered pin with (B) Lower level
a diameter of less than 0.64 mm (0.025 in) in order
to avoid poor contact. Do not insert the pin more 4. FRONT DIFFERENTIAL OIL LEVEL
than 6.5 mm (0.256 in). Make sure the front differential oil level is in the
a:INSPECTION specification.

1. BATTERY
Measure the battery voltage and specific gravity of
electrolyte.
Standard voltage: 12V or more
Specific gravity: Above 1.260
2. TRANSMISSION GROUND
Make sure that the ground terminal bolt is tightened B3M01748
securely.
Chassis side (A) Upper level
Tightening torque: (B) Lower level
13 N.m (1.3 kgf-m, 9.4 ff-lb)
5. OPERATION OF SHIFT SELECT LEVER
Make sure there is no abnormal noise, dragging or
contact pattern in each select lever range.
WARNING:
Stop the engine while checking operation of the
selector lever.

TR0373

AT-5
 GENERAL DESCRIPTION
I
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

C: PREPARATION TOOL
1. SPECIAL TOOLS

I
ILLUSTRATION TOOLNUMBER I
I
DESCRIPTION REMARKS
Troubleshooting for electrical systems.
(Newly adopted tool)

02M3876
22771AA030 SELECT MONITOR Troubleshootingfor electrical systems.
KIT * English:
22771AA030 (Without printer)
German:
22771AA070 (Without printer)
French:
22771AA080 (Without printer)
Spanish:
22771AA090 (Without printer)

B2M3877

2. GENERAL PURPOSE TOOLS

TOOL NAME REMARKS

Circuit Tester Used for measuring resistance, voltage and ampere.
Oscilloscope Used for measuring sensor.

AT-6
 ELECTRICAL COMPONENTS LOCATION
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

4. Electrical Components Loca-

tion
A: LOCATION
1. CONTROL MODULE

(1) Engine control module (ECM) (3) Transmission control module (TCM)
(2) ATF temperature warning light (AT diagnostic indicator (4) Data link connector
light)

B3M1575A

TR0563 TR0382

AT-7
 ELECTRICAL COMPONENTS LOCATION
I
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

2. SENSOR

TR0565

(1) Throttle position sensor (4) Rear vehicle speed sensor (6) ATF temperature sensor
(2) Front vehicle speed sensor (5) Torque converter turbine speed (7) Dropping resistor (Non-turbo
(3) Inhibitor switch sensor model)

AT-8
 ELECTRICAL COMPONENTS LOCATION
I
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

don-turbo model

--/
S2M0262B TR0387
Turbo model

_J

TR0592
\\ol (3) ' TR0388

(6)

I , ,

TR0390 TR0389

TR0593

AT-9
 ELECTRICAL COMPONENTS LOCATION
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

3. SOLENOID

B3M 1 186A

(1) Solenoid 1 (4) Low clutch timing solenoid (7) 2-4 brake timing solenoid
(2) Solenoid 2 (5) Lock-up duty solenoid (8) Transfer duty solenoid
(3) Line pressure duty solenoid (6) 2-4 brake duty solenoid

.-,
B2M2264E

AT-10
 TRANSMISSION CONTROL MODULE (TCM) I/O SIGNAL
I
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

5. Transmission Control Mod-

ule (TCM) I/O Signal
A: ELECTRICAL SPECIFICATION
1. NON-TURBO MODEL

to @ to @

Check with ignition switch ON.

Con- Resistanceto
Termi-
Content nector Measuring conditions Voltage (V)
nal No. body (ohms)
No.
Back-up power supply B55 6 lanition switch OFF I 10-13 I -
Ignition power supply
854
B54
23
24
Ignition switch ON (with
-
enaine OFF)
Select lever in “ P range
10 - 13

Less than 1
l -
“ P range -
B55 23 Select lever in any other than
switch More than 8
“ P ranae (except “N” ranae)
Select lever in “N” range I Less than 1 I
“ N range
switch
B55 22 Select lever in any other than
“N” ranae lexceDt “ P ranae)
- “ % I “ I
1
,
Morethan8 1
I
-

“R” range
Select lever in ‘W ranae - I Less than 1
-
655 17 Select lever in any other than
switch More than 8
“R” range
Select lever in “D” range I Less than 1 I
Inhibitor
switch
“ D range
switch
B55 8 Select lever in any other than
“D ranae I
I
I
More than8 1
I
-

Select lever in “ 3 ranae I

I
Less than 1
“ 3 range 1

-
B55 18 Select lever in any other than
switch More than 8
“3”ranae
Select lever in “2” range I Less than 1
“ 2 range
switch
854 10 Select lever in any other than
“ 2 ranae
I More than8 I -

“ I ” range
Select lever in “1”ranae I Less than 1 I
654 1 Select lever in any other than -
switch More than 8
“1” range

AT-1 1
 TRANSMISSION CONTROL MODULE (TCM) I/O SIGNAL
I
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

Check with ignition switch ON.

Termi- Resistanceto
Content nector Measuring conditions Voltage (V)
nal No. body (ohms)
No.
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
Light ON Less than 1 -
AT OIL TEMP light B54 3

+
Light OFF More than 9
I Throttle fully closed.
Throttle position sensor B55 2 Approx. 0.5 -
Throttle fullv open. Approx. 4.3
Throttle position sensor power Ignition switch ON (With -
4.8 - 5.3
SUDDlV engine OFF)
ATF temperature 20°C
1.6 - 2.0 2.1 - 2.9 k
(68°F)
ATF temperature sensor B55 11
ATF temperature 80°C
0.4 - 0.9 275 - 375
(176°F)
Vehicle stopped. I 0 I
Rear vehicle speed sensor Vehicle speed at least 20 More than (AC range) 450 - 650
km/h (12 MPH)
..
Vehicle stowed 0
Front vehicle speed sensor Vehicle speed at least 20 450 - 650
More than (Ac
km/h (12 MPH)
Engine idling after warm-up I n
u I
Torque converter turbine (D range)
B55 12 450 - 650
speed sensor Engine idling after warm-up
More than (AC
(N range)
Vehicle speed at most 10 Less than I t -
Vehicle speed output signal 855 13
km/h (6 MPH) +More than 5
Ignition switch ON (with
0
engine OFF) -
Engine speed signal B55 4
Ignition switch ON (with
0 - 13 or more
engine ON)
When cruise control is set
Less than 1
(SET liaht ON)
Cruise set signal 854 11 ~~

When cruise control is not

More than 6.5
set (SET light OFF)
Ignition switch ON (with
Torque control signal 1 More than 4.8 -
enaine
" ON)
Ignition switch ON (with -
Torque control signal 2 More than 4.8
enaine ON)
I
~

Toraue control cut simal 854 2 Ignition switch ON I a I -

Intake manifold pressure sig-
Engine idling after warm-up. I .2 - 1.a
nal
1st gear More than 9
Shift solenoid 1 10-16
3rd aear Less than 1
2nd gear More than 9
Shift solenoid 2
4th gear Less than 1

4
Throttle fully closed (with
1.5 - 5.0
Line pressure duty solenoid B54 2.0 - 4.5
Less than 1
engine OFF) after warm-up.

AT-I 2
 TRANSMISSION CONTROL MODULE (TCM) 1/0 SIGNAL I
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

I I
'On-
Termi- Resistanceto
Content Measuring conditions Voltage (V) body (ohms)
nal NO.
No.
Throttle fully closed (with
More than 8.5
engine OFF) after warm-up.
Dropping resistor 854 18
Throttle fully open (with
enaine
a -~OFF) after warm-uD.
I
1 Less than 0.5
I
9- 15

When lock up occurs. More than 8.5

Lock-up duty solenoid B54 16 10- 17
When lock up is released. Less than 0.5
Fuse on FWD switch More than 8.5
~

Fuse removed from FWD

Transfer duty solenoid 854 15 switch (with throttle fully 10- 17
Less than 0.5
open and with select lever in
1st gear).
Throttle fully closed (with
1.5 - 5.0
engine OFF) after warm-up.
2-4 brake duty solenoid B54 8 2.0 - 4.5
Throttle fully open (with
Less than 1
enaine OFF) after warm-uD.
d

Throttle fully closed (with

More than 8.5
engine OFF) after warm-up.
--2-4 brake dropping resistor B54 17 9-16 "
Throttle fully open (with
Less than 0.5
engine OFF) after warm-up.
1st gear Less than 1
2-4 brake timing solenoid B54 5 10- 16
3rd gear More than 9
2nd gear Less than 1
Low clutch timing solenoid B54 14 10- 16
4th gear More than 9
Sensor ground line 1 855 10 - 0 Less than 1
Sensor ground line 2 855 21 - 0 Less than 1
9 -
System ground line 0 Less than 1
B55 19
Fuse removed. More than 9 -
FWD switch B55 14
Fuse installed. Less than 1
Fuse ONFWD switch Less than 1

I FWD indicator light

I B54 I l2
Fuse removed from FWD
switch
More than 9

Less than I t
-

-
AT diagnosis signal B54 4 Ignition switch ON
-+More than 4
Data link signal (Subaru Select
B55 7
Monitor) 16

AT-I 3
 TRANSMISSION CONTROL MODULE (TCM) I/O SIGNAL
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

2. TURBO MODEL

to @
n n n

I TR0532

Check with ianition switch ON.

Con- Resistance
Content nector Terminal No. Measuring conditions Voltage (V) to body
No. (ohms)
Back-up power supply 856 1 Ignition switch OFF IO- 13 -
B54 23 Ignition switch ON (with IO- 13 -
Ignition power supply
B54 24 engine OFF)
1
I I I I

I Select lever in “ P range I Less than 1

“ P range Select lever in any other
1
switch than “P” range (except “N” More than 8
range)
Select lever in “N” range Less than 1
“N” range Select lever in any other
14
switch than “N” range (except “P” More than 8
range)

“R” range
I Select lever in “R” ranae
“ I Less than 1 t
3 Select lever in any other
switch More than 8
than “R” ranae

I
Inhibitor I I
switch “D” range
I Select lever in “D” range
- Less than 1 I
B55 4 Select lever in any other -
switch More than 8
I I
than “D” ranae“ I I
I
“ 3 range
switch
B55 I 5
I Select lever in “ 3ranae
“
Select lever in any other
than “ 3 range
I Less than 1

More than 8
-

“ 2 range
I I Select lever in “2” range
- I Less than 1 I
switch
B55 I
I
6

I
I
Select lever in any other
than “2” ranae”
Select lever in “1” range
I

I
More than 8

Less than 1
I
-

“1” range
switch
7
1 Select lever in any other
than “1” range
1 More than 8
-

Brake switch B55 I 12

Brake pedal depressed.
Brake Dedal released.
I
I
More than 10.5
Less than 1
-
Light ON Less than 1 -
AT OIL TEMP warning light 856 10
Liaht OFF More than 9

AT-I 4
 TRANSMISSION CONTROL MODULE (TCM) I/O SIGNAL I
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

I Check with ianition switch ON.

Con- Resistance
Content nector Terminal No. Measuring conditions Voltage (V) to body
No. (ohms)
Throttle fully closed. Approx. 0.5 -
Throttle position sensor 654 3
Throttle fullv- open.
. Auprox.
.. 4.3
Throttle position sensor
654 2 Ignition switch ON (With Approx. 5.0 -
engine OFF)
ATF temperature 20°C
1.6 - 2.0 2.1 k - 2.9 k
(68°F)
ATF temperature sensor 654 11
ATF temperature 80°C
0.4 - 0.9 275 - 375
(176°F)
I Vehicle stopped.
. . I 0 I
Rear vehicle speed sensor 655 24 Vehicle speed at least 20 More than (Ac range) 450 - 650
km/h (12 MPH)
Vehicle stotmed.
,. 0
Front vehicle speed sensor 655 18 Vehicle speed at least 20 More than (AC range) 450 - 650
km/h (12 MPH)
I Engine idling after warm- I n
V
I
Torque converter turbine - up. (D-range)
655 8 450 - 650
speedsensor Engine idling after warm-
More than 1 (AC range)
UP. (N ranae)
~

Vehicle speed at most 10 Less than I t -

Vehicle speed output signal 656 17
km/h (6 MPH) +More than 5
Ignition switch ON (with
0
engine OFF) -
Engine speed signal 655 17
Ignition switch ON (with
0- 13 or more
engine ON)
When cruise control is set
Less than 1
(SET lamp ON) -
Cruise set signal 655 22
When cruise control is not
More than 6.5
set (SET lamp OFF)

I Torque control signal 1 656

~~

5
Ignition switch ON (with
engine ON)
More than 4 -

Torque control signal 2 656 14 Ignition switch ON (with More than 4 -

enaine ON)
655 10 lanition switch ON 8 -

654 1
I Engine idling after warm-
UD.
--r
0.5 - 1.2
l -
I Shift solenoid 1 654 22 -
1st or 4th gear
2nd or 3rd gear
1st or 2nd gear
More than 9
Less than 1
More than 9
10-16

Shift solenoid 2 654 5 ' 10-16

-
3rd or 4th gear Less than 1
Ignition switch ON (with
engine OFF)
1.5 - 5.0
Throttle fully closed after
warm-up.
Line pressure duty solenoid 654 9 2.0 - 4.5
Ignition switch ON (with
engine OFF) Less than 1
Throttle fully open after
warm-up.
When lock up occurs. More than 8.5
Lock-up duty solenoid 654 7 10-17
When lock up is released. Less than 0.5
- More than 8.5
Transfer duty solenoid 654 6 Throttle fully open and with 10 - 17
Less than 0.5
select lever in 1st gear.

AT-15
 TRANSMISSION CONTROL MODULE (TCM) I/O SIGNAL I
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

Check wi I ignition switch ON.

Con- Resistance
Content nector Terminal No. Measuring conditions Voltage (V) to body
No. (ohms)
Throttle fully closed (with
engine OFF) after warm- 1.5 - 5.0
2-4 brake duty solenoid B54 18 UP.
2.0 - 4.5
Throttle fully open (with
engine OFF) after warm- Less than 1
UP.
1st gear Less than 1
2-4 brake timing solenoid 854 16 10-16
3rd gear More than 9
2nd gear Less than 1
-ow clutch timing solenoid 854 15 10-16
4th gear More than 9
ABS switch ON Less than 1
4BS signal 855 21
ABS switch OFF More than 6.5
Sensor around line 1 854 20 Less than 1
Sensor ground line 2 B55 9 - 0 Less than 1
B56 19 I
-
System ground line
B54 21
-
I
I
0 Less than 1

:.ensor ground line 3 854 10 0 Less than 1

Sensor ground line 4 B54 19 - I 0 Less than 1
Less than 1 t
AT diagnosis signal B56 21 Ignition switch ON
+ More than 4
lata link signal (Subaru 15
856
Select Monitor) 6

AT-I 6
TRANSMISSION CONTROL MODULE (TCM) I/O SIGNAL
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

AT-1 7
 TRANSMISSION CONTROL MODULE (TCM) I10 SIGNAL I
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

B: SCHEMATIC
1. NON-TURBO MODEL

I
TR0566

AT-I 8
 TRANSMISSION CONTROL MODULE (TCM) I/O SIGNAL
Transmission control module
Data link connector
Cruise set switch
ABS control module
Ignition switch
Brake switch
Brake light
Battery
Combination meter
AT OIL TEMP warning light
FWD indicator light
FWD switch
“ P range indicator light
“R” range indicator light
“N” range indicator light
“ D range indicator light
“ 3 range indicator light
E
AUTOMATIC TRANSMISSION (DIAGNOSTICS)
“ 2 range indicator light ATF temperature sensor
”1” range indicator light Torque converter turbine speed
“ P range switch sensor
“R” range switch Front vehicle speed sensor
“N” range switch Rear vehicle speed sensor
“ D range switch Shift solenoid 1
“ 3 range switch Shift solenoid 2
“ 2 range switch 2-4 brake timing solenoid
“1” range switch Line pressure duty solenoid
Throttle position sensor Line pressure dropping resistor
Engine speed signal 2-4 brake duty solenoid
Torque control cut signal 2-4 brake dropping resistor
Torque control signal 2 Lock-up duty solenoid
Torque control signal 1 Low clutch timing solenoid
AT load signal Transfer duty solenoid
AT diagnostics signal
Engine control module
AT-19
I TRANSMISSION CONTROL MODULE (TCM) I10 SIGNAL I
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

2. TURBO MODEL

r-
r"" 1 -
(4)

c- "

m
(9)

TR0567

AT-20
 TRANSMISSION CONTROL MODULE (TCM) I/O SIGNAL
Transmission control module
Cruise control module
ABS control module
Ignition switch
Brake switch
Brake light
Battery
Combination meter (Speedome-
ter circuit)
AT OIL TEMP light
“ P range indicator light
“P” range switch
“R” range indicator light
“R” range switch
“N” range indicator light
“N” range switch
I
AUTOMATIC TRANSMISSION (DIAGNOSTICS)
(16) “ D range indicator light Engine control module
(17) “ D range switch ATF temperature sensor
(18) “ 3 range indicator light Torque converter turbine speed
(19) “ 3 range switch sensor
(20) “2” range indicator light Rear vehicle speed sensor
(21) “ 2 range switch Front vehicle speed sensor
(22) “1” range indicator light Shift solenoid 1
(23) “1” range switch Shift solenoid 2
(24) Data link connector 2-4 brake timing solenoid
(25) Throttle position sensor Line pressure duty solenoid
(26) Engine speed signal 2-4 brake duty solenoid
(27) Torque control cut signal Lock-up duty solenoid
(28) Torque control signal 2 Low clutch timing solenoid
(29) Torque control signal 1 Transfer duty solenoid
(30) Mass air flow signal
(31) AT diagnostics signal
AT-21
I SUBARU SELECT MONITOR
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

6. Subaru Select Monitor (2) Connect the diagnosis cable to data link
connector.
A: OPERATION CAUTION:
1. READ DIAGNOSTIC TROUBLE CODE Do not connect scan tools except for Subaru
Select Monitor and OBD-ll general scan tool.
(DTC)
5) Turn the ignition switch to ON (engine OFF) and
1) Prepare the Subaru Select Monitor kit. Subaru Select Monitor switch to ON.
.

I S2M0285

2) Connect the diagnosis cable to Subaru Select

Monitor.
3 Insert the cartridge into Subaru Select Monitor.
<Ref. to AT-6, PREPARATION TOOL, General De-
scription.>
(A) Power switch
’’ S2M0288C

6) On the ((Main Menu,) display screen, select the

{Each System Check} and press the [YES] key.
7) On the ((System Selection Menu,, display
screen, select the {Transmission Control System}
and press the [YES] key.
8) Press the [YES] key after displayed the informa-
tion of transmission type.
9) On the ((Transmission Diagnosis)) display
screen, select the {Diagnostic Code@) Display}
and press the [YES] key.
10) On the ((Diagnostic Code(s) Display)) display
screen, select the {Latest Diagnostic Code(s)} or
{Memorized Diagnostic Code(s)} and press the
1 S2M028E
[YES] key.
4) Connect the Subaru Select Monitor to dati link NOTE:
connector. For detailed operation procedure, refer to the
(1) Data link connector located in the lower por- SUBARU SELECT MONITOR OPERATION MAN-
tion of the instrument panel (on the driver’s UAL.
side). For detailed concerning diagnostic trouble
codes, refer to the DIAGNOSTIC TROUBLE CODE
LIST (DTC). <Ref. to AT-29, List of Diagnostic
Trouble Code (DTC).>
2. READ CURRENT DATA
1) On the ((Main Menu,) display screen, select the
{Each System Check} and press the [YES] key.
2) On the ((System Selection Menu)) display
screen, select the {Transmission Control System}
and press the [YES] key.
3) Press the [YES] key after displayed the informa-
tion of transmission type.
(A) Data link connector
4) On the ((Transmission Diagnosis,, display
screen, select the {Current Data Display & Save}
and press the [YES] key.

AT-22
 SUBARU SELECT MONITOR
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

Contents Display Unit of measure

Batterv voltaae I Batterv Voltaae V
I Rear vehicle speed sensor signal 1 Rear Wheel Speed I km/h or MPH I
I Front vehicle speed sensor signal I Front Wheel Speed I km/h or MPH I
Engine speed signal Engine Speed rPm
Automatic transmission fluid temperature signal ATF Temp. "Cor OF
Throttle position signal Throttle Sensor Voltage V
Gear Dosition Gear Position -
I &ne pressure control dutv ratio 1 Line Pressure Dutv Ratio I YO I
I Lock up clutch control duty ratio I Lock Up Duty Ratio I O/O I
I Transfer clutch control duty ratio 1 Transfer Duty Ratio I % I
Power supply for throttle position sensor Throttle Sensor Power V
Torque converter turbine speed signal Turbine Revolution Speed rPm
2-4 brake timina Dressure control dutv ratio Brake Clutch Dutv Ratio - -
YO
-

IMass air flow sensor sianal (Turbo model) I Air Flow Sensor Voltaae -1 V -1
-4 -Intake manifold pressure sensor voltage (Non-turbo model) I Mani. Pressure Voltage I V I
I 2 wheel drive switch signal (Non-turbo model) 1 FWD Switch I ON or OFF I
-Stop lamp switch signal Stop Light Switch ON or OFF
Anti lock brake system signal ABS Signal ON or OFF
Cruise control system signal Cruise Control Signal ON or OFF
NeutraVParkina ranae sianal N/P RanQeSianal ON or OFF
I Reverse range signal I R Range Signal I ON or OFF I
I Drive range signal 1 D Range Signal I ON or OFF I
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 #I 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 Diagnosis Lamp ON or OFF

3. CLEAR MEMORY MODE NOTE:

For detailed operation procedure, refer to the SUB-
1) On the ((Main Menu)) display screen, select the ARU SELECT MONITOR OPERATION MANUAL.
12.Each System Check} and press the [YES] key.
2) On the ((System Selection Menu), display
screen, select the {Transmission Control System}
and press the [YES] key.
3) Press the [YES] key after displayed the informa-
tion of transmission type.
4) On the ((Transmission Diagnosis)) display
screen, select the {Clear Memory} and press the
[YES] key.

AT-23
I READ DIAGNOSTIC TROUBLE CODE (DTC)
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

7. Read Diagnostic Trouble

Code (DTC)
A: OPERATION
1. WITHOUT SUBARU SELECT MONITOR
~~

Step Check Yes No

PERFORM READ DIAGNOSTIC TROUBLE Does the indicator light blink at Repair power sup- 30 to step 2.
CODE. 4-Hz intervals? NOTE: Blinks ply and ground cir-
1)Warm-up the engine. every 0.125 (1/8) seconds cuit.<Ref. to AT-36,
2)Turn the ignition switch to OFF. (until ignition switch is turned CHECK POWER
3)Turn the ignition switch to ON. OFF). SUPPLY AND
4)Start the engine. GROUND LINE,
5)Drive the vehicle at speeds greater than 20 Diagnostic Proce-
km/h (12 MPH). dure for AT OIL
6)Stop the vehicle. TEMP Warning
7)Brake pedal depressed and move the select Light.>
lever to 1 range.
8)Turn the ignition switch to OFF.
9)Turn the ignition switch to ON.
1O)Move the select lever 2 range.
11)Move the select lever 1 range.
12)Movethe select lever 2 range.
13)Movethe select lever 3 range.
14)Move the select lever D range.
CHECK INDICATOR LIGHT. Does the indicator light blink at AT system is nor- 30 to step 3.
2-Hz intervals? NOTE: Blinks mal.
every 0.25 (1/4) seconds (until
ignition switch is turned OFF).
CHECK INDICATOR LIGHT. Is a trouble code outputted? Inspect the prob- 30 to step 4.
lem correspond-
ing with diagnostic
trouble code
(DTC).
NOTE:
Record all diag-
iostic trouble code
(DTC).
CHECK INDICATOR LIGHT. Does the indicator light remain Repair the AT OIL 2alling up the
illuminated? TEMP warning liagnostic trouble
ight circuit <Ref. :ode (DTC) again.
to AT-31, Diagnos-
:ic Procedure for
4T OIL TEMP
Uarning Light.>,
3r Inspect inhibitor
switch, wiring,
TCM, etc.

AT-24
 READ DIAGNOSTIC TROUBLE CODE (DTC) I
AUTOMATIC TRANSMISSION [DIAGNOSTICS)

The AT OIL TEMP warning light flashes the code corresponding to the faulty part.
The long segment (1.2 sec on) indicates a “ten”, and the short segment (0.2 sec on) signifies a “one”

Normal code
0.25

DTC 11
0.3 0.2
\ /

Unit: Seconds
TR056!

2. WITH SUBARU SELECT MONITOR

Refer to SUBARU SELECT MONITOR for informa-
tion about how to obtain and understand trouble
codes. <Ref. to AT-22, OPERATION, Subaru Se-
lect Monitor.>

AT-25
I INSPECTION MODE
AUTOMATIC TRANSMISSION (DIAGNOSTICS)
~~

8. Inspection Mode
A: OPERATION
Raise the vehicle using a garage jack and place on
safety stands or drive the vehicle onto free rollers.
WARNING:
Before raising the vehicle, ensure parking
brakes are applied.
Do not use a pantograph jack in place of a
safety stand.
Secure a rope or wire to the front and rear
towing or tie-down hooks to prevent the lateral
runout of front wheels.
Do not abruptly depresshelease clutch pedal
or accelerator pedal during works even when
the engine is operating at low speeds since this
may cause vehicle to jump off free rollers.
In order to prevent the vehicle from slipping
due to vibration, do not place any wooden
blocks or similar items between the safety
%landsand the vehicle.
Since the rear wheels will also rotate, do not
place anything near them. Also, make sure that
nobody goes in front of the vehicle.

(B)
B2M2969C

(A) Safety stand

(B) Free rollers

AT-26
 CLEAR MEMORY MODE I
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

9. Clear Memory Mode

A: OPERATION
1. WITHOUT SUBARU SELECT MONITOR
Current trouble codes shown on the display are
cleared by turning the ignition switch OFF after
conducting the on-board diagnostics operation.
Previous trouble codes, however, cannot be
cleared since they are stored in the TCM memory
which is operating on the back-up power supply.
These trouble codes can be cleared by removing
the specified fuse (located under the light or left
lower position of the instrument panel).
CLEAR MEMORY:
Removal of No. 4 fuse (for at least one
minute)
The No. 4 fuse is located in the line to the mem-
ory back-up power supply of the TCM. Removal of
this fuse clears the previous trouble codes stored in
-+he TCM memory.
Be sure to remove the No. 4 fuse for at least the
specified length of time. Otherwise, trouble codes
may not be cleared.
2. WITH SUBARU SELECT MONITOR
Refer to SUBARU SELECT MONITOR for informa-
tion about how to clear trouble codes.
<Ref. to AT-23, CLEAR MEMORY MODE, OPER-
ATION, Subaru Select Monitor.>

AT-27
 AT OIL TEMP WARNING LIGHT DISPLAY
I
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

10.AT OIL TEMP Warning Light
Display
A: INSPECTION
When any on-board diagnostics item is malfunc-
tioning, the display on the Power indicator light
blinks from the time the malfunction is detected af-
ter starting the engine until the ignition switch iS
turned OFF. The malfunctioning part or unit can be
determined by a trouble code during the on-board
diagnostics operation. Problems which occurred
previously can also be identified through the mem-
ory function. If the AT OIL TEMP warning does not
show a problem (although a problem is occurring),
the problem can be determined by checking the
performance characteristics of each sensor using
the selectmonitor. indicator signal is as shown in
the figure.

Normal

ON
2 secs

I .

OFF -

ON
-_ -_ -
0.25 secs
_ _
2 secs

OFF -- _ _ _ _ __
Normal (power switch ON)
I I-
Blink

I
Power indicator light ON

S3M0062A

AT-28
 I
LIST OF DIAGNOSTIC TROUBLE CODE (DTC)
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

11.List of Diagnostic Trouble

Code (DTC)
A: LIST
DTC No. Item Content of diagnosis Index
<Ref. to AT-44, DTC 11 ENGINE SPEED SIGNAL,
Detects open or shorted input
11 Engine speed signal Diagnostic Procedure with Diagnostic Trouble
signal circuit.
Code (DTC).>
<Ref. to AT-46, DTC 23 MASS AIR FROW SIG-
Detects Open Or shorted input
23 Mass air flow signal NAL, Diagnostic Procedure with Diagnostic Trou-
signal circuit.
ble Code (DTC).>
<Ref. to AT-48, DTC 27 ATF TEMPERATURE
27 ATF temperature sensor signal
Detectscircuit,
Open Or shorted input SENSOR, Diagnostic Procedure with Diagnostic
Trouble Code (DTC).>
<Ref. to AT-52, DTC 31 THROTTLE POSITION
31 Throttle position sensor signal
Detectscircuit,
Open Or shorted input SENSOR, Diagnostic Procedure with Diagnostic
Trouble Code (DTC).>
<Ref. to AT-57, DTC 33 FRONT VEHICLE SPEED
Front vehicle speed Detects Open Or shorted input
33 SENSOR, Diagnostic Procedure with Diagnostic
sensor signal circuit.
Trouble Code (DTC).>
<Ref. to AT-62, DTC 36 TORQUE CONVERTER
Torque converter tur- Detects Open Or shorted input
36 TURBINE SPEED SENSOR, Diagnostic Proce-
bine speed sensor signal circuit.
dure with Diagnostic Trouble Code (DTC).>
<Ref. to AT-66, DTC 38 TORQUE CONTROL SIG,
38 Torque control signal Detects Open Or shorted input NAL, Diagnostic Procedure with Diagnostic Trou-
signal circuit.
ble Code (DTC).>
~

Intake manifold pres-

<Ref. to AT-68, DTC 45 INTAKE MANIFOLD
sure Detects open or shorted input
45 PRESSURE SIGNAL, Diagnostic Procedure with
signal (Non-turbo signal circuit.
Diagnostic Trouble Code (DTC).>
model)
<Ref. to AT-70, DTC 71 SHIFT SOLENOID 1,
Detects open or shorted out-
71 Shift solenoid 1 Diagnostic Procedure with Diagnostic Trouble
put signal circuit.
Code (DTC).>
<Ref. to AT-74, DTC 72 SHIFT SOLENOID 2,
Detects open or shorted out-
72 Shift solenoid 2 Diagnostic Procedure with Diagnostic Trouble
put signal circuit.
Code (DTC).>
<Ref. to AT-78, DTC 73 LOW CLUTCH TIMING
Low clutch timing sole- Detects open or shorted out-
73 SOLENOID, Diagnostic Procedure with Diagnostic
noid put signal circuit.
Trouble Code (DTC).>
<Ref. to AT-82, DTC 74 2-4 BRAKE TIMING
2-4 brake timing sole- Detects open or shorted out-
74 SOLENOID, Diagnostic Procedure with Diagnostic
noid put signal circuit.
Trouble
_ _ _
Code
~
(DT
~ ~
Cb
<Ref. to AT-86, DTC 75 LINE PRESSURE DUTY
Line pressure duty sole- Detects open or shorted out-
75 SOLENOID, Diagnostic Procedure with Diagnostic
noid put signal circuit.
Trouble Code (DTC).>
<Ref. to AT-90, DTC 76 2-4 BRAKE DUTY SOLE-
Detects open or shorted out-
76 2-4 brake duty solenoid NOID, Diagnostic Procedure with Diagnostic Trou.
put signal circuit.
ble Code (DTC).>
<Ref. to AT-94, DTC 77 LOCK-UP DUTY SOLE-
Detects open or shorted out-
77 Lock-up duty solenoid NOID, Diagnostic Procedure with Diagnostic Trou,
put signal circuit.
ble Code ( D T C b
~~

<Ref. to AT-100, DTC 79 TRANSFER DUTY

Detects open or shorted out-
79 Transfer duty solenoid SOLENOID, Diagnostic Procedure with Diagnostic
put signal circuit.
Trouble Code (DTC).>
<Ref. to AT-104, DTC 93 REAR VEHICLE SPEED
Rear vehicle speed Detects open or shorted input
93 SENSOR, Diagnostic Procedure with Diagnostic
sensor signal circuit.
Trouble Code (DTC).>

AT-29
 LIST OF DIAGNOSTIC TROUBLE CODE (DTC)
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

r.

AT-30
 DIAGNOSTIC PROCEDURE FOR AT OIL TEMP WARNING LIGHT
a
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

12.Diagnostic Procedure for AT OIL TEMP Warning Light

A: AT OIL TEMP WARNING LIGHT DOES NOT COME ON OR GO OFF
DIAGNOSIS:
The AT OIL TEMP warning light circuit is open or shorted.
TROUBLE SYMPTOM:
When the ignition switch is turned to ON (engine OFF), AT OIL TEMP warning light does not illuminate.
When the on-board diagnostics is performed, AT OIL TEMP warning light remains illuminated.

--

AT-31
 I
DIAGNOSTIC PROCEDURE FOR AT OIL TEMP WARNING LIGHT
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

WIRING DIAGRAM:

IGNITION
SWITCH
SBF-1 SBF-4

I i

COMBINATION
METER

B AT OIL

INHIBITOR SWITCH

r- ~

3 3
I A: @
3
B: @ TCM

7 8 9101112
dR\
9 101112

A: @ B: @

TR0570

AT-32
 1
DIAGNOSTIC PROCEDURE FOR AT OIL TEMP WARNING LIGHT
AUTOMATIC TRANSMISSION (DIAGNOSTICS)
~~~ ~

Step Check Yes No

CHECK AT OIL TEMP WARNING LIGHT. )oes the AT OIL TEMP warn- Go to step 3. 30 to step 2.
Turn the ignition switch to ON (engine OFF). i g light illuminate?
CHECK AT OIL TEMP WARNING LIGHT. ;the AT OIL TEMP warning Go to step 4. 3eplace the AT
1)Turn the ignition switch to OFF. ght bulb OK? 31L TEMP warn-
2)Remove the combination meter. ng light bulb.
3)Remove the ATF temp warning light bulb
from combination meter.
CHECK AT OIL TEMP WARNING LIGHT. )oes the AT OIL TEMP warn- A temporary poor 30 to step 10.
Perform “Read Diagnostic Trouble Code”. i g light blink? contact of the con-
<Ref. to AT-24, WITHOUT SUBARU SELECT nector or harness
MONITOR, OPERATION, Read Diagnostic may be the cause.
Trouble Code (DTC).> Repair the har-
ness or connector
in TCM, inhibitor
switch and combi-
nation meter.
CHECK FUSE (No. 13). 5 the fuse (No. 13) blown out? Replace the fuse 30 to step 5.
Remove the fuse (No. 13). (No. 13). If the
replaced fuse (No.
13) is blown out
easily, repair short
circuit in harness
between fuse (No.
13) and combina-
tion meter.
CHECK HARNESSCONNECTOR BETWEEN 5 the voltage more than 9 V? Go to step 6. 3epair open or
COMBINATION METER AND IGNITION short circuit in har-
SWITCH. less between
1)Turnthe ignition switch to ON (engine OFF). :ombination meter
2)Measure the voltage between combination md battery.
meter connector and chassis ground.
Connector & terminal
(il0) No. 7 (+) - Chassis ground (-):
CHECK COMBINATION METER. 3 the voltage less than 1 V? Go to step 7 . 3epair the combi-
Measure the voltage between combination iation meter.
meter connector and chassis ground. :Ref. to IDI-11,
Connector & terminal zombination
( i l l ) No. 5 (+) - Chassis ground (-): Meter Assembly.>
CHECK OPEN CIRCUIT OF HARNESS. s the resistance less than 1 Go to step 8. 3epair open circuit
1)Turn the ignition switch to OFF. l? n harness
2)Disconnect the connector from combination ietween TCM and
meter connector. :ombination
3)Measure the resistance of harness between neter, and poor
combination meter. :ontact in cou-
Connector & terminal iling connector.
Non-turbo model
(854) NO. 3 - ( i l l ) NO. 5:
Turbo model
(856) NO. 11 - ( i l l ) NO. 5:

AT-33
I DIAGNOSTIC PROCEDURE FOR AT OIL TEMP WARNING LIGHT
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

Step Check Yes No

I CHECK INPUT SIGNAL FOR TCM. 5 the voltage less than 1 V? Even if the AT OIL Replace the TCM.
1)Connectthe connector to TCM and combina- TEMP warning <Ref. to AT-45,
tion meter. lights up, the cir- Transmission Con-
2)Turn the ignition switch to ON (engine OFF). cuit has returned trol Module
3)Measure the voltage between TCM connec- to a normal condi- (TCM).>
tor and chassis ground. tion at this time. A
Connector & terminal temporary poor
Non-turbo model contact of the con-
-
(B54)No. 3 (+) Chassis ground (-): nector or harness
Turbo model may be the cause.
(B56)No. 11 (+) - Chassis ground (-): Repair the har-
ness or connector
in TCM.
1 CHECK SUBARU SELECT MONITOR. 10 you have a SUBARU Go to step 10. Go to step 11.
SELECT MONITOR?
0 CHECK INHIBITOR SWITCH. Vhen each range is selected, Go to step 11. Check the inhibi-
1)Connect the Subaru Select Monitor to data loes the LED of Subaru Seleci tor switch circuit.
link connector. Aonitor light up? <Ref. to AT-115,
2)Turn the ignition switch to ON. CHECK INHIBI-
3)Subaru Select Monitor to ON. TOR SWITCH.,
4)Read the data of range switch using Subaru Diagnostic Proce-
._ Select Monitor. dure for No-Diag-
*Range switch is indicated in ON w OFF. nostic Trouble
Code (DTC).>
1 CHECK SHORT CIRCUIT OF HARNESS. s the resistance less than 1 Replace the TCM. Repair short circuil
1)Disconnectthe connector from TCM. AR? <Ref. to AT-45, in harness
2)Remove the combination meter. Transmission Con- between combina-
3)Disconnect the connector from combination trol Module tion meter connec.
meter. (TCM).> tor and TCM
4)Measure the resistance of harness connec- connector.
tor between TCM and chassis ground.
Connector & terminauspecified resistance
Non-turbo model
(854)No. 3 (+) - Chassis ground (-):
Turbo model
(B56)No. 11 (+) - Chassis ground (-):

AT-34
I DIAGNOSTIC PROCEDURE FOR AT OIL TEMP WARNING LIGHT
I
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

AT-35
I I
DIAGNOSTIC PROCEDURE FOR AT OIL TEMP WARNING LIGHT
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

B: CHECK POWER SUPPLY AND GROUND LINE

WIRING DIAGRAM:

BATTERY
n

I -
i
m
(I)

INITION DATALINK
NITCH CONNECTOR

by
TB

m,@ : NON-TURBO MODEL

m, :TURBO MODEL

9 110 11 111211 311 411 511 6

112131415] 16171819110111
1211311411511 611 711 8119120121122123124

TR0571

AT-36
I DIAGNOSTIC PROCEDURE FOR AT OIL TEMP WARNING LIGHT I
AUTOMATIC TRANSMISSION (DIAGNOSTICSI

Step Check Yes No

1 CHECK IGNITION SWITCH. Is the ignition switch ON? Go to step 2. Turn the ignition
switch ON.
2 CHECK GENERATOR. Is the voltage between 10 and Go to step 3. Repair the genera
1)Start the engine. 15 V? tor. <Ref. to SC-
2)ldle the engine. 13, Generator.>
3)Measure the voltage between generator and
chassis ground.
Terminal
Generator B terminal (+) - Chassis
ground (-):
3 CHECK BATTERY TERMINAL. Is there poor contact at battery Repair the battery Go to step 4.
Turn the ignition switch to OFF. terminal? terminal.
I CHECK POWER SUPPLY OF TCM. Is the voltage between 10 and Go to step 6. Go to step 5.
1)Disconnectthe connector from TCM. 15 V?
2)Turn the ignition switch to ON.
3)Measure the voltage between TCM connec-
tor and chassis ground.
Connector & terminal
Non-turbo model
(654) No. 6 (+) - Chassis groundI)-(
Turbo model
(B56) No. 1 (+)- Chassis ground (-):
5 CHECK FUSE (NO. 4). Is the fuse (No. 4) blown out? Replace the fuse Repair open circuii
Remove fuse (No. 4). (No. 4). If the in harness
replaced fuse (No. between fuse (No.
4) has blown out 4) and TCM, or
easily, repair short fuse (No. 4) and
circuit in harness battery, and poor
between fuse (No. sontact in cou-
4) and TCM. pling connector.
5 CHECK IGNITION POWER SUPPLY CIR- Is the voltage more than 10 V? Go to step 8. Go to step 7.
CUIT.
1)Turn the ignition switch to ON (engine OFF).
2)Measure the ignition power supply voltage
between TCM connector and chassis ground.
Connector & terminal
(B54) No. 23 (+) - Chassis ground (-):
(654) No. 24 (+)- - Chassis ground (-):
7 CHECK FUSE (NO. 11). Is the fuse (No. 11) blown out? Replace the fuse Repair open circuii
Remove the fuse (No. 11). (No. 11). If the in harness
replaced fuse (No. Detween fuse (No.
11) has blown out 4) and TCM, or
easily, repair short fuse (No. 4) and
circuit in harness Dattery, and poor
between fuse (No. :ontact in cou-
11) and TCM. Dling connector.
3 CHECK HARNESSCONNECTOR BETWEEN Is the resistance less than 1 Go to step 9. Repair open circuii
TCM AND TRANSMISSION. n? n harness
1)Turn the ignition switch to OFF: Detween TCM,
2)Disconnect the connector from TCM and ransmission har-
transmission. less connector,
3)Measure the resistance of harness between and poor contact
TCM and transmission connector. n coupling con-
Connector & terminal lector.
Non-turbo model
(B55) NO. 9 - (B1 1) NO. 16
(B55) NO. 19 - (Bl 1) NO. 16
Turbo model
(B56) NO. 19 - ( B l l ) NO. 16
(654) NO.21 - (611) NO. 16

AT-37
 DIAGNOSTIC PROCEDURE FOR AT OIL TEMP WARNING LIGHT
I
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

Step Check Yes No

9 CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 30 to step 10. Repair open circuit
TRANSMISSION AND TRANSMISSION n? in harness
GROUND. between transmis-
Measure the resistance of harness between sion and transmis-
transmission and transmission ground. sion ground.
Connector & terminal
(T4) No. 16 - Transmission ground:
10 CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in control Repair the con- Replace the TCM.
module power supply, ground lector. <Ref. to AT-45,
line and data link connector? Transmission Con-
trol Module
(TCM).>

AT-38
I DIAGNOSTIC PROCEDURE FOR SELECT MONITOR COMMUNICATION
E
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

13.Diagnostic Procedure for Select Monitor Communication

A: COMMUNICATION FOR INITIALIZING IMPOSSIBLE
DIAGNOSIS:
Faulty harness connector
TROUBLE SYMPTOM:
Select the monitor communication failure

AT-39
 DIAGNOSTIC PROCEDURE FOR SELECT MONITOR COMMUNICATION
I
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

WIRING DIAGRAM:

BATTERY

P
0

5 DATALINK
=
12
CONNECTOR
-
13
r- ~

1 A:@ B:@
m
2 2
m *
9 2

C @ : m
*

TCM

TRANSMISSION

m,@ : NON-TURBO MODEL

TR0571

AT-40
DIAGNOSTIC PROCEDURE FOR SELECT MONITOR COMMUNICATION
I
AUTOMATIC TRANSMISSION (DIAGNOSTICS)
~~

Step Check Yes No

CHECK SUBARU SELECT MONITOR POW- s the voltage more than lOV? 30 to step 2. 3epair harness
ER SUPPLY CIRCUIT. and connector
Measure the voltage between data link con- 3etween battery
nector and chassis ground. and data link con-
Connector & terminal lector, and poor
(840) No. 1 - Chassis ground: :ontact in cou-
Dling connector.
CHECK SUBARU SELECT MONITOR Is the resistance less than In? 30 to step 3. Repair open circuii
GROUND CIRCUIT. in harness
Measure the resistance of harness between between data link
data link connector and chassis ground. sonnector and
Connector & terminal ground terminal,
(840) No. 12 - Chassis ground: and poor contact
(840) No. 13 - Chassis ground: in coupling con-
nector.
CHECK COMMUNICATIONOF SELECT Are the name and year of the 30 to step 8. Go to step 4.
MONITOR. system displayed on the select
1)Turn the ignition switch to ON. monitor?
2)Using the select monitor, check whether
communication to other systems (such as
engine, ABS etc.) can be executed normally.
CHECK COMMUNlCATtON OF SELECT Are the name and year of the So to step 10. Go to step 5.
MONITOR. system displayed on the select
1)Turn the ignition switch to OFF. monitor?
2)Disconnect the TCM connector.
3)Check whether communication to other sys-
tems (such as ABS etc.) can be executed nor-
mally.
CHECK COMMUNICATIONOF SELECT Are the name and year of the Inspect the ECM. Go to step 6.
MONIT0R . system displayed on the select
1)Turnthe ignition switch to OFF. monitor?
2)Connect the TCM connector.
3)Disconnect the ECM connector.
4)Check whether communication to other sys-
tems (such as ABS etc.) can be executed nor-
mally.
CHECK COMMUNICATIONOF SELECT Are the name and year of the Inspect the Go to step 7.
MONITOR. system displayed on the select ABSCM&H/U.
1)Turn the ignition switch to OFF. monitor?
2)Connect the ECM connector.
3)Disconnect the ABSCM&H/U connector.
4)Check whether communication to other sys-
tems (such as engine etc.) can be executed
normally.
CHECK COMMUNICATIONOF SELECT Are the name and year of the Inspect the cruise Go to step 8.
MONITOR. system displayed on the select control module.
1)Turn the ignition switch to OFF. monitor?
2)Connect the ABSCM&H/U module connec-
tor.
3)Disconnect the cruise control module con-
nector.
4)Check whether communication to other sys-
tems (such as engine etc.) can be executed
normally.
NOTE:
If the vehicle is not equipped with cruise contro
Go to step 8.

AT-41
I DIAGNOSTIC PROCEDURE FOR SELECT MONITOR COMMUNICATION
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

Step Check

R? and connector
between each con.
trol module and
data link connec-
tor.

(840) No. 4-Chassis ground:

I CHECK OUTPUT SIGNAL FOR TCM. Is the voltage more than 1 V? 3epair harness A temporary poor
ind connector contact or har-
letween each con- ness may be the
rol module and case. Repair har-
jata link connec- ness or connector
or. in the select moni-
tor communication
circuit.
0 CHECK HARNESSKONNECTORBETWEEN Is the resistance less than 0.5 i o to step 11. Repair harness
TCM AND DATA LINK CONNECTOR. R? and connector
Measure the resistance between TCM connec- between TCM and
tor and data link connector. data link connec-
Connector & terminal tor.
Non-turbo model
-
(855) NO. 7 (840) NO. 5:
(855) NO. 16 - (840) NO. 4:
Turbo model
(856) NO. 6 - (840) NO. 5:
(856) NO. 15 - (840) NO. 4:
1 CHECK INSTALLATION OF TCM CONNEC- Is TCM connector inserted into i o to step 12. Insert the TCM
TOR. TCM? connector into
Turn the ignition switch to OFF. TCM.
2 CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in control 3epair the poor Replace the TCM.
module and data link connec- :ontact. <Ref. to AT-45,
tor? Transmission Con-
trol Module
(TCM).>

AT-42
DIAGNOSTIC PROCEDURE FOR SELECT MONITOR COMMUNICATION
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

AT-43
 I
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

14.Diagnostic Procedure with Diagnostic Trouble Code (DTC)

A: DTC 11 ENGINE SPEED SIGNAL
DIAGNOSIS:
Engine speed input signal circuit is open or shorted.
TROUBLE SYMPTOM:
No lock-up (after engine warm-up).
AT OIL TEMP warning light remains on when the vehicle speed is ''0'.
WIRING DIAGRAM:

1
@TCM

: NON-TURBO MODEL

: TURBO MODEL

I ECM I

TR0572

AT-44
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) I
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

Step Check Yes No

CHECK HARNESS CONNECTOR BETWEEN s the resistance less than 1 io to step 2. 3epair open circuit
TCM AND ECM. 2? n harness
1)Turn the ignition switch to OFF. letween TCM and
2)Disconnect the connectors from TCM and X M connector.
ECM.
3)Measure the resistance of harness between
TCM and ECM connector.
Connector & terminal
Non-turbo model
(B55) NO. 4 - (8134) NO. 30:
Turbo model
(B55) NO. 17 - (8136) NO. 9:
CHECK HARNESSCONNECTOR BETWEEN s the resistance more than 1 i o to step 3. 3epair short circuit
TCM AND ECM. VlR? n harness
Measure the resistance of harness between ietween TCM and
TCM connector and chassis ground. ICM connector.
Connector & terminal
Non-turbo model
(B55) No. 4 - Chassis ground:
Turbo model
(B55) No. 17 - Chassis ground:
PREPARE SUBARU SELECT MONITOR. l o you have a Subaru Select i o to step 5. 30 to step 4.
Vlonitor?
CHECK INPUT SIGNAL FOR TCM. s the voltage 0 V? gven if the AT OIL 30 to step 6.
1)Connect the connectors to TCM and ECM. rEMP warning
2)Turn the ignition switch to ON (engine OFF). ights up, the cir-
3)Measure the voltage between TCM connec- :uit has returned
tor and chassis ground. o a normal condi-
Connector & terminal ion at this time. A
Non-turbo model emporary poor
(B55) No. 4 (+) - Chassis ground (-): :ontact of the con
Turbo model lector or harness
(B55) No. 17 (+) - Chassis ground (-): nay be the cause
3epair harness or
:onnector in the
E M and ECM.
I CHECK INPUT SIGNAL FOR TCM USING Is the revolution value the Iven if the AT OIL 30 to step 6.
SUBARU SELECT.MONITOR. same as the tachometer read- rEMP warning
1)Connect the connectors to TCM and ECM. ng shown on the combination ights up, the cir-
2)Connect the Subaru Select Monitor to data neter? x i t has returned
link connector. o a normal condi.
3)Start the engine, and turn the Subaru Select ion at this time. A
Monitor switch to ON. emporary poor
4)Warm-up the engine until engine coolant :ontact of the con
temperature is above 80°C (176°F). lector or harness
5)Engine idling. nay be the cause
6)Read the data of engine speed using the qepair harness or
Subaru Select Monitor. :onnector in the
-Display shows engine speed signal value sent TCM and ECM.
from ECM.
i CHECK POOR CONTACT. Is there poor contact in engine qepair poor con- Go to step 7.
speed signal circuit? :act.
I CONFIRM DTC 11. Replace the ECM with a new Replace the TCM. Replace the ECM.
one. Does the trouble code <Ref. to AT-45,
appear again, after the mem- Transmission Con
ory has been cleared? :rol Module
[TCM).>

AT-45
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

B: DTC 23 MASS AIR FROW SIGNAL

DIAGNOSIS:
Input signal circuit of TCM from ECM is open or shorted.
TROUBLE SYMPTOM:
Excessive shift shock.
WIRING DIAGRAM:

TR0573

Step Check Yes No

Repair ground ter- Go to step 2.
I
I GROUND CIRCUIT OF ECM minal and/or
<Ref. to AT-52, DTC 31 THROTTLE POSITION ground circuit of
SENSOR, Diagnostic Procedure with Diagnos- ECM.
tic Trouble Code (DTC).>
2 CHECK HARNESS CONNECTOR BETWEEN s the resistance less than 1 Go to step 3. Repair open circuit
TCM AND ECM. n? in harness
1)Turn the ignition switch to OFF. between TCM and
2)Disconnect the connectors from TCM and ECM connector.
~ ECM.
3)Measure the resistance of harness between
TCM and ECM connector.
Connector & terminal
(B54) NO. 1 - (8135) NO. 28:
3 CHECKHARNESSCONNECTORBETWEEN s the resistance more than 1 Go to step 4. Repair short circuit
TCM AND ECM. M1R? in harness
Measure the resistance of harness between between TCM and
TCM connector and chassis ground. ECM connector.
Connector & terminal
(854) No. 1 - Chassis ground:
4 PREPARE SUBARU SELECT MONITOR. l o you have a Subaru Select Go to step 6. Go to step 5.
vlonitor?

AT-46
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) I
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

Step Check Yes No

1 CHECK INPUT SIGNAL FOR TCM. s the voltage between 0.4 and Even if the AT OIL ;o to step 7.
1)Connect the connectors to TCM and ECM. I .8 V? TEMP warning
2)Start the engine, and warm-up the transmis- lights up, the cir-
sion until ATF temperature is above 80°C cuit has returned
(176°F). to a normal condi-
NOTE: tion at this time. A
If ambient temperature is below 0°C (32°F) temporary poor
drive the vehicle until the ATF reaches its oper contact of the con-
ating temperature. nector or harness
3)Engine idling. may be the cause.
4)Measure the voltage between TCM connec- Repair harness or
tor and chassis ground. connector in the
Connector & terminal TCM and ECM.
(854) No. 1 (+) - Chassis ground (-):
i CHECK INPUT SIGNAL FOR TCM USING s the value between 0.4 and Even if the AT OIL 30 to step 7.
SUBARU SELECT MONITOR. 1.8 V? TEMP warning
1)Connect the connectors to TCM and ECM. lights up, the cir-
2)Connect the Subaru Select Monitor to data cuit has returned
link connector. to a normal condi-
3)Start the engine, and turn the Subaru Seleci tion at this time. A
monitor switch to ON. temporary poor
4)Warm-upthe engine until the engine coolani contact of the con-
temperature is above 80°C (176°F). nector or harness
5)Engine idling. may be the cause.
6)Read the data of intake manifold pressure Repair harness or
signal using Subaru Select Monitor. connector in the
*Display shows the intake manifold pressure TCM and ECM.
signal value sent from ECM.
r CHECK POOR CONTACT. s there poor contact in intake Repair the poor 3eplace the TCM.
nanifold pressure signal cir- contact. :Ref. to AT-45,
rransmission Con-
rot Module
'TCMb

AT-47
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
I
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

C: DTC 27 ATF TEMPERATURE SENSOR

DIAGNOSIS:
Input signal circuit of TCM to ATF temperature sensor is open or shorted.
TROUBLE SYMPTOM:
Excessive shift shock.
WIRING DIAGRAM:

TCM

w o
a m
w w
:TURBO MODEL
LL
+
4:

TRANSMISSION

TR0574

AT-48
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) 1
AUTOMATIC TRANSMISSION (DIAGNOSTICS)
~~~ ~

Step Check Yes No

CHECK HARNESSCONNECTOR BETWEEN ;the resistance less than 1 io to step 2. Repair open circuit
TCM AND ATF TEMPERATURE SENSOR. 1? in harness
1)Turn the ignition switch to OFF. between TCM and
2)Disconnect the connector from transmission transmission con-
and TCM. nector.
3)Measure the resistance of harness between
TCM and transmission connector.
Connector & terminal
Non-turbo model
(655) NO. 10 - (61 1) NO. 12:
Turbo mode
(654) NO.20 - ( 6 1 1) NO. 12:
CHECK HARNESSCONNECTOR BETWEEN 3 the resistance less than 1 io to step 3. Repair open circuit
TCM AND ATF TEMPERATURE SENSOR. I? in harness
Measure the resistance of harness between between TCM and
TCM and transmission connector. transmission con-
Connector & terminal nector.
Non-turbo model
(655) No. 11 - (611) NO. 11:
Turbo mode
(654) NO. 11 - (611) NO. 11:
c .- CHECK HARNESSCONNECTOR BETWEEN ;the resistance more than 1 io to step 4. Repair short circuit
TCM AND ATF TEMPERATURE SENSOR. AR? in harness
Measure the resistance of harness between between TCM and
TCM connector and chassis ground. transmission con-
Connector & terminal nector.
Non-turbo model
(655) No. 10 - Chassis ground:
Turbo mode
(654) No. 20 - Chassis ground:
I CHECK HARNESS CONNECTOR BETWEEN s the resistance more than 1 So to step 5. Repair short circuil
TCM AND ATF TEMPERATURE SENSOR. An? in harness
Measure the resistance of harness between between TCM and
TCM connector and chassis ground. transmission con-
Connector & terminal nector.
Non-turbo model
(655) No. 11 - Chassis ground:
Turbo mode
(654) No. 11 - Chassis ground:
1 CHECK ATF TEMPERATURE SENSOR. s the resistance between 275 So to step 6. Go to step 11.
1)Turn the ignition switch to OFF. md 375 n?
2)Connect the connectors to transmission and
TCM.
3)Turn the ignition switch to ON and start
engine.
4)Warm-up the transmission until the ATF tern
perature reaches to 80°C (176°F).
NOTE:
If ambient temperature is below 0°C (32°F)
drive the vehicle until the ATF reaches its oper
ating temperature.
5)Disconnect the connector from transmission
6)Measure the resistance between transmis-
sion connector terminals.
Connector & terminal
(T4) NO. 11 - NO. 12:

AT-49
I DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
AUTOMATIC TRANSMISSION (DIAGNOSTICS)
~~

Step Check Yes No

6 CHECK ATF TEMPERATURE SENSOR. Does the resistance value Go to step 7. So to step 11.
1)Turn the ignition switch to ON (engine OFF). ncrease while the ATF temper
2)Measure the resistance between transmis- 3ture decreases?
sion connector terminals.
Connector & terminal
(T4) NO. 11 - NO. 12:
7 PREPARE SUBARU SELECT MONITOR. 30 you have a Subaru Select Go to step 9. 30 to step 8.
Monitor?
CHECK INPUT SIGNAL FOR TCM. s the voltage between 0.4 and Even if the AT OIL 30 to step 10.
1)Connect the connector to transmission. 1.9 V? TEMP warning
2)Warm-up the transmission until the ATF tem- lights up, the cir-
perature is about 80°C (176°F). cuit has returned
NOTE: to a normal condi-
If ambient temperature is below 0°C (32°F) tion at this time.
drive the vehicle until the ATF reaches its oper. Temporary poor
ating temperature. :ontact of the con.
3)Measure the voltage between TCM connec- lector or harness
tor terminal. nay be the case.
Connector & terminal Repair harness or
Non-turbo model :ontact in the ATF
(B55)NO. 11 (+) - NO. 10 (-): :emperatwe sen-
r. ~ Turbo model ;or and transmis-
(B54) NO. 11 (+) - NO. 20 (-): sion connector.
9 CHECK INPUT SIGNAL FOR TCM USING 1oes the ATF temperature Even if the AT OIL 50 to step 10.
SUBARU SELECT MONITOR. jradually decrease? rEMP warning
1)Connect the connector to transmission. ights up, the cir-
2)Turn the ignition switch to ON (engine OFF). :uit has returned
o a normal condi-
ion at this time.
remporary poor
:ontact of the con-
lector or harness
nay be the case.
3epair harness or
:ontact in the ATF
emperature sen-
ior and transmis-
;ion connector.
3 there poor contact in ATF Iepair poor con- ieplace the TCM.
smperature sensor circuit? act. :Ref. to AT-45,
tansmission Con-
'01 Module
TCM).>

AT-50
I DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

Step Check Yes No

I1 CHECK HARNESS CONNECTOR BETWEEN s the resistance less than 1 ;o to step 12. lepair open circuit
TRANSMISSION AND ATF TEMPERATURE 2? 1 harness
SENSOR. letween ATF tem-
1)Turnthe ignition switch to OFF. lerature sensor
2)Disconnect the connector from transmission. .nd transmission
3)Remove the transmission connector from onnector.
bracket.
4)Lift-up the vehicle and place safety stand.
CAUTION:
On AWD models, raise all wheels off
ground.
5)Drain the automatic transmission fluid.
CAUTION:
Do not drain the automatic transmission flu.
id until it cools down.
6)Remove the oil pan, and disconnect the con-
nector from ATF temperature sensor connec-
tor.
7)Measure the resistance of harness between
ATF temperature sensor and transmission con.
nector. I

Connector & terminal

(T4) NO. 11 - (AT1) NO. 2:
12 CHECK HARNESSCONNECTOR BETWEEN s the resistance less than 1 50 to step 13. iepair open circuit
TRANSMISSION AND ATF TEMPERATURE n? iharness
SENSOR. letween ATF tem-
Measure the resistance of harness between Ierature sensor
ATF-temperaturesensor and transmission con. ind transmission
nector. :onnector.
Connector & terminal
(T4) NO. 12 - (ATl) NO. 1:
13 CHECK HARNESSCONNECTOR BETWEEN Is the resistance more than 1 20 to step 14. iepair short circuit
TRANSMISSION AND ATF TEMPERATURE Ma? iharness
SENSOR. jetween ATF tem-
Measure the resistance of harness between erature sensor
transmission connector and transmission nd transmission
ground. onnector.
Connector & terminal
(T4) No. 11 - Transmissionground:
4 CHECK HARNESS CONNECTOR BETWEEN s the resistance more than 1 leplace the ATF lepair short circuit
TRANSMISSION AND ATF TEMPERATURE An? mperature sen- 1 harness
SENSOR. ,or. <Ref. to AT- etween ATF tem-
Measure the resistance of harness between 19,Shift Sole- erature sensor
transmission connector and transmission ioids, Duty Sole- nd transmission
ground. ioids and ATF onnector.
Connector & terminal emperature Sen-
-
(T4) No. 12 Transmissionground: ,or.>

AT-51
I DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) I
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

D: DTC 31 THROTTLE POSITION SENSOR

DIAGNOSIS:
Input signal circuit of throttle position sensor is open or shorted.
TROUBLE SYMPTOM:
Shift point too high or too low; excessive shift shock; excessive tight corner “braking”.
WIRING DIAGRAM:
NON-TURBO MODEL

@ TCM 000
A. 6134 B 8135 C 6136 ECM

L
THROTTLE
POSITION SENSOR
SHIELD AND
SENSOR GROUND
JOINT CONNECTOR

AT-52
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
I
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

TURBO MODEL

@ TCM
A: 8134

C:@
'O
B 6135

D:@
ECM

I
I I

r. .

SHIELD AND
THROTTLE SENSORGROUND
POSITION SENSOR JOINT CONNECTOR

TR0576

AT-53
I DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

Step Check Yes No

I CHECK ENGINE GROUND TERMINALS. -lave engine ground terminals 20 to step 2. righten the engine
ieen tightened? ground terminals.
! CHECK GROUND CIRCUIT OF ECM. s the resistance less than 5 :o to step 3. 3epair open circuit
1)Turn the ignition switch to OFF. 3? n harness
2)Disconnect the connector from ECM. letween ECM
3)Measure the resistance of harness between :onnector and
ECM and engine ground. mgine grounding
Connector & terminal erminal.
Non-turbo model
(6134) No. 27 - Engine ground:
( 6 134)No. 8 - Engine ground:
(6134) No. 7 - Engine ground:
(6136) No. 21 -Engine ground:
(6136) No. 22 - Engine ground:
(6134) No. 35 - Engine ground:
(6134) No. 34 - Engine ground:
Turbo model
(6134) No. 7 - Engine ground:
(6134) No. 15 - Engine ground:
(6134) No. 22 - Engine ground:
(6136) No. 8 -Engine ground:
(6136) No. 17 - Engine ground:
(6136) No. 18 -Engine ground:
_I
~

(6137) No. 8 - Engine ground:

(6137) No. 9 -Engine ground:
t CHECK THROTTLE POSITION SENSOR. s the resistance between 3.0 20 to step 4. 3eplace the throt-
1)Disconnect the connector from throttle posi- 2nd 4.2 kfi? le position sensor.
tion sensor.
2)Measure the resistance between throttle
position sensor connector receptacle's termi-
nals.
Terminals
Non-turbo model
NO. 4 - NO. 2:
Turbo model
NO. 1 - NO. 2:
I CHECK THROTTLE POSITION SENSOR. s the resistance between 0.35 ;o to step 5. 3eplace the throt-
Measure the resistance between throttle posi- md 0.5 kR? le position sensor.
tion sensor connector receptacle's terminals.
Terminals
NO. 2 - NO. 3:
> CHECK HARNESS CONNECTOR BETWEEN s the resistance less than 1 20 to step 6. 3epair open circuit
TCM AND THROTTLE POSITION SENSOR. n? n harness
1)Disconnect the connector from TCM. ietween TCM and
2)Measure the resistance of harness between hrottle position
TCM and throttle position sensor connector. sensor connector,
Connector & terminal 3nd poor contact
Non-turbo model n coupling con-
-
(655) NO. 2 (€13) NO. 3: lector.
Turbo model
-
(B54) NO. 3 (E13) NO. 3:
i CHECK HARNESS CONNECTOR BETWEEN s the resistance less than 1 ;o to step 7. 3epair open circuit
TCM AND THROlTLE POSITION SENSOR. n? n harness
Measure the resistance of harness between ietween TCM and
TCM and throttle position sensor connector. hrottle position
Connector & terminal sensor connector,
Non-turbo model md poor contact
-
(655) NO. 1 (€13) NO. 4: n coupling con-
Turbo model lector.
-
(654) NO. 2 (€13) NO. 4:

AT-54
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
I
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

Step Check Yes No

CHECK HARNESSCONNECTOR BETWEEN s the resistance more than 1 o step 8. Repair short circuit
TCM AND THROTTLE POSITION SENSOR. An? n harness
Measure the resistance of harness between Detween TCM and
TCM connector and chassis ground. throttle position
Connector & terminal sensor connector.
Non-turbo model
(655) No. 2 - Chassis ground:
Turbo model
(654) No. 3 - Chassis ground:
CHECK HARNESSCONNECTOR BETWEEN s the resistance more than 1 o step 9. Repair short circuit
TCM AND THROTTLE POSITION SENSOR. dR? in harness
Measure the resistance of harness between between TCM and
TCM connector and chassis ground. throttle position
Connector & terminal sensor connector.
Non-turbo model
(655) No. 1 - Chassis ground:
Turbo model
(654) No. 2 - Chassis ground:
I CHECK HARNESS CONNECTOR BETWEEN s the resistance less than 1 o step 10. Repair open circuit
TCM AND ECM. 2? in harness
Measure the resistance of harness between between TCM and
TCM and ECM connector. ECM connector.
Connector & terminal
Non-turbo model
(655) NO.2 - (6136) NO. 17:
Turbo model
(654) NO. 3 - (6135) NO. 7:
0 CHECK HARNESSCONNECTOR BETWEEN Is the resistance less than 1 to step 11. Repair open circuit
TCM AND ECM. n? in harness
Measure the resistance of harness between between TCM and
TCM and ECM connector. ECM connector.
Connector & terminal
Non-turbo model
(655) NO. 1 - (6136) NO. 15:
Turbo model
(654) NO. 2 - (6135) NO. 9:
I1 PREPARE SUBARU SELECT MONITOR. Do you have a Subaru Select to step 14. Go to step 12.
Monitor?
12 CHECK INPUT SIGNAL FOR TCM. Is the voltage between approx. to step 13. Go to step 18.
1)Connect the connectors to TCM, throttle 0.5 V in throttle fully closed?
position sensor and ECM.
2)Turn the ignition switch to ON (engine OFF)
3)Close the throttle completely.
4)Measure the voltage between TCM connec-
tor and chassis ground.
Connector & terminal
Non-turbo model
(655) No. 2 (+) - Chassis ground (-):
Turbo model
(654) No. 3 (+) - Chassis ground (-):
13 CHECK INPUT SIGNAL FOR TCM. Is the voltage between approx. to step 16.
1)Open the throttle completely. 4.3 V with throttle fully open?
2)Measure the voltage between TCM connec-
tor and chassis ground.
Connector & terminal
Non-turbo model
(655) No. 2 (+) - Chassis ground (-):
Turbo model
(654) No. 3 (+) - Chassis ground (-):

AT-55
I DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
AUTOMATIC TRANSMISSION [DIAGNOSTICS)

Step Check Yes No

4 CHECK INPUT SIGNAL FOR TCM USING s the value voltage between 30 to step 15. 20 to step 18.
SUBARU SELECT MONITOR. ipprox. 0.5 V?
1)Connect the connectors to TCM, throttle
position sensor and ECM.
2)Connect the Subaru Select Monitor to data
link connector.
3)Turn the ignition switch to ON (engine OFF).
4)Turn the Subaru Select Monitor switch to ON.
5)Throttle fully closed.
6)Read the data of throttle position sensor
using Subaru Select Monitor.
*Throttle position sensor input signal is indi-
cated.
5 CHECK INPUT SIGNAL FOR TCM USING s the value voltage between 30 to step 17. i o to step 18.
SUBARU SELECT MONITOR. ipprox. 4.3 V?
Throttle fully open.
NOTE:
Must be changed correspondingly with acceler-
ator pedal operation (from “released” to “de-
pressed” position).
6 CHECK INPUT SIGNAL FOR TCM (THROT- s the voltage between 4.8 and Even if the AT OIL i o to step 18.
.- TLE POSITION SENSOR POWER SUPPLY). i.3 V? rEMP warning
Measure the voltage between TCM connector ights up, the cir-
and chassis ground. :uit has returned
Connector & terminal o a normal condi-
Non-turbo model ion at this time. A
(855)No. 1 (+) - Chassis ground (-): emporary poor
Turbo model :ontact of the con-
(B54) No. 2 (+) - Chassis ground (-): lector or harness
nay be the cause.
3epair harness or
:onnector in throt-
le position sensor
:ircuit.
7 CHECK INPUT SIGNAL FOR TCM USING s the value voltage between Even if the AT OIL i o to step 18.
SUBARU SELECT MONITOR (THROTTLE ..8 and 5.3 V? rEMP warning
POSITION SENSOR POWER SUPPLY). ights up, the cir-
Read the data of throttle position sensor power :uit has returned
supply using Subaru Select Monitor. o a normal condi-
*Throttle position sensor power supply voltage ion at this time. A
is indicated. emporary poor
:ontact of the con-
lector or harness
nay be the cause.
3epair harness or
:onnector in throt-
le position sensor
:ircuit.
8 CHECK POOR CONTACT. s there poor contact in throttle
losition sensor circuit? :ontact. <Ref. to AT-45,
Transmission Con-
trol Module

AT-56
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
3
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

E: DTC 33 FRONT VEHICLE SPEED SENSOR

DIAGNOSIS:
The vehicle speed signal is abnormal.
The circuit in combination meter is faulty.
The harness connector between TCM and vehicle speed sensor is in short or open.
TROUBLE SYMPTOM:
Erroneous idling.
Engine stalls.
Poor driving performance.

--

AT-57
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
I
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

WIRING DIAGRAM:

TCM

SHIELD AND
SENSORGROUND
JOINT CONNECTOR

I
I
I I
I I
I I
I I

..
I I
I I
I I
I

I I
1
I
I
JI
I I
I I
I I
I I
I I
I I
I
r *I

(I II COMBINATON FRONT
VEHICLE SPEED
SENSOR

A: a

TR0577

AT-58
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
I
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

Step Check Yes No

CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 20 to step 2. Repair open circuit
TCM AND TRANSMISSION. R? in harness
1)Turn the ignition switch to OFF. between TCM and
2)Disconnect the connector from TCM and transmission con-
transmission. nector.
3)Measure the resistance of harness between
TCM and transmission connector.
Connector & terminal
Non-turbo model
(B55) NO. 5 - (B11)NO. 17:
Turbo model
(B55) NO. 18 - (B11)NO. 17:
CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 30 to step 3. Repair open circuit
TCM AND TRANSMISSION. R? in harness
Measure the resistance of harness between between TCM and
TCM and transmission connector. transmission con-
Connector & terminal nector, and poor
Non-turbo model contact in cou-
(B55) NO. 21 - (Bll)NO. 18: pling connector.
Turbo model
(854) NO. 10 - (B 1 1) NO. 18:
1 CHECK HARNESS CONNECTOR BETWEEN Is the resistance more than 1 30 to step 4. Repair short circuit
TCM AND TRANSMISSION. MR? in harness
Measure the resistance of harness between between TCM and
TCM and transmission connector. transmission con-
Connector & terminal nector.
Non-turbo model
(B55) No. 21 - Chassis ground:
Turbo model
(854) No, 10 - Chassis ground:
CHECK HARNESS CONNECTOR BETWEEN Is the resistance more than 1 30 to step 5. Repair short circuit
TCM AND TRANSMISSION. MR? in harness
Measure the resistance of harness between between TCM and
TCM and transmission connector. transmission con-
Connector & terminal nector, and poor
Non-turbo model contact in cou-
(B55) No. 5 - Chassis ground: pling connector.
Turbo model
(B55) No. 18 - Chassis ground:
I CHECK FRONT VEHICLE SPEED SENSOR. Is the resistance between 450 30 to step 6. Replace the front
Measure the resistance between transmission and 650 R? vehicle speed sen.
connector receptacle's terminals. sor. <Ref. to AT-32,
'

Connector & terminal Front Vehicle

(T4) NO. 17- NO. 18: Speed Sensor.>
i PREPARE OSCILLOSCOPE. Do you have an oscilloscope? 30 to step 9. Go to step 7.
I PREPARE SUBARU SELECT MONITOR. Do you have a Subaru Select 30 to step 10. Go to step 8.
Monitor?

AT-59
I DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

Step Check Yes No

CHECK INPUT SIGNAL FOR TCM. Is the voltage more than AC 1 %en if the AT OIL 20 to step 11.
1)Connect all connectors. V? rEMP warning
2)Lift-up or raise the vehicle and place safety ights up, the cir-
stands. :uit has returned
CAUTION: o a normal condi-
On AWD models, raise all wheels off floor. ion at this time. A
3)Start the engine and set the vehicle in 20 km emporary poor
h (12 MPH) condition. :ontactor or har-
less may be the
NOTE:
The speed difference between front and real :ase. Repair har-
wheels may light the ABS warning light, but thk less or connector
indicates no malfunction. When the AT contro n the front vehicle
diagnosis is finished, perform the ABS memorq ;peed sensor cir-
clearance procedure of on-board diagnostic5 :uit.
system. <Ref. to ABS-22, Clear Memor)
Mode.>
4)Measure the voltage between TCM connec-
tor terminals.
Connector & terminal
i
Non-turbo model
(655) NO. 5 (+) - (654) NO. 21 (-):
Turbo model
(655) NO. 18 (+) - (654) NO. 10 (-):
CHECK FRONT VEHICLE SPEED SENSOR s the voltage more than AC 4 h e n if the AT OIL ;o to step 11.
USING OSCILLOSCOPE. J? rEMP warning
1)Connect all connectors. ights up, the cir-
2)Lift-up the vehicle and place safety stands. :uit has returned
CAUTION: o a normal condi-
On AWD models, raise all wheels off ion at this time. A
ground. emporary poor
3)Set the oscilloscope to TCM connector ter- :ontactor or har-
minals. less may be the
Non-turbo model :ase. Repair har-
Positive probe; (855) No. 18 less or connector
Earth lead; (B54) No. 10 Ithe front vehicle
Turbo model ;peed sensor cir-
Positive probe; (855) No. 5 :uit.
Earth lead; (854) No. 21
4)Start the engine, and drive the wheels slowly,
NOTE:
The speed difference between front and real
wheels may light the ABS warning light, but this
indicates no malfunctions.When the AT control
diagnosis is finished, perform the ABS memory
clearance procedure of self-diagnosis system.
<Ref. to ABS-22, Clear Memory Mode.>
5)Measure the signal voltage indicated on
oscilloscope.

AT-60
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
I
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

Step Check Yes No

0 CHECK INPUT SIGNAL FOR TCM USING Does the speedometer indica- Even if the AT OIL ;o to step 11.
SUBARU SELECT MONITOR. tion increase as the Subaru TEMP warning
1)Connect all connectors. Select Monitor data increases? lights up, the cir-
2)Connect the Subaru Select Monitor to data cuit has returned
link connector. to a normal condi-
3)Lift-up or raise the vehicle and place safety tion at this time. A
stands. temporary poor
CAUTION: connector or har-
On AWD models, raise all wheels off floor. ness may be the
4)Turn the ignition switch to ON and turn the case. Repair har-
Subaru Select Monitor switch to ON. ness or connector
5)Start the engine. in the front vehicle
6)Read the data of vehicle speed using Subaru speed sensor cir-
Select Monitor. cuit.
Compare the speedometer with Subaru
Select Monitor indications.
*Vehicle speed is indicated in “km/h” or “MPH”.
1)Slowly increase the vehicle speed to 60 km/h
or 37 MPH.
NOTE:
The speed difference between front and rear
wheels may light the ABS warning light, but this
indicates no malfunction. When the AT control
diagnosis is finished, perform the ABS memory
clearance procedure of on-board diagnostics
system. <Ref. to ABS-22, Clear Memory
Mode.>
1 CHECK POOR CONTACT. IS there poor contact in front Repair poor con- Replace the TCM.
vehicle speed sensor circuit? tact. <Ref. to AT-45,
Transmission Con-
trol Module
(TCM).>

AT-61
 I
DIAGNOSTIC P 3OCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
AUTOMATIC TRANSMISSI( IN (DIAGNOSTICS)

F: DTC 36 TORQUE CONVERTER TURBINE SPEED SENSOR

DIAGNOSIS:
Input signal circuit of TCM is open or shorted.
TROUBLE SYMPTOM:
Excessive shift shock.
WIRING DIAGRAM:

: NON-TURBO MODEL

: TURBO MODEL

SHIELD AND
SENSOR GROUND
JOINT CONNECTOR
r.

I
I
I
I I
I I
t
*a
4

la
1I
I
I
I
I
I
I
I

.
\
I

-
I
TORQUE
CONVERTER
TURBINE SPEED
SENSOR

TRQ570

AT-62
I DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
I
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

Step Check Yes No

I CHECK TORQUE CONVERTER TURBINE Is the resistance between 450 ;o to step 2. Replace the tur-
SPEED SENSOR. and 650 Q? bine speed sensor.
1)Turn the ignition switch to OFF. <Ref. to AT-36,
2)Disconnect the connector from transmission. Torque Converter
3)Measure the resistance between transmis- Turbine Speed
sion connector receptacle's terminals. Sensor.>
Connector & terminal
(T4) NO. 14 - NO. 15:
! CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 ;o to step 3. Repair open circuit
TCM AND TRANSMISSION. Q? in harness
1)Disconnectthe connector from TCM. between TCM and
2)Measure the resistance of harness between transmission con-
TCM and transmission connector. nector.
Connector & terminal
Non-turbo model
(B55) NO. 12 - (Bll)NO. 14:
Turbo model
-
(B55) NO. 8 (Bll)NO. 14:
t CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 $0 to step 4. Repair open circuit
TCM AND TRANSMISSION. Q? in harness
Measure the resistance of harness between between TCM and
TCM and transmission connector. transmission con-
Connector & terminal nector, and poor
Non-turbo model contact in cou-
(B55) NO. 21 - (Bll)NO. 15: pling connector.
Turbo model
(B55) NO. 9 - (B11) NO. 15:
I CHECK HARNESS CONNECTOR BETWEEN Is the resistance more than 1 ;o to step 5. Repair short circuit
TCM AND TRANSMISSION. MQ? in harness
Measure the resistance of harness between between TCM and
TCM and chassis ground. transmission con-
Connector & terminal nector.
Non-turbo model
(B55) No. 21 - Chassis ground:
Turbo model
(B55) No. 9 - Chassis ground:
I CHECK HARNESS CONNECTOR BETWEEN Is the resistance more than 1 20 to step 6. Repair short circuit
TCM AND TRANSMISSION. MQ? in harness
Measure the resistance of harness between between TCM and
TCM and chassis ground. transmission con-
Connector & terminal nector, and poor
Non-turbo model contact in cou-
(B55) No. 12 - Chassis ground: pling connector.
Turbo model
(B55) No. 8 - Chassis ground:
5 PREPARE OSCILLOSCOPE. Do you have an oscilloscope? ;o to step 10. Go to step 7.
7 PREPARE SUBARU SELECT MONITOR. Do you have a Subaru Select o
; to step 9. Go to step 8.
Monitor?

AT-63
I DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

Step Check Yes f

8 CHECK INPUT SIGNAL FOR TCM. s the voltage more than AC 1 Even if the AT OIL 20 to stc
1)Connect the connectors to TCM and trans- I? TEMP warning
mission. lights up, the cir-
2)Start the engine and move select lever to “P” cuit has returned
or “N” range. to a normal condi-
3)Measure the voltage between TCM connec- tion at this time. A
tor terminals. temporary poor
Connector & terminal contact of the con-
Non-turbo model nector or harness
(855) NO. 12 (+) - NO. 21 (-): may be the cause.
Turbo model Repair harness or
(855) NO. 8 (+) - NO. 9 (-): connector in the
TCM and trans-
mission.
9 CHECK INPUT SIGNAL FOR TCM USING s the revolution value same as Even if the AT OIL 20 to ste
SUBARU SELECT MONITOR. he tachometer reading shown TEMP warning
1)Connect the connectors to TCM and trans- In the combination meter? lights up, the cir-
mission. cuit has returned
2)Connect the Subaru Select Monitor to data to a normal condi-
link connector. tion at this time. A
3)Turn the ignition switch to ON and turn the temporary poor
r. - Subaru Select Monitor switch to ON. contact of the con-
4)Start the engine. nector or harness
5)Move the select lever to “P” or “N” range. may be the cause.
6)Read the data of turbine speed using Subaru Repair harness or
Select Monitor. connector in the
Compare the tachometer with Subaru Select TCM and trans-
Monitor indications. mission.
10 CHECK INPUT SIGNAL FOR TCM USING s the signal voltage more than Even if the AT OIL 30 to stt
OSCILLOSCOPE. 4c 1 V? TEMP warning
1)Connect the connectors to TCM and trans- lights up, the cir-
mission. cuit has returned
2)Set the oscilloscope to TCM connector ter- to a normal condi-
minals. tion at this time. A
Turbo model temporary poor
Positive probe; (B55) No. 8 contact of the con-
Earth lead; (B55) No. 9 nector or harness
Non-turbo model may be the cause.
Positive probe; (B55) No. 12 Repair harness or
Earth lead; (B55) No. 21 connector in the
3)Start the engine and move the select lever to TCM and trans-
“P” or “N” range. mission.
11 CHECK POOR CONTACT. s there poor contact in torque Repair poor con- z$5EG
:onverter turbine speed sensor tact. :Ref. to
:ircuit? rransmi:
rol Modi
I I TCM).>

AT-64
 I
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

AT-65
I DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

G: DTC 38 TORQUE CONTROL SIGNAL

DIAGNOSIS:
The signal circuit is open or shorted.
TROUBLE SYMPTOM:
Excessive shift shock.
WIRING DIAGRAM:

I : NON-TURBO MODEL

.TURBO MODEL

I TR0579

1
TCM AND ECM.
Step

1)Turnthe ignition switch to OFF.

2)Disconnect the connectors from TCM and
ECM.
3)Measure the resistance of harness between
TCM and ECM connector.
Connector & terminal
Check
CHECK HARNESSCONNECTOR BETWEEN I Is the resistance less than 1

t
Go to step 2. Repair open circuit
in harness
between TCM and
ECM connector.

Non-turbo model
(854) NO. 21 - (8134) NO. 17:
(854) NO. 13 - (8134) NO. 16:1

Turbo model
(B56) NO. 14 - (8135) NO. 18:
(856) NO. 5 -(8135) NO. 19:

AT-66
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
I
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

Step Check Yes No

CHECK HARNESS CONNECTOR BETWEEN s the resistance more than 1 Go to step 3. 3epair short circuit
TCM AND ECM. An? I harness
Measure the resistance of harness between ietween TCM and
TCM connector and chassis ground. ICM connector.
Connector & terminal
Non-turbo model
(B56) No. 21 - Chassis ground:
(854) No. 13 - Chassis ground:
Turbo model
(B56) No. 14 - Chassis ground:
(B56) No. 5 - Chassis ground:
CHECK OUTPUT SIGNAL EMITTED FROM s the voltage more than 4.8 V' Even if the AT OIL ;o to step 4.
TCM. TEMP warning
1)Connect the connectors to TCM and ECM. lights up, the cir-
2)Turn the ignition switch to ON (engine OFF). cuit has returned
3)Measure the voltage between TCM connec- to a normal condi-
tor terminals. tion at this time. A
Connector & terminal temporary poor
Non-turbo model contact of the con-
(B54) No. 21 (+) - Chassis ground (-): nector or harness
(B54) No. 13 (+) - Chassis ground (-): may be the cause.
Turbo model Repair harness or
(B56) No. 14 (+) - Chassis ground (-): connector in the
(B56) No. 5 (+) - Chassis ground (-): TCM and ECM.
I CHECK POOR CONTACT. s there poor contact in torque Repair poor con- ;o to step 5.
:ontrol signal circuit? tact.
1 CHECK GROUND LINE BETWEEN TRANS- s there any dirt or rust at Remove dirt and ;o to step 6.
MISSION AND BODY. lround line installing point? rust.
Check the installing condition of ground line in
transmission and body.
i CHECK GROUND LINE BETWEEN TRANS- s the tightening torque value Go to step 7. 7ghten to speci-
MISSION AND BODY. vithin specification? ied torque.
Check the installing condition of ground line in
transmission and body.
Tightening torque:
13f3 N.m (1.3i0.3 kgf-m, 9.4i9.2 ft-lb)
, CHECK GROUND LINE INSIDE TRANSMIS- s the tightening torque value Go to step 9. 7ghten to speci-
SION. vithin specification? ied torque.
1)Drain the AT fluid and remove the oil pan.
2)Check the tightening torque value of ground
line installing bolt.
Tightening torque:
T: Bfl N-m (O.BiO.l kgf-m, 5.8i0.7 ft-lb)
I CHECK GROUND CIRCUIT OF ECM. s there any trouble? Repair ground ter- So to step 9.
<Ref. to AT-52, DTC 31 THROTTLE POSITION minal and/or
SENSOR, Diagnostic Procedure with Diagnos, ground circuit of
tic Trouble Code (DTC).> ECM.
1 RECHECK OUTPUT SIGNAL EMITTED s each voltage more than 4.8 Replace the TCM. 3eplace the ECM.
FROM TCM. I? <Ref. to AT-45,
Measure the voltage between TCM connector Transmission Con-
and chassis ground. trol Module
Connector & terminal (TCM).>
Non-turbo model
(B54) No. 21 (+) - Chassis ground (-):
(B54) No. 13 (+) - Chassis ground (-):
Turbo model
(B56) No. 14 (+) - Chassis ground (-):
(B56) No. 5 (+) - Chassis ground (-):

AT-67
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
I
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

H: DTC 45 INTAKE MANIFOLD PRESSURE SIGNAL

DIAGNOSIS:
Input signal circuit of TCM from ECM is open or shorted.
TROUBLE SYMPTOM:
Excessive shift shock.
WIRING DIAGRAM:

TR0580

~~

Step Check Yes No

1 CHECK ENGINE GROUND TERMINALSAND Is there any trouble? Repair ground ter- Go to step 2.
GROUND CIRCUIT OF ECM minal and/or
<Ref. to AT-52, DTC 31 THROTTLE POSITION ground circuit of
SENSOR, Diagnostic Procedure with Diagnos- ECM.
tic Trouble Code (DTC).>
2 CHECK HARNESSCONNECTOR BETWEEN Is the resistance less than 1 Go to step 3. Repair open circuit
TCM AND ECM. n? in harness
1)Turn the ignition switch to OFF. between TCM and
2)Disconnect the connectors from TCM and
ECM.
3)Measure the resistance of harness between
TCM and ECM connector.
Connector 81terminal
(B55)NO. 20 -(8136) NO. 11:
3 CHECK HARNESSCONNECTOR BETWEEN
TCM AND ECM. in harness
Measure the resistance of harness between between TCM and
TCM connector and chassis ground. ECM connector.
Connector & terminal
(B55)No. 20 - Chassis ground:
1 PREPARE SUBARU SELECT MONITOR. Do you have a Subaru Select Go to step 6. Go to step 5.
Monitor?

AT-68
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) I
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

Step Check Yes No

CHECK INPUT SIGNAL FOR TCM. s the voltage between 1.2 and Even if the AT OIL 30 to step 7.
1)Connect the connectors to TCM and ECM. i.8 V? TEMP warning
2)Start the engine, and warm-up the transmis- lights up, the cir-
sion until the ATF temperature is above 80°C cuit has returned
(176°F). to a normal condi-
NOTE: tion at this time. A
If ambient temperature is below 0°C (32"F), temporary poor
drive the vehicle until the ATF reaches its oper- contact of the con-
ating temperature. nector or harness
3)Engine idling. may be the cause.
4)Measure the voltage between TCM connec- Repair harness or
tor and chassis ground. connector in the
Connector & terminal TCM and ECM.
(855) No. 20 (+) - Chassis ground (-):
CHECK INPUT SIGNAL FOR TCM USING s the value between 1.2 and Even if the AT OIL o ; to step 7.
SUBARU SELECT MONITOR. 1.8 V? TEMP warning
1)Connect the connectors to TCM and ECM. lights up, the cir-
2)Connect the Subaru Select Monitor to data cuit has returned
link connector. to a normal condi-
3)Start the engine, and turn the Subaru Select tion at this time. A
monitor switch to ON. temporary poor
4)Warm-up the engine until the engine coolant contact of the con-
temperature is above 80°C (176°F). nector or harness
5)Engine idling. may be the cause.
6)Read the data of intake manifold pressure Repair harness or
signal using Subaru Select Monitor. connector in the
*Display shows the intake manifold pressure TCM and ECM.
signal value sent from ECM.
CHECK POOR CONTACT.
<Ref. to AT-45,
%it? Transmission Con-
trol Module

AT-69
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
I
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

I: DTC 71 SHIFT SOLENOID 1

DIAGNOSIS:
Output signal circuit of shift solenoid 1 is open or shorted.
TROUBLE SYMPTOM:
Does not shift.
WIRING DIAGRAM:

TRANSMISSION

TR0581

AT-70
I DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
I
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

Step Check Yes No

CHECK HARNESS CONNECTOR BETWEEN j the resistance less than 1 ;o to step 2. iepair open circuit
TCM AND TRANSMISSION. 1? 1 harness
1)Turn the ignition switch to OFF. letween TCM and
2)Disconnect the connector from TCM and *ansmissioncon-
transmission. lector.
3)Measure the resistance of harness between
TCM and shift solenoid 1 connector.
Connector & terminal
Non-turbo model
(854) NO. 7 - (B 1 1) NO. 1:
Turbo model
(B54) NO.22 - (B1 1) NO. 1:
CHECK HARNESS CONNECTOR BETWEEN 3 the resistance more than 1 ;o to step 3. iepair short circuit
TCM AND TRANSMISSION. An? i harness
Measure the resistance of harness between letween TCM and
TCM connector and chassis ground. ransmission con-
Connector & terminal lector.
Non-turbo model
(B54) No. 7 - Chassis ground:
Turbo model
(B54) No. 22 - Chassis ground:
b CHECK SHIFT SOLENOID 1. s the resistance between 10 30 to step 4. ;o to step 7.
Measure the resistance between transmission ind 16 Q?
connector terminals.
Connector & terminal
(T4) NO. 1 - NO. 16:
I CHECK OUTPUT SIGNAL EMITTED FROM s the voltage more than 9V? 30 to step 5. ;o to step 6.
TChk
1)Connect the connectors to TCM and trans-
mission.
2)Turn the ignition switch to ON (engine OFF).
3)Move the select lever to “ D range.
4)Measure the voltage between TCM connec-
tor and chassis ground.
Connector & terminal
Non-turbo model
(B54) No. 7 (+) - Chassis ground (-):
Turbo model
(B54) No. 22 (+) - Chassis ground (-):
1 CHECK OUTPUT SIGNAL EMIlTED FROM s the voltage less than l V ? Even if the AT OIL 20 to step 6.
TCM. rEMP warning
1)Move the select lever to “ 2 range. ights up, the cir-
2)Measure the voltage between TCM connec- :uit has returned
tor and chassis ground. :o a normal condi-
Connector & terminal :ion at this time. A
Non-turbo model :emporary poor
(854) No. 7 (+) - Chassis ground (-): :ontact of the con.
Turbo model lector or harness
(B54) No. 22 (+) - Chassis ground (-): nay be the cause.
qepair harness or
:ontact in the
TCM.
i CHECK POOR CONTACT. s there poor contact in shift Repair poor con- 3eplace the TCM.
;olenoid 1 circuit? :act. :Ref. to AT-45,
rransmission Con,
rol Module
TCM).>

AT-71
I DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
AUTOMATIC TRANSMISSION [DIAGNOSTICSI

Step Check Yes No

r CHECK SHIFT SOLENOID 1 (IN TRANSMIS- s the resistance between 10 Go to step 8. 3eplace the shift
SION). ind 16 Q? ;olenoid 1. <Ref.
1)Remove the transmission connector from o AT-39, Shift
bracket. Solenoids, Duty
2)Lift-up or raise the vehicle and support with Solenoids and ATF
safety stand. remperature Sen-
CAUTION: ior.>
On AWD models, raise all wheels off
ground.
3)Drain the automatic transmission fluid.
CAUTION:
Do not drain the automatic transmission flu-
id until it cools down.
4)Remove the oil pan, and disconnect the con-
nector from shift solenoid 1.
5)Measure the resistance between shift sole-
noid 1 connector and transmission ground.
Terminal
No. 1 - Transmissionground:
I CHECK HARNESS CONNECTOR BETWEEN s the resistance less than 1 [Go to step 9. 3epair open circuit
SHIFT SOLENOID 1 AND TRANSMISSION. 2? n harness
.. Measure the resistance of harness between )etween shift sole-
shift solenoid 1 and transmission connector. ioid 1 and trans-
Connector & terminal nission connector.
(AT5) NO. 1 - (T4) NO. 1:
1 CHECK HARNESS CONNECTOR BETWEEN s the resistance more than 1 Even if the AT OIL 3epair short circuit
SHIFT SOLENOID 1 AND TRANSMISSION. An? TEMP warning iarness between
Measure the resistance of harness between lights up, the cir- ;hift solenoid 1
shift solenoid 1 connector and transmission cuit has returned ind transmission
ground. to a normal condi- :onnector.
Connector & terminal tion at this time. A
(T4) No. 1 - Transmissionground: temporary poor
contact of the con-
nector or harness
may be the cause.
Repair harness or
connector in shift
solenoid 1 and
transmission.

AT-72
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

r.

AT-73
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

J: DTC 72 SHIFT SOLENOID 2

DIAGNOSIS:
Output signal circuit of shift solenoid 2 is open or shorted.
TROUBLE SYMPTOM:
Does not shift.
WIRING DIAGRAM:

<
z (D

m v)
I-

TR0582

AT-74
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
1
AUTOMATIC TRANSMISSION (DIAGNOSTICS)
~~

Step Check Yes No

CHECK HARNESSCONNECTOR BETWEEN s the resistance less than 1 ;o to step 2. 3epair open circuit
TCM AND TRANSMISSION. l? n harness
1)Turn the ignition switch to OFF. letween TCM and
2)Disconnect the connector from TCM and ransmission con-
transmission. lector.
3)Measure the resistance of harness between
TCM and shift solenoid 2 connector.
Connector & terminal
Non-turbo model
(654) NO. 6 - (611) NO. 2:
Turbo model
(B54) NO. 5 - (611) NO. 2:
! CHECK HARNESSCONNECTOR BETWEEN s the resistance more than 1 30 to step 3. 3epair short circuit
TCM AND TRANSMISSION. VlQ? n harness
Measure the resistance of harness between letween TCM and
TCM connector and chassis ground. ransmission con-
Connector & terminal lector.
Non-turbo model
(654) No. 6 - Chassis ground:
Turbo model
(654) No. 5 - Chassis ground:
1- CHECK SHIFT SOLENOID 2. s the resistance between 10 30 to step 4. 30 to step 6.
Measure the resistance between transmission ind 16 Q?
connector terminals.
connector & terminal
(T4) NO.2 - NO. 16:

AT-75
I DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
AUTOMATIC TRANSMISSION (DIAGNOSTICS)
~~

Step Check Yes No

I CHECK OUTPUT SIGNAL EMITTED FROM I Is the voltage less than 1 V? Even if the AT OIL 30 to step 5.
TCM. TEMP warning
1)Connect the connectors to TCM and trans- lights up, the cir-
mission. suit has returned
2)Lift-up or raise the vehicle and support with to a normal condi-
safety stand. tion at this time. A
CAUTION: temporary poor
On AWD models, raise all wheels off :ontact of the con-
ground. lector or harness
3)Start the engine and warm-up the transmis- nay be the cause.
sion until the ATF temperature is above 80°C 3epair harness or
(176°F). :onnector in the
NOTE: TCM and trans-
If the ambient temperature is below 0°C (32°F) nission.
drive the vehicle until the ATF reaches its oper
ating temperature.
4)Move the selector lever to “D”, and slowly
increase the vehicle speed to 50 km/h (31
MPH).
NOTE:
The speed difference between front and real
wheels may light the ABS warning light, but thi:
indicates no malfunction. When the AT contro
diagnosis is finished, perform the ABS memo0
clearance procedure of on-board diagnostics
system. <Ref. to ABS-22, Clear Memor)
Mode.>
5)Measure the voltage between TCM connec-
tor and chassis ground.
Connector & terminal
Non-turbo model
(654) No. 6 (+) - Chassis groundI)-(
Turbo model
(654) No. 5 (+) - Chassis ground (-):
CHECK POOR CONTACT. IS there poor contact in shift 3eoair Door con-
-3.- I----- denlace the TCM
I. . - ~ .
solenoid 2 circuit? act. <Ref. to AT-45,
Transmission Con.
trol Module
(TCM).>
CHECK SHIFT SOLENOID 2 (IN TRANSMIS- Is the resistance between 10 $0to step 7. Replace the shift
SION). and 16 !2? solenoid 2 assem-
1)Remove the transmission connector from bly. <Ref. to AT-39
bracket. Shift Solenoids,
2)Drain the automatic transmission fluid. Duty Solenoids
CAUTION: and ATF Tempera-
Do not drain the automatic transmission flu- ture Sensor.>
id until it cools down.
3)Remove the oil pan, and disconnect the con-
nector from shift solenoid 2.
4)Measure the resistance between shift sole-
noid 2 connector and transmission ground.
Connector & terminal
No. 1 - Transmissionground:
CHECK HARNESS CONNECTOR BETWEEN s the resistance less than 1
SHIFT SOLENOID 2 AND TRANSMISSION. R? in harness
Measure the resistance of harness between between shift sole.
shift solenoid 2 and transmission connector. noid 2 and trans-
Connector & terminal mission connector,
(AT6) NO. 1 - (T4) NO.2:

AT-76
I DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) I
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

Step Check Yes

I CHECK HARNESS CONNECTOR BETWEEN s the resistance more than 1 Even if the AT OIL
SHIFT SOLENOID 2 AND TRANSMISSION. An? TEMP warning harness between
Measure the resistance of harness between lights up, the cir- shift solenoid 2
shift solenoid 2 connector and transmission cuit has returned and transmission
ground. to a normal condi- connector.
Connector & terminal
i tion at this time. A
(T4) No. 2 - Transmissionground: temporary poor
contact of the con-
nector or harness
may be the cause.
Repair harness or
connector in shift
solenoid 2 and
transmission.

-. .

AT-77
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

K: DTC 73 LOW CLUTCH TIMING SOLENOID

DIAGNOSIS:
Output signal circuit of low clutch timing solenoid is open or shorted.
TROUBLE SYMPTOM:
Excessive shift shock.
WIRING DIAGRAM:

TCM

I
LOW CLUTCH
TIMING
SOLENOID

TRANSMISSION

AT-78
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) I
AUTOMATIC TRANSMISSION (DIAGNOSTICS)
~

Step Check Yes No

CHECK HARNESSCONNECTOR BETWEEN s the resistance less than 1 o
; to step 2. 3epair open circuit
TCM AND TRANSMISSION. 2? n harness
1)Turn the ignition switch to OFF ietween TCM and
2)Disconnect the connector from TCM and .ransmissioncon-
transmission. lector.
3)Measure the resistance of harness between
TCM and transmission connector.
Connector & terminal
Non-turbo model
(954) NO. 14 - (91 1) NO. 3:
Turbo model
(954) NO. 15 - (91 1) NO. 3:
CHECK HARNESS CONNECTOR BETWEEN Is the resistance more than 1 30 to step 3. 3epair short circuit
TCM AND TRANSMISSION. MR? n harness
Measure the resistance of harness between 3etween TCM and
TCM connector and transmission ground. transmission con-
Connector & terminal nector.
Non-turbo model
(954) No. 14 - Chassis ground:
Turbo model
(B54) No. 15 - Chassis ground:
CHECK LOW CLUTCH TIMING SOLENOID. Is the resistance between 10 30 to step 4. Go to step 7.
Measure the resistance between transmission and 16 R?
connector terminals.
Connector & terminal
(T4) NO. 3 - NO. 16:
CHECK OUTPUT SIGNAL EMITTED FROM Is the voltage more than 9V? 30 to step 5. Go to step 6.
TCM.
1)Connect the connectors to TCM and trans-
mission.
2)Turn the ignition switch to ON (engine OFF).
3)Move the select lever to “ D range.
4)Measure the voltage between TCM connec-
tor and chassis ground.
Connector & terminal
Non-turbo model
(854) No. 14 (+) - Chassis ground (-):
Turbo model
(954) No. 15 (+) - Chassis ground (-):
CHECK OUTPUT SIGNAL EMITTED FROM Is the voltage less than 1V? Even if the AT OIL Go to step 6.
TCM. TEMP warning
1)Move the select lever to “ 2 range. lights up, the cir-
2)Measure the voltage between TCM connec- cuit has returned
tor and chassis ground. to a normal condi-
Connector & terminal tion at this time. A
Non-turbo model temporary poor
(954) No. 14 (+) - Chassis ground (-): contact of the con-
Turbo model nector or harness
(954) No. 15 (+) - Chassis ground (-): may be the cause.
Repair harness or
contact in the TCM
and transmission.
1 CHECK POOR CONTACT. Is there poor contact in low Repair poor con- Replace the TCM.
clutch timing solenoid circuit? tact. <Ref. to AT-45,
Transmission Con
trol Module
(TCM).>

AT-79
I DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

Step Check Yes No

r CHECK LOW CLUTCH TIMING SOLENOID s the resistance between 10 i o to step 8. 3eplace the low
(IN TRANSMISSION). md 16 R? :lutch timing sole-
1)Remove the transmission connector from ioid. <Ref. to AT-
bracket. 39,Shift Sole-
2)Lift-up or raise the vehicle and support with ioids, Duty Sole-
safety stands. ioids and ATF
CAUTION: remperature Sen-
On AWD models, raise all wheels off ior.>
ground.
3)Drain the automatic transmission fluid.
CAUTION:
Do not drain the automatic transmission flu-
id until it cools down.
4)Remove the oil pan, and disconnect the con-
nector from low clutch timing solenoid.
5)Measure the resistance between low clutch
timing solenoid connector and transmission
ground.
Terminal
No. 1 - Transmission ground:
I CHECK HARNESSCONNECTOR BETWEEN s the resistance less than 1 i o to step 9. 3epair open circuit
LOW CLUTCH TIMING SOLENOID AND 2? n harness
TRANSMISSION. )etween low clutch
Measure the resistance of harness between iming solenoid
low clutch timing solenoid and transmission md transmission
connector. :onnector.
Connector & terminal
(ATS) NO. 7 - (T4) NO. 3:
1 CHECK HARNESSCONNECTOR BETWEEN s the resistance more than 1 hen if the AT OIL 3epair short circuit
LOW CLUTCH TIMING SOLENOID AND dR? -EMP warning iarness between
TRANSMISSION. ghts up, the cir- OW clutch timing
Measure the resistance of harness between :uit has returned ;olenoid and
low clutch timing solenoid connector and trans- 3 a normal condi- ransmission con-
mission ground. ion at this time. A lector.
Connector & terminal smporary poor
(T4) No. 3 - Transmission ground: :ontact of the con-
iector or harness
nay be the cause.
lepair harness or
:onnector in low
:lutchtiming sole-
ioid and transmis-
,ion.

AT-80
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) I
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

r.

AT-81
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) 1
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

L: DTC 74 2-4 BRAKE TIMING SOLENOID

DIAGNOSIS:
Output signal circuit of 2-4 brake timing solenoid is open or shorted.
TROUBLE SYMPTOM:
Excessive shift shock.
WIRING DIAGRAM:

I
2-4 BRAKE
TIMING
SOLENOID

TRANSMISSION

TR0584

AT-82
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
I
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

Step Check
CHECK HARNESSCONNECTOR BETWEEN Is the resistance less than 1 ) to step 2.
in harness
between TCM and
1)Turnthe ignition switch to OFF.
transmission con-
2)Disconnect the connector from TCM and
nector.
transmission.
3)Measure the resistance of harness between
TCM and transmission connector.
Connector & terminal
Non-turbo model
(B54) NO. 5- (B11) NO. 4:
Turbo model
(854) NO. 16 - (81I ) NO. 4:
CHECK HARNESSCONNECTOR BETWEEN Is the resistance more than 1
MQ? in harness
TCM AND TRANSMISSION.
between TCM and
Measure the resistance of harness between

+---
transmission con-
TCM connector and transmission ground.
nector.
Connector & terminal
Non-turbo model
(854) No. 5 - Chassis ground:
Turbo model
(B54) No. 16 - Chassis ground:
Is the resistance between 10 o to step 4. Go to step 7.
CHECK 2-4 BRAKE TIMING SOLENOID.
Measure the resistance between transmission and 16 Q?
connector terminals.
Connector & terminal

CHECK OUTPUT SIGNAL EMllTED FROM 1 Is the voltage less than 1 V?

TCM.
1)Connect the connectors to TCM and trans-
mission.
2)Lift-up or raise the vehicle and support with
safety stands.
CAUTION:
On AWD models, raise all wheels off
ground.
3)Start the engine and warm-up the transmis-
sion until the ATF temperature is above 80°C
(176°F).
NOTE:
If the ambient temperature is below 0°C (32°F)
drive the vehicle until the ATF reaches its oper,
ating temperature.
4)Move the select lever to “l”,and slowly
increase vehicle speed to 10 km/h (6 MPH).
NOTE:
The speed difference between front and rea
wheels may light the ABS warning light, but thi!
indicates no malfunction. When the AT contrc
diagnosis is finished, perform the ABS memo?
clearance procedure of on-board diagnostic!
system. <Ref. to ABS-22, Clear Memor
Mode.>
5)Measure the voltage between TCM connec-
tor and chassis ground.
Connector & terminal
Non-turbo model
(B54) No. 5 (+) - Chassis ground (-):
Turbo model
(B54) No. 76 (+) - Chassis ground (-):

AT-83
I DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

Step Check Yes No

1 CHECK OUTPUT SIGNAL EMITTED FROM I Is the voltage more than 9 V? Zven if the AT OIL 30 to step 6.
TCM. rEMP warning
1)Move the select lever to “D”, and slowly ights up, the cir-
increase vehicle speed to 65 km/h (40 MPH). :uit has returned
NOTE: o a normal condi-
The speed difference between front and rear ion at this time. A
wheels may light the ABS warning light, but this emporary poor
indicates no malfunction. When the AT control :ontact of the con-
diagnosis is finished, perform the ABS memory lector or harness
clearance procedure of on-board diagnostics nay be the cause.
system. <Ref. to ABS-22, Clear Memory qepair harness or
Mode.> :ontact in the
2)Measure the voltage between TCM connec- ransmission.
tor and chassis ground.
Connector & terminal
Non-turbo model
(854) No. 5 (+) - Chassis ground (-):
Turbo model
(B54) No. 16 (+) - Chassis ground (-):
I CHECK POOR CONTACT. Is there poor contact in 2-4 3epair poor con- Replace the TCM.
brake timing solenoid circuit? act. <Ref. to AT-45,
Transmission Con.
trol Module
(TCM).>
I
CHECK 2-4 BRAKE TIMING SOLENOID (IN I Is the resistance between 10 30 to step 8. Replace the 2-4
TRANSMISSION). and 16 R? brake timing sole-
1)Remove the transmission connector from noid. <Ref. to AT-
‘20 ChiH Crrln.
bracket.
2)Lift-up or raise the vehicle and support with noids, Duty Sole-
safety stands. noids and ATF
CAUTION: Temperature Sen-
On AWD models, raise all wheels off sor.>
ground.
3)Drain the automatic transmission fluid. I

CAUTION:
Do not drain the automatic transmission flu,
id until it cools down.
4)Remove the oil pan,.and disconnect the con-
nector from 2-4 brake timing solenoid.
5)Measure the resistance between 2-4 brake
timing solenoid connector and transmission
ground.
Terminal
No. 1 - Transmission ground:
I CHECK HARNESSCONNECTOR BETWEEN Is the resistance less than 1 30 to step 9. Repair open circuit
2-4 BRAKE TIMING SOLENOID AND R? in harness
TRANSMISSION. between 2-4 brake
Measure the resistance of harness between 2- timing solenoid
4 brake timing solenoid and transmission con- and transmission
nector. connector.
Connector & terminal
(AT8) NO. 1 - (T4) NO. 4:

AT-84
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) 1
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

Step Check Yes No

9 CHECK HARNESSCONNECTOR BETWEEN Is the resistance more than 1 Even if the AT OIL Repair short circuit
2-4 BRAKE TIMING SOLENOID AND MR? TEMP warning harness between
TRANSMISSION. lights up, the cir- 2-4 brake timing
Measure the resistance of harness between 2- cuit has returned solenoid and
4 brake timing solenoid connector and trans- to a normal condi- transmission con-
mission ground. tion at this time. A nector.
Connector & terminal temporary poor
(T4) No. 4 - Transmissionground: contact of the con-
nector or harness
may be the cause.
Repair harness or
connector in 2-4
brake timing sole-
noid and transmis-
sion.

AT-85
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
I
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

M: DTC 75 LINE PRESSURE DUTY SOLENOID

DIAGNOSIS:
Output signal circuit of line pressure duty solenoid is open or shorted.
TROUBLE SYMPTOM:
Excessive shift shock.
WIRING DIAGRAM:

: NON-TURBO MODEL

U
DROPPING
RESISTOR

Ir""lB L

TRANSMISSION

TR0585

Step Check Yes No

I CHECK VEHICLE. - I
Go to step 7.
! CHECK RESISTOR. s the resistance between 9 I Go to step 3. Replace the drop-
1)Turn the ignition switch to OFF. ping resistor. <Ref.
2)Disconnect the connector from dropping to AT-46, Dropping
resistor. Resistor.>
3)Measure the resistance between dropping
resistor terminal.
Terminals
NO. 1 -NO. 2:

AT-86
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) I
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

Step Check Yes No

3 CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 i o to step 4. Repair open circuit
TCM AND DROPPING RESISTOR. n? in harness
1)Disconnectthe connector from TCM. between TCM and
2)Measure the resistance of harness between dropping resistor
TCM connector and dropping resistor connec- connector.
tor.
Connector & terminal
(B54) NO. 18 - (84) NO. 1:
4 CHECK HARNESS CONNECTOR BETWEEN Is the resistance more than 1 ;o to step 5. Repair short circuit
TCM AND DROPPING RESISTOR. MR? in harness
Measure the resistance of harness between between TCM and
dropping resistor connector and chassis dropping resistor
ground. connector.
Connector & terminal
(B4) No. 1 - Chassis ground:
5 CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 ;o to step 6. Repair open circuit
TRANSMISSION AND DROPPING RESIS- Q? in harness
TOR. between dropping
1 )Disconnect the connector from transmission. resistor and trans-
2)Measure the resistance of harness between mission connector.
transmission and dropping resistor connector.
Connector & terminal
(B4) NO. 2 - ( B l l ) NO. 5:
6 CHECK HARNESSCONNECTOR BETWEEN Is the resistance more than 1 ;o to step 7. Repair short circuit
TRANSMISSION AND DROPPING RESIS- MQ? in harness
TOR. between dropping
Measure the resistance of harness between resistor and trans-
dropping resistor connector and chassis mission connector.
I
ground.
Connector & terminal
(B4) No. 2 - Chassis ground:
7 CHECK HARNESSCONNECTOR BETWEEN Is the resistance less than 1 i o to step 8. Repair open circuit
TCM AND TRANSMISSION. n? in harness
1)Turn the ignition switch to OFF. between TCM and
2)Disconnect the connector from transmission transmission con-
and TCM. nector.
3)Measure the resistance of harness between
TCM and transmission connector.
Connector & terminal
-
(B54) NO. 9 (B1 1) NO. 5:
8 CHECK HARNESSCONNECTOR BETWEEN Is the resistance more than 1 ;o to step 9. Repair short circuit
TCM AND CHASSIS GROUND. MR? in harness
Measure the resistance of harness between between TCM and
TCM and chassis ground. transmission con-
Connector & terminal nector.
(B54) No. 9 - Chassis ground:
9 CHECK LINE PRESSURE DUTY SOLENOID. Is the resistance between 2.0 20 to step 10. Go to step 16.
Measure the resistance between transmission and 4.5 R?
connector receptacle's terminals.
Terminal
(T4) NO. 5 - NO. 16:
10 PREPARE SUBARU SELECT MONITOR. Do you have a Subaru Select ;o to step 13. Go to step 11.
Monitor?

AT-87
I DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

Step Check Yes No

1 CHECK OUTPUT SIGNAL EMITTED FROM s the voltage between 1.5 and Go to step 12. ;o to step 15.
TCM.
1)Connect all connectors.
2)Start the engine and warm-up the transmis-
sion until the ATF temperature is above 80°C
(176°F).
NOTE:
If the ambient temperature is below 0°C (32°F:
drive the vehicle until the ATF reaches its ope1
ating temperature.
3)Turn the ignition switch to ON (engine OFF).
4)Move the select lever to “N”.
5)Measure the voltage between TCM connec-
tor and chassis ground.
Connector & terminal
(854) No. 9 (+) - Chassis ground (-):
-
2 CHECK OUTPUT SIGNAL EMITTED FROM s the voltage less than 1 V Even if the AT OIL ;o to step 15.
TCM. iith throttle fully open? TEMP warning
Measure the voltage between TCM connector lights up, the cir-
and chassis ground. cuit has returned
Connector & terminal to a normal condi-
.. ~
(B54) No. 9 (+) - Chassis ground (-): tion at this time. A
temporary poor
contact of the con-
nector or harness
may be the cause.
Repair harness or
connector in trans-
mission.
3 CHECK OUTPUT SIGNAL EMITTED FROM j the value 1OO%? Go to step 14. io to step 15.
TCM USING SUBARU SELECT MONITOR.
1)Connect the connectors to TCM and trans-
mission.
2)Connect the Subaru Select Monitor to data
link connector.
3)Start the engine, and turn the Subaru Select
Monitor switch to ON.
4)Warm-up the transmission until the ATF tem.
perature is above 80°C (176°F).
NOTE:
If the ambient temperature is below 0°C (32°F)
drive the vehicle until the ATF reaches its oper
ating temperature.
5)Stop the engine and turn the ignition switch
to ON (engine OFF).
6)Move the select lever to “N”.
7)Read the data of line pressure duty solenoid
using Subaru Select Monitor.
*Line pressure duty solenoid is indicated in
“o/o”,

1)Throttle is fully closed.

AT-88
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
I
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

Step Check Yes No

4 CHECK OUTPUT SIGNAL EMITTED FROM s the value less than 25%? lven if the AT OIL ;o to step 15.
TCM USING SUBARU SELECT MONITOR. 'EMP warning
1)Turnthe ignition switch to ON (Engine OFF). ghts up, the cir-
2)Throttle is fully open. uit has returned
3 a normal condi-
on at this time. A
zmporary poor
ontact of the con-
lector or harness
lay be the cause.
iepair harness or
onnector in trans-
nission.
5 CHECK POOR CONTACT. s there poor contact in line Iepair poor con- 3eplace the TCM.
)ressure duty solenoid circuit? act. :Ref. to AT-45,
rransmissionCon-
rol Module
TCM).>
6 CHECK LINE PRESSURE DUTY SOLENOID s the resistance between 2.0 io to step 17. 3eplace the line
(IN TRANSMISSION). ind 4.5 Q? )ressure duty
1)Remove the transmission connector from ;olenoid. <Ref. to
bracket. 4T-39, Shift Sole-
2)Drain the automatic transmission fluid. ioids, Duty Sole-
CAUTION: \aids and ATF
Do not drain the automatic transmission flu- Temperature Sen-
id until it cools down. ;or.>
3)Remove the oil pan, and disconnect the con-
nector from line pressure duty solenoid.
4)Measure the resistance between line pres-
sure duty solenoid connector and transmission
ground.
Terminal
No. 1 - Transmissionground:
17 CHECK HARNESSCONNECTOR BETWEEN s the resistance less than 1 ;o to step 18. 3epair open circuit
TRANSMISSION AND LINE PRESSURE a? n harness
DUTY SOLENOID. )etween line pres-
Measure the resistance of harness between jure duty solenoid
line pressure duty solenoid and transmission md transmission
connector. :onnector.
Connector & terminal
(T4) NO. 5 - (AT2) NO. 1:
18 CHECK HARNESS CONNECTOR BETWEEN s the resistance more than 1 iven if the AT OIL 3epair short circuit
TRANSMISSION AND LINE PRESSURE dQ? -EMP warning n harness
DUTY SOLENOID. ghts up, the cir- jetween line pres-
Measure the resistance of harness between :uit has returned ;ure duty solenoid
transmission connector and transmission D a normal condi- ind transmission
ground. ion at this time. A :onnector.
Connector & terminal emporary poor
(T4) No. 5 - Transmissionground: :ontact of the con-
lector or harness
nay be the cause.
3epair harness or
:onnector in line
)ressure duty
;olenoid and
ransmission.

AT-89
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

N: DTC 76 2-4 BRAKE DUTY SOLENOID

DIAGNOSIS:
Output signal circuit of 2-4 brake duty solenoid is open or shorted.
TROUBLE SYMPTOM:
Excessive shift shock.
WIRING DIAGRAM:

$ m
I-
m a
2

Ey*-
_.
SOLENOID
~

TI30586

Step Check Yes No

1 CHECK VEHICLE. Is the target non-turbo model? Go to step 2. Go to step 7.
2 CHECK RESISTOR. Is the resistance between 9 Go to step 3. Replace the drop-
1)Turnthe ignition switch to OFF. and 15 Q? ping resistor. <Ref.
2)Disconnect the connector from dropping to AT-46, Dropping
resistor. Resistor.>
3)Measure the resistance between dropping
resistor terminal.
Terminals
NO. 3 - NO. 4:

AT-90
 I
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
AUTOMATIC TRANSMISSION (DIAGNOSTICS)
~~~ ~~

Step Check Yes No

CHECK HARNESSCONNECTOR BETWEEN s the resistance less than 1 Go to step 4. Repair open circuit
TCM AND DROPPING RESISTOR. 2? in harness
1)Disconnectthe connector from TCM. between TCM and
2)Measure the resistance of harness between dropping resistor
TCM connector and dropping resistor connec- connector.
tor.
Connector & terminal
(B54) NO. 17 - (B4) NO. 3:
CHECK HARNESSCONNECTOR BETWEEN s the resistance more than 1 Go to step 5. Repair short circuit
TCM AND DROPPING RESISTOR. VlQ? in harness
Measure the resistance of harness between between TCM and
dropping resistor connector and chassis dropping resistor
ground. connector.
Connector & terminal
(B4) No. 3 - Chassis ground:
CHECK HARNESS CONNECTOR BETWEEN s the resistance less than 1 Go to step 6. Repair open circuit
TRANSMISSION AND DROPPING RESIS- n? in harness
TOR. between dropping
1)Disconnect the connector from transmission. resistor and trans-
2)Measure the resistance of harness between mission connector.
transmission and dropping resistor connector.
Connector & terminal
(B4) NO. 4 - ( B l l ) NO. 9:
CHECK HARNESSCONNECTOR BETWEEN s the resistance more than 1 Go to step 7. Repair short circuit
TRANSMISSION AND DROPPING RESIS- Ua? in harness
TOR. between dropping
Measure the resistance of harness between resistor and trans-
dropping resistor connector and chassis mission connector.
ground.
Connector & terminal
(B4) No. 4 - Chassis ground:
CHECK HARNESS CONNECTOR BETWEEN s the resistance less than 1 Go to step 8. Repair open circuit
TCM AND TRANSMISSION. n? in harness
1)Turnthe ignition switch to OFF. between TCM and
2)Disconnect the connector from transmission transmission con-
and TCM. nector.
3)Measure the resistance of harness between
TCM and transmission connector.
Connector & terminal
Non-turbo model
(B54) NO. 8 - ( B l l ) NO. 9:
Turbo model
(B54) NO. 18 - ( B l l ) NO. 9:
CHECK HARNESS CONNECTOR BETWEEN Is the resistance more than 1 Go to step 9. Repair short circuii
TCM AND CHASSIS GROUND. Ma? in harness
Measure the resistance of harness between between TCM and
TCM and chassis ground. transmission con-
Connector & terminal nector.
Non-turbo model
(B54) No. 8 - Chassis ground:
Turbo model
(B54) No. 18 - Chassis ground:
CHECK 2-4 BRAKE DUTY SOLENOID. Is the resistance between 2.0 Go to step 10. Go to step 16.
Measure the resistance between transmission and 4.5 R?
connector receptacle's terminals.
Terminal
(T4) NO. 16 - NO. 9:
I PREPARE SUBARU SELECT MONITOR. Do you have a Subaru Select Go to step 13. Go to step 11.
Monitor?

AT-9 1
I DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
AUTOMATIC TRANSMISSION (DIAGNOSTICS)
~~

Step Check Yes No

1 CHECK OUTPUT SIGNAL EMITTED FROM ;the voltage between 1.5 and 30 to step 12. i o to step 15.
TCM. i.0 V with throttle fully closed?
1)Connect all connectors.
2)Start the engine and warm-up the transmis-
sion until the ATF temperature is above 80°C
(176°F).
NOTE:
If the ambient temperature is below 0°C (32"F),
drive the vehicle until the ATF reaches its oper-
ating temperature.
3)Turn the ignition switch to ON (engine OFF).
4)Move the select lever to "N".
5)Measure the voltage between TCM connec-
tor and chassis ground.
Connector & terminal
Non-turbo model
(B54) No. 8 (+) - Chassis groundI)-(
Turbo model
(854) No. 18 (+) - Chassis ground (-):
2 CHECK OUTPUT SIGNAL EMITTED FROM s the voltage less than 1 V Even if the AT OIL io to step 15.
TCM. with throttle fully open? rEMP warning
._ Measure the voltage between TCM connector ights up, the cir-
and chassis ground. :uit has returned
Connector & terminal o a normal condi-
Non-turbo model ion at this time. A
(B54) No. 8 (+) - Chassis ground (-): emporary poor
Non-turbo model :ontact of the con-
(B54) No. 18 (+) - Chassis ground (-): lector or harness
nay be the cause.
3epair harness or
:onnector in TCM
2nd transmission.
3 CHECK OUTPUT SIGNAL EMIlTED FROM s the value 1OO%? 30 to step 14. ;o to step 15.
TCM USING SUBARU SELECT MONITOR.
1)Connect all connectors.
2)Connect the Subaru Select Monitor to data
link connector.
3)Start the engine, and turn the Subaru Select
Monitor switch to ON.
4)Warm-up the transmission until the ATF tem-
perature is above 80°C (176°F).
NOTE:
If the ambient temperature is below 0°C (32"F),
drive the vehicle until the ATF reaches its oper-
ating temperature.
5)Stop the engine and turn the ignition switch
to ON (engine OFF).
6)Move the select lever to "N".
7)Read the data of 2-4 brake duty solenoid
using Subaru Select Monitor.
*2-4 brake duty solenoid is indicated in "%".
1)Throttle is fully closed.

AT-92
 I
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

Step- Check Yes No

5 CHECK POOR CONTACT. Is there poor contact in 2-4 3epair poor con- Heplace the TCM.
brake duty solenoid circuit? act. <Ref. to AT-45,
Transmission Con-
trol Module
(TCM).>
6 CHECK 2-4 BRAKE DUTY SOLENOID (IN Is the resistance between 2.0 30 to step 17. Replace the 2-4
TRANSMISSION). and 4.5 R? brake duty sole-
1)Remove the transmission connector from noid. <Ref. to AT-
bracket. 39, Shift Sole-
2)Drain the automatic transmission fluid. . noids, Duty Sole-
CAUTION: noids and ATF
Do not drain the automatic transmission flu- Temperature Sen-
id until it cools down. sor.>
3)Remove the oil pan, and disconnect the con.
nector from 2-4 brake duty solenoid.
4)Measure the resistance between 2-4 brake
duty solenoid connector and transmission
ground.
Terminal
No. 1 - Transmissionground:
7 CHECK HARNESS CONNECTOR BETWEEN IS the resistance less than 1 30 to step 18. Repair open circuil
TRANSMISSION AND 2-4 BRAKE DUTY SO- Q? in harness
LENOID. between 2-4 brake
Measure the resistance of harness between 2- duty solenoid and
4 brake duty solenoid and transmission con- transmission con-
nector. nector.
Connector & terminal
(T4) NO. 9 - (AT7) NO. 1:
8 CHECK HARNESSCONNECTOR BETWEEN Is the resistance more than 1 Even if the AT OIL Repair short circuil
TRANSMISSION AND 2-4 BRAKE DUTY SO- MQ? rEMP warning in harness
LENOID. ights up, the cir- between 2-4 brake
Measure the resistance of harness between :uit has returned duty solenoid and
transmission connector and transmission o a normal condi- transmission con-
ground. ion at this time. A nector.
Connector & terminal emporary poor
(T4) No. 9 - Transmissionground: :ontact of the con-
lector or harness
nay be the cause.
3epair harness or
:onnector in line
3ressure duty
solenoid and
ransmission.

AT-93
I DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

0:DTC 77 LOCK-UP DUTY SOLENOID

DIAGNOSIS:
Output signal circuit of lock-up duty solenoid is open or shorted.
TROUBLE SYMPTOM:
No “lock-up” (after engine warm-up).
WIRING DIAGRAM:

@ TCM

TRANSMISSION

TR0587

AT-94
 I
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

Step Check Yes No

I CHECK DTC. l o multiple trouble codes So to another trou- Go to step 2.
ippear in the on-board diag- )le code.
iostics test mode?
! CHECK HARNESS CONNECTOR BETWEEN s the resistance less than 1 o
; to step 3. Repair open circui
TCM AND TRANSMISSION. 2? in harness
1)Turn the ignition switch to OFF. between TCM anc
2)Disconnect the connector from TCM and transmission con-
transmission. nector.
3)Measure the resistance of harness between
TCM and transmission connector.
Connector & terminal
Non-turbo model
(654) NO. 16 - (61 1) NO. 13:
Turbo model
(654) NO. 7 - (61 1) NO. 13:
i CHECK HARNESS CONNECTOR BETWEEN s the resistance more than 1 ;o to step 4. Repair short circui
TCM AND TRANSMISSION. fin? in harness
Measure the resistance of harness connector between TCM anc
between TCM and chassis ground. transmission con-
Connector & terminal nector.
Non-turbo model
(654) No. 16 - Chassis ground:
Turbo model
(654) No. 7 - Chassis ground:
I CHECK LOCK-UP DUTY SOLENOID. s the resistance between 10 ;o to step 5. Go to step 11.
Measure the resistance between transmission 2nd 17 Q?
connector receptacle's terminals.
Connector & terminal
(T4) NO. 13 - NO. 16:
) PREPARE SUBARU SELECT MONITOR. l o you have a Subaru Select ;o to step 8. Go to step 6.
donitor?

AT-95
I
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

Step Check Yes

, CHECK OUTPUT SIGNAL EMITTED FROM j the voltage more than 8.5 V? 30 to step 7.
TCM.
1)Connect the connectors to TCM and trans-
mission.
2)Lift-up the vehicle and place safety stand.
CAUTION:
On AWD models, raise all wheels off
ground.
3)Start the engine and warm-up the transmis-
sion until the ATF temperature is above 80°C
(176°F).
NOTE:
If the ambient temperature is below 0°C (32°F)
drive the vehicle until the ATF reaches its oper.
ating temperature.
4)Move the select lever to “D” and slowly
increase the vehicle speed to 75 km/h (47
MPH). Wheels will lock-up.
NOTE:
The speed difference between front and real
.. wheels may light the ABS warning light, but thiz
indicates no malfunction. When the AT contro
diagnosis is finished, perform the ABS memoq
clearance procedure of on-board diagnostic:
system. <Ref. to ABS-22, Clear Memoq
Mode.>
5)Measure the voltage between TCM connec-
tor and chassis ground.
Connector & terminal
Non-turbo model
(B54)No. 16 (+) - Chassis ground (-):
Turbo model
(44)No. 7 (+) - Chassis ground (-):
CHECK OUTPUT SIGNAL EMITTED FROM s the voltage less than 0.5 V? :veri if the AT OIL
TCM. rEMP warning
1)Return the engine to idling speed and move ights up, the cir-
the select lever to “N”. :uit has returned
2)Measure the voltage between TCM connec- o a normal condi-
tor and chassis ground. ion at this time. A
Connector & terminal emporary poor
Non-turbo model :ontact of the con-
(854)No. 16 (+) - Chassis ground (-): lector or harness
Turbo model nay be the cause.
(B54)No. 7 (+) - Chassis ground (-): 3epair harness or
:onnector in TCM
and transmission.

AT-96
 I
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

Step Check Yes No

CHECK OUTPUT SIGNAL EMllTED FROM Is the value 95%? 30 to step 9. 30 to step 10.
TCM USING SUBARU SELECT MONITOR.
1)Connect the connectors to TCM and trans-
mission.
2)Lift-up the vehicle and place safety stand.
CAUTION:
On AWD models, raise all wheels off
ground.
3)Connect the Subaru Select Monitor to data
link connector.
4)Start the engine, and turn the Subaru Select
Monitor switch to ON.
5)Start the engine and warm-up the transmis-
sion until the ATF temperature is above 80°C
(176°F).
NOTE:
If the ambient temperature is below 0°C (32°F)
drive the vehicle until the ATF reaches its oper.
ating temperature.
6)Read the data of lock-up duty solenoid using
Subaru Select Monitor.
*Lock-up duty solenoid is indicated in “Yo”.
1)Move the select lever to “ D and slowly
increase the vehicle speed to 75 km/h (47
MPH). Wheels will lock-up.
NOTE:
The speed difference between front and real
wheels may light the ABS warning light, but this
indicates no malfunction. When the AT contro
diagnosis is finished, perform the ABS memor)
clearance procedure of on-board diagnostics
system. <Ref. to ABS-22, Clear Memor),
Mode.>
CHECK OUTPUT SIGNAL EMllTED FROM Is the value 5%? Even if the AT OIL 30 to step 10.
TCM USING SUBARU SELECT MONITOR. TEMP warning
Return the engine to idling speed and move lights up, the cir-
the select lever to “N”. cuit has returned
NOTE: to a normal condi-
The speed difference between front and real tion at this time. A
wheels may light the ABS warning light, but this temporary poor
indicates no malfunction. When AT control di- contact of the con-
agnosis is finished, perform the ABS memor) nector or harness
clearance procedure of on-board diagnostics may be the cause.
system. <Ref. to ABS-22, Clear Memor) Repair harness or
Mode.> connector in TCM
and transmission.
CHECK POOR CONTACT. Is there poor contact in lock-up Repair poor con- 3eplace the TCM.
duty solenoid circuit? tact. :Ref. to AT-45,
rransmission Con-
rol Module
I I
TCM).>

AT-97
I
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

Step No
CHECK LOCK-UP DUTY SOLENOID (IN Replace the lock-
TRANSMISSION). ind 17 R? up duty solenoid.
1)Remove the transmission connector from <Ref. to AT-39,
bracket. Shift Solenoids,
2)Drain the automatic transmission fluid. Duty Solenoids
CAUTION: and ATF Tempera-
Do not drain the automatic transmission flu- ture Sensor.>
id until it cools down.
3)Remove the oil pan, and disconnect the con-
nector from lock-up duty solenoid.
4)Measure the resistance between lock-up
duty solenoid connector and transmission
ground.
Terminal
No. 1 - Transmission ground:
CHECK HARNESSCONNECTOR BETWEEN s the resistance less than 1 IGo to step 13. Repair open circuit
LOCK-UP DUTY SOLENOID AND TRANS- 2? in harness
MISSION. between TCM and
Measure the resistance of harness between transmission con-
lock-up duty solenoid and transmission con- nector.
nector.
Connector & terminal
(T4) NO. 13 - (AT3) NO. 1:
CHECK HARNESSCONNECTOR BETWEEN s the resistance more than 1 Even if the AT OIL Repair short circuit
LOCK-UP DUTY SOLENOID AND TRANS- dR? TEMP warning in harness
MISSION. lights up, the cir- between lock-up
Measure the resistance of harness between cuit has returned duty solenoid and
transmission connector and transmission to a normal condi- transmission con-
ground. tion at this time. A nector.
Connector & terminal temporary poor
(T4) No. 13 - Transmission ground: contact of the con.
nector or harness
may be the cause.
Repair harness or
connector in lock-
up duty solenoid
and transmission.

AT-98
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

r- .

AT-99
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

P: DTC 79 TRANSFER DUTY SOLENOID

DIAGNOSIS:
Output signal circuit of transfer duty solenoid is open or shorted.
TROUBLE SYMPTOM:
Excessive “braking” in tight corners.
WIRING DIAGRAM:

@ TCM

I -
-
TRANSMISSION

TR0588

AT-I 00
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
I
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

Step Check Yes No

1 CHECK HARNESSCONNECTOR BETWEEN s the resistance less than 1 i o to step 2. 3epair open circuit
TCM AND TRANSMISSION. 2? n harness
1)Turn the ignition switch to OFF. setween TCM and
2)Disconnect the connector from TCM and [ransmissioncon-
transmission. lector.
3)Measure the resistance of harness between
TCM and transmission connector.
Connector & terminal
Non-turbo model
-
(B54) NO. 15 (Bl 1) NO. 6:
Turbo model
(B54) NO. 6 - (811) NO. 6:
2 CHECK HARNESS CONNECTOR BETWEEN s the resistance more than 1 i o to step 3. Repair short circuii
TCM AND TRANSMISSION. An? in harness
Measure the resistance harness connector between TCM and
between TCM and chassis ground. transmission con-
Connector & terminal lector.
Non-turbo model
-
(854) No. 15 Chassis ground:
Turbo model
(B54) No. 6 - Chassis ground:
.3 CHECK TRANSFER DUTY SOLENOID. s the resistance between 10 ;o to step 4. Go to step 13.
Measure the resistance between transmission ind 17 R?
connector and transmission terminals.
Connector & terminal
(T4) NO. 6- NO. 16:
4 PREPARE SUBARU SELECT MONITOR. 10 you have a Subaru Select ;o to step 7 . Go to step 5.
A o nito r?
CHECK OUTPUT SIGNAL EMITTED FROM s the voltage less than 1 V in ;o to step 6. Go to step 12.
TCM. P” range?
1)Connect the connectors to TCM and trans-
mission.
2)Turn the ignition switch to ON (engine OFF).
3)Throttle is fully closed.
4)Measure the voltage between TCM connec-
tor and chassis ground.
Connector & terminal
Non-turbo model
(854) No. 15 (+) - Chassis ground (-):
Turbo model
(854) No. 6 (+) - Chassis ground (-):
CHECK OUTPUT SIGNAL EMITTED FROM s the voltage between 5 and 7 iven if the AT OIL Go to step 12.
TCM. J in “D” range? -EMP warning
Measure the voltage between TCM connector ights up, the cir-
and chassis ground. :uit has returned
Connector & terminal o a normal condi-
Non-turbo model ion at this time. A
(854) No. 15 (+) - Chassis ground (-): emporary poor
Turbo model :ontact of the con.
(854) No. 6 (+) - Chassis ground (-): rector or harness
nay be the cause.
Iepair harness or
:onnector in the
TCM and trans-
nission.
7 CHECK VEHICLE s the taraet non-turbo model S o
; to step 8. Go to step 10.

AT-I 01
I DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

Step Check Yes No

CHECK OUTPUT SIGNAL EMITTED FROM s the value between 5 and Go to step 9. 30 to step 12.
TCM USING SUBARU SELECT MONITOR. I O%?
1)Connect the connectors to TCM and trans-
mission.
2)Connect the Subaru Select Monitor to data
link connector.
3)Turn the ignition switch to ON (engine OFF)
and turn the Subaru Select Monitor switch to
ON.
4)Move the select lever to “D” with throttle fully
open (vehicle speed 0 km/h or 0 MPH).
5)Read the data of transfer duty solenoid using
Subaru Select Monitor.
*Transfer duty solenoid is indicated in “ O h ” .
CHECK OUTPUT SIGNAL EMITTED FROM s the value between approx. Even if the AT OIL 30 to step 12.
TCM USING SUBARU SELECT MONITOR. SO% and approx. 70%? TEMP warning
1)Move the select lever to “D” with throttle fully lights up, the cir-
closed (vehicle speed 0 km/h or 0 MPH). cuit has returned
2)Rear the data of transfer duty solenoid using to a normal condi-
Subaru Select Monitor. tion at this time. A
*Transfer duty solenoid is indicated in “%”. temporary poor
contact of the con-
nector or harness
may be the cause.
Repair harness or
connector in the
TCM and trans-
mission.
I CHECK OUTPUT SIGNAL EMITTED FROM s the value between 80 and Go to step 11. 30 to step 12.
TCM USING SUBARU SELECT MONITOR. )5%?
1)Connect connectors to TCM and transmis-
sion.
2)Connect Subaru Select Monitor to data link
connector.
3)Turn ignition switch to ON (engine OFF) and
turn Subaru Select Monitor switch to ON.
4)Move select lever to “ D with throttle fully
open (vehicle speed 0 km/h or 0 MPH).
5)Read data of transfer duty solenoid using
Subaru Select Monitor.
*Transfer duty solenoid is indicated in ‘Yo”.
CHECK OUTPUT SIGNAL EMllTED FROM s the value approx. 40%? Even if the AT OIL 30 to step 12.
TCM USING SUBARU SELECT MONITOR. TEMP warning
1)Move select lever to “N” with throttle fully lights up, the cir-
close (vehicle speed 0 km/h or 0 MPH). cuit has returned
2)Rear data of transfer duty solenoid using to a normal condi-
Subaru Select Monitor. tion at this time. A
*Transfer duty solenoid is indicated in “Yo”. temporary poor
contact of the con-
nector or harness
may be the cause.
Repair harness or
connector in the
transfer duty sole-
noid and TCM
connector.

AT-I 02
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) I
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

Step Check Yes No

2 CHECK POOR CONTACT. Is there poor contact in transfer lepair poor con- 3eplace the TCM.
duty solenoid circuit? act. :Ref. to AT-45,
rransmission Con-
rol Module
'TCM).r
3 CHECK TRANSFER DUTY SOLENOID (IN Is the resistance between 10 ;o to step 14. 3eplace the trans-
TRANSMISSION). and 17 Q? er duty solenoid.
1)Lift-up the vehicle and place safety stand.
CAUTION:
On AWD models, raise all wheels off
ground.
2)Drain the automatic transmission fluid.
CAUTION:
Do not drain the automatic transmission flu.
id until it cools down.
3)Remove the extension case, and disconnect
the connector from transfer duty solenoid.
4)Measure the resistance between transfer
duty solenoid connector and transmission
ground.
Connector & terminal
(AT4) No. 1 - Transmissionground:
4 CHECK HARNESS CONNECTOR BETWEEN IS the resistance less than 1 o; to step 15. 3epair open circuit
TRANSFER DUTY SOLENOID AND TRANS- Q? n harness
MISSION. ietween transfer
Measure the resistance of harness between juty solenoid and
transfer duty solenoid and transmission con- ransmission con-
nector. lector.
Connector & terminal
(T4) NO. 6 - (AT4) NO. 1:
5 CHECK HARNESS CONNECTOR BETWEEN Is the resistance more than 1 %en if the AT OIL 3epair short circuit
TRANSFER DUTY SOLENOID AND TRANS- MQ? rEMP warning n harness
MISSION. ights up, the cir- ietween transfer
Measure the resistance of harness between :uit has returned luty solenoid and
transmission connector and transmission o a normal condi- ransmission con-
ground. ion at this time. A lector.
Connector & terminal emporary poor
(T4) No. 6 - Transmissionground: :ontact of the con,
lector or harness
nay be the cause.
3epair harness or
:ontact in the
ransfer duty sole-
ioid and transmis.
;ion.

AT-I 03
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
I
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

Q: DTC 93 REAR VEHICLE SPEED SENSOR

DIAGNOSIS:
Input signal circuit of TCM is open or shorted.
TROUBLE SYMPTOM:
No lock-up or excessive tight corner “braking”
WIRING DIAGRAM:

: NON-TURBO MODEL

: TURBO MODEL

REAR VEHICLE

SPEED SENSOR

TR0589

AT-I 04
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) I
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

Step Check Yes No

CHECK HARNESSCONNECTOR BETWEEN s the resistance less than 1 20 to step 2. Repair open circuit
TCM AND TRANSMISSION. 2? in harness
1)Turn the ignition switch to OFF. between TCM and
2)Disconnect the connector from TCM and transmission con-
transmission. nector.
3)Measure the resistance of harness between
TCM and transmission connector.
Connector & terminal
Non-turbo model
(B55)NO. 3 - (B11)NO. 19:
Turbo model
(B55)NO.24 - (B11)NO. 19:
CHECK HARNESS CONNECTOR BETWEEN s the resistance less than 1 o
; to step 3. Repair open circuit
TCM AND TRANSMISSION. 2? in harness
Measure the resistance of harness between between TCM and
TCM and transmission connector. transmission, and
Connector & terminal poor contact in
Non-turbo model coupling connec-
(B55)NO.21 - (B11)NO.20: tor.
Turbo model
(B54)NO. 19 - ( 6 1 1) NO. 20:
CHECK HARNESSCONNECTOR BETWEEN s the resistance more than 1 30 to step 4. Repair short circuit
TCM AND TRANSMISSION. Uln? in harness
Measure the resistance of harness between between TCM and
TCM and chassis ground. transmission con-
Connector & terminal nector.
Non-turbo model
(B55)No. 3 - Chassis ground:
Turbo model
(655)No. 24 - Chassis ground:
CHECK HARNESS CONNECTOR BETWEEN s the resistance more than 1 30 to step 5. Repair short circuit
TCM AND TRANSMISSION. wn? in harness
Measure the resistance of harness between between TCM and
TCM and chassis ground. transmission con-
Connector & terminal nector.
Non-turbo model
(655)No. 21 - Chassis ground:
Turbo model
(B54)No. 19 - Chassis ground:
CHECK REAR VEHICLE SPEED SENSOR. s the resistance between 450 30 to step 6. Replace the rear
Measure the resistance between transmission and 650 Q? vehicle speed sen.
connector receptacle'sterminals. sor. <Ref. to AT-
Connector & terminal 35, Rear Vehicle
(T4) NO. 19 - NO.20: Speed Sensor.>
PREPARE OSCILLOSCOPE. l o you have an oscilloscope? 30 to step 10. Go to step 7.
PREPARE SUBARU SELECT MONITOR. 30 you have a Subaru Select 30 to step 9. Go to step 8.
Monitor?

AT-I 05
I DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

Step Check Yes No

CHECK INPUT SIGNAL FOR TCM. s the voltage more than AC 1 Even if the AT OIL 30 to step 11.
1)Connect the connectors to TCM and trans- /? TEMP warning
mission. ights up, the cir-
2)Lift-up or raise the vehicle and place safety :uit has returned
stands. :o a normal condi-
CAUTION: :ion at this time. A
On AWD models, raise all wheels off floor. :emporary poor
3)Start the engine and set vehicle in 20 km/h :ontact of the con-
(12 MPH) condition. lector or harness
NOTE: nay be the cause.
The speed difference between front and rea 3epair harness or
wheels may light the ABS warning light, but thi: :onnector in the
indicates no malfunction. When the AT contro TCM and trans-
diagnosis is finished, perform the ABS memor) nission.
clearance procedure of on-board diagnostic5
system. <Ref. to ABS-22, Clear Memor)
Mode.>
4)Measure the voltage between TCM connec-
tor terminals.
Connector & terminal
Non-turbo model
(655) NO. 3 (+) - (654) NO. 21 (-):
Turbo model
(655) NO.24 (+) - (654) NO. 19 (-):
CHECK INPUT SIGNAL FOR TCM USING )oes the speedometer indica- Even if the AT OIL i o to step 11.
SUBARU SELECT MONITOR. on increase as the Subaru rEMP warning
1)Connect the connectors to TCM and trans- ielect Monitor data increases? ights up, the cir-
mission. :uit has returned
2)Connect the Subaru Select Monitor to data o a normal condi-
link connector. ion at this time. A
3)Lift-up or raise the vehicle and place safety emporary poor
stands. :ontact of the con-
CAUTION: lector or harness
Raise all wheels off floor. nay be the cause.
4)Turn the ignition switch to ON and turn the 3epair harness or
Subaru Select Monitor switch to ON. :onnector in the
5)Start the engine. T M and trans-
6)Read the data of vehicle speed using Subaru nission.
Select Monitor.
Compare the speedometer with Subaru
Select Monitor indications.
*Vehicle speed is indicated in “km/h” or “MPH”.
1)Slowly increase the vehicle speed to 60 km/h
or 37 MPH.
NOTE:
The speed difference between front and rear
wheels may light the ABS warning light, but this
indicates no malfunction. When the AT control
diagnosis is finished, perform the ABS memory
clearance procedure of on-board diagnostics
system. <Ref. to ABS-22, Clear Memory
Mode.>

AT-106
 DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) I
AUTOMATIC TRANSMISSION (DIAGNOSTICS)
~ ~

Step Check Yes No

IO CHECK INPUT SIGNAL FOR TCM USING s the signal voltage more than Even if the AT OIL 30 to step 11.
OSCILLOSCOPE. 4c 1 V? rEMP warning
1)Connect the connectors to TCM and trans- ights up, the cir-
mission. :uit has returned
2)Lift-up or raise the vehicle and place safety o a normal condi-
stands. ion at this time. A
CAUTION: emporary poor
Raise all wheels off floor. :ontact of the con-
3)Set the oscilloscope to TCM connector ter- lector or harness
minals. nay be the cause.
Turbo model 3epair harness or
Positive probe; (655) No. 24 :onnector in the
Earth lead; (855) No. 19 TCM and trans-
Non-turbo model nission.
Positive probe; (B55) No. 3
Earth lead; (B55) No. 21
4)Start the engine and set the vehicle in 20 km,
h (12 MPH) condition.
NOTE:
The speed difference between front and real
wheels may light the ABS warning light, but this
indicates no malfunction. When the AT contro
diagnosis is finished, perform the ABS memoq
clearance procedure of on-board diagnostic:
system. <Ref. to ABS-22, Clear Memoq
Mode.>
5)Measure the signal voltage indicated on
oscilbscope.
I1 CHECK POOR CONTACT. s there poor contact in rear 3epair poor con- 3eplace the TCM.
iehicle speed sensor circuit? act. :Ref. to AT-45,
rransmission Con-
rol Module
'TCM).>

AT-1 07
I DIAGNOSTIC PROCEDURE FOR NO-DIAGNOSTIC TROUBLE CODE (DTC)
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

15.Diagnostic Procedure for No-Diagnostic Trouble Code (DTC)

A: CHECK GEAR POSITION.
Step Check Yes No
CHECK GEAR POSITION. Does the transmission gear 30 to step 2. Check shift sole-
1)Lift-up the vehicle and place safety stand. correspond to the gear which noid 1 and shift
CAUTION: is shown on display? solenoid 2 signal
On AWD models, raise all wheels off circuit. <Ref. to AT-
ground. 70, DTC 71 SHIFT
2)Start the engine. SOLENOID 1,
3)Move the select lever to “D”, and drive the Diagnostic Proce-
vehicle. dure with Diagnos-
4)Read the data of gear position using Subaru tic Trouble Code
Select Monitor. (DTC).> and <Ref.
*Gear position is indicated. to AT-74, DTC 72
SHIFT SOLE-
NOTE:
The speed difference between front and rear NOID 2, Diagnos-
wheels may light the ABS warning light, but this tic Procedure with
indicates no malfunction. When the AT control Diagnostic Trou-
diagnosis is finished, perform the ABS memory ble Code (DTC).>
clearance procedure of on-board diagnostics
system. <Ref. to ABS-22, Clear Memory
Mode.>
I CHECK VEHICLE. s the target no6turbo model? 30 to step CHECK Go to step CHECK
=WD BRAKE SWITCH.
;WITCH.<Ref. to <Ref. to AT-1 12,
4T-110, CHECK CHECK BRAKE
IWD SWITCH., SWITCH., Diag-
liagnostic Proce- nostic Procedure
lure for No-Diag- for No-Diagnostic
iostic Trouble Trouble Code
;ode (DTC).> (DTC).>

AT-I 08
DIAGNOSTIC PROCEDURE FOR NO-DIAGNOSTIC TROUBLE CODE (DTC)
ALJTOMATIC TRANSMISSION (DIAGNOSTICS)

AT-I 09
 DIAGNOSTIC PROCEDURE FOR NO-DIAGNOSTIC TROUBLE CODE (DTC)
I
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

B: CHECK FWD SWITCH.

DIAGNOSIS:
LED does not come on even if FWD switch is ON.
FWD switch circuit is open or short.
WIRING DIAGRAM:

2
z
0
- 0
IGNITION
SWITCH

0
SBF-4 SEF-1
BATTERY

3 0
1

I
-
E
FWD SWITCH

COMBINATION
METER
) FWD
r.
A: @
B:@

B:@ A:@

4- 8 11 12 16 19 20 24 27 28 30

TI30590

AT-I 10
 DIAGNOSTIC PROCEDURE FOR NO-DIAGNOSTIC TROUBLE CODE (DTC) 1
AUTOMATIC TRANSMISSION (DIAGNOSTICS)
~~

Step Check Yes No

I CHECK FWD SWITCH. When the fuse is inserted to Go to step CHECK Go to step 2.
FWD switch, does the LED BRAKE
light up? SWITCH.<Ref. to
AT-1 12, CHECK
BRAKE SWITCH.,
Diagnostic Proce-
dure for No-Diag-
nostic Trouble
Code (DTC).>
! CHECK FWD INDICATOR LIGHT. Is the FWD indicator light bulb Go to step 3. Replace the FWD
1)Turnthe ignition switch to OFF. indicator light bulb.
2)Remove the combination meter. <Ref. to IDI-11,
3)Remove the FWD indicator light bulb from Combination

I
combination meter.

TCM AND FWD SWITCH.

r---f-
CHECK HARNESSCONNECTOR BETWEEN Is the resistance less than 1 Go to step 4.
Meter Assembly.>
Repair open circuit
in harness
1)Turn the ignition switch to OFF. between TCM and
2)Disconnect the connector from TCM and FWD switch con-
FWD switch. nector.
I
3)Measure the resistance of harness between
TCM and FWD switch connector.
Connector & terminal
-
(B55) NO. 14 (F67) NO. 30:
I CHECK HARNESSCONNECTOR BETWEEN Is the resistance less than 1 Go to step 5. Repair open circuit
FWD SWITCH AND CHASSIS GROUND. D? in harness
Measure the resistance of harness between between FWD
FWD switch and chassis ground. switch connector
Connector & terminal and chassis
-
(F67) No. 29 Chassis ground: ground.
CHECKHARNESSCONNECTORBETWEEN Is the resistance more than 1 1 Go to step 6. Repair short circuit
TCM AND FWD SWITCH. MQ? in harness
Measure the resistance of harness connector between TCM and
between TCM and body to make sure that cir- FWD switch con-
cuit does not short. nector.
Connector & terminal
-
(B55) No. 14 Chassis ground:
i CHECK INPUT SIGNAL FOR TCM. Go to step 12.
1)Turn the ignition switch to OFF. FWD switch while installing?
2)Connect the connector to TCM and FWD
switch.
3)Turn the ignition switch to ON.
4)Measure the signal voltage for TCM while
installing the fuse to FWD switch connector.
Connector & terminal
(B55) No. 14 (+) - Chassis ground (-):
r CHECK INPUT SIGNAL FOR TCM. Replace the TCM.
Measure the signal voltage for TCM while FWD switch while removing? <Ref. to AT-45,
removing the fuse from FWD switch connector. Transmission Con-

I
Connector & terminal
(B55) No. 14 (+) - Chassis ground (-):

TCM AND COMBINATION METER.

1)Turn the ignition switch to OFF.
7j--
CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 Go to step 9.
trol Module
(TCM).>
Repair open circuit
in harness
between TCM and
2)Disconnect the connector from TCM and combination meter
combination meter. and poor contact
3)Measure the resistance of harness between in coupling con-
TCM and diagnosis connector. nector.
Connector & terminal
-
(B54) No. 12 ( i l l ) No. 4:
I DIAGNOSTIC PROCEDURE FOR NO-DIAGNOSTIC TROUBLE CODE (DTC)
AUTOMATIC TRANSMISSION (DIAGNOSTICS)
~~ ~

Step Check Yes No

9 CHECK HARNESS CONNECTOR BETWEEN the resistance more than 1 30 to step 1Q. Repair short circuii
TCM AND COMBINATION METER. n? ,n harness
Measure the resistance of harness connector between TCM and
between TCM and chassis ground to make :ombination meter
sure that circuit does not short. zonnector.
Connector & terminal
-
(854) No. 12 Chassis ground:
10 CHECK OUTPUT SIGNAL EMITTED FROM the voltage less than 1 V in 30 to step 11. So to step 12.
TCM. YD switch while installing?
1)Turn the ignition switch to OFF.
2)Connect the connector to TCM and combina-
tion meter.
3)Turn the ignition switch to ON.
4)Measure the signal voltage for TCM while
installing and removing the fuse to FWD switch
connector.
Connector & terminal
(854) No. 12 - Chassis ground:
11 CHECK OUTPUT SIGNAL EMITTED FROM the voltage more than 9 V in 30 to step 12. Replace the TCM.
TCM. 'VDswitch while removing? <Ref. to AT-45,
Measure the signal voltage for TCM while Transmission Con.
_.. removing the fuse from FWD switch connector. trol Module
Connector & terminal [TCM).>
-
(854) No. 12 Chassis ground:
12 CHECK POOR CONTACT. there poor contact in FWD 3epair poor con- Replacethe TCM.
[itch circuit? act. <Ref. to AT-45,
Transmission Con.
trol Module
(TCM).>

C: CHECK BRAKE SWITCH.

I
Check Yes No
CHECK BRAKE SWITCH. When the brake pedal is Go to step CHECK Check the brake
depressed, does the LED light ABS SWITCH. switch circuit.
up? <Ref. to AT-113,
CHECK ABS
SWITCH., Diag-
nostic Procedure
for No-Diagnostic
Trouble Code
(DTC).>

AT-1 12
 DIAGNOSTIC PROCEDURE FOR NO-DIAGNOSTIC TROUBLE CODE (DTC) I
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

D: CHECK ABS SWITCH.

Step Check Yes No
Go to step CHECK
1 light up? [switch circuit. CRUISE CON-
<Ref. to ABS1 38, TROL SWITCH.
DTC 44 ABS-AT <Ref. to AT-113,
CONTROL (NON CHECK CRUISE
CONTROLLED), CONTROL
Diagnostics Chart SWITCH., Diag-
with Subaru Select nostic Procedure
Monitor.> and for No-Diagnostic
<Ref. to ABS-140, Trouble Code
DTC 44 ABS-AT (DTC).>
CONTROL (CON-
TROLLED), Diag-
nostics Chart with
Subaru Select
Monitor.>

E: CHECK CRUISE CONTROL

r- SWITCH.
~

Step Check Yes No

1 CHECK CRUISE CONTROL SWITCH. When cruise control is set, Go to step CHECK Check the cruise
does the LED light up? INHIBITOR control. <Ref. to
SWITCH. <Ref. to CC-28, Diagnos-
AT-1 15, CHECK tics Chart with
INHIBITOR Diagnostic Trou-
SWITCH., Diag- ble Code.>
nostic Procedure
for No-Diagnostic
Trouble Code
(DTC).>

AT-I 13
I DIAGNOSTIC PROCEDURE FOR NO-DIAGNOSTIC TROUBLE CODE (DTC)
I
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

r. .

AT-I 14
 DIAGNOSTIC PROCEDURE FOR NO-DIAGNOSTIC TROUBLE CODE (DTC) I
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

F: CHECK INHIBITOR SWITCH.

DIAGNOSIS:
Input signal circuit of inhibitor switch is open or shorted.
TROUBLE SYMPTOM:
Shift characteristics are erroneous.
Engine brake is not effected when selector lever is in “ 3 range.
Engine brake is not effected when selector lever is in “2” range.
Engine brake is not effected when selector lever is in “1” range.

AT-1 15
 DIAGNOSTIC PROCEDURE FOR NO-DIAGNOSTIC TROUBLE CODE (DTC) I
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

WIRING DIAGRAM:

IGNITION
SWITCH
SBF-1 SBF-4 0 No 13
0 c

COMBINATION
METER
I - A@

I @" C@

TR0591

AT-I 16
 DIAGNOSTIC PROCEDURE FOR NO-DIAGNOSTIC TROUBLE CODE (DTC) 3
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

Step Check Yes No

CHECK “P” RANGE SWITCH. When “ P range is selected, i o to step 2. 20 to step 22.
loes the LED light up?
CHECK INDICATOR LIGHT. >oes the combination meter ;o to step 3. o
; to step 26.
P” range indicator illuminate?
CHECK “P” RANGE SWITCH. When the “R” range is io to step 28. o
; to step 4.
;elected, does the “ P range
.ED light up?
CHECK “R” RANGE SWITCH. Nhen the “R” range is ;o to step 5. 30 to step 29.
;elected, does the LED light
lp?
CHECK INDICATOR LIGHT. loes the combination meter ;o to step 6. 30 to step 32.
R” range indicator illuminate?
CHECK “R” RANGE SWITCH. Nhen the “N” range is 20 to step 34. 30 to step 7.
;elected, does the “R” range
-ED light up?
CHECK “N” RANGE SWITCH. Nhen the “N” range is 30 to step 8. 30 to step 35.
;elected, does the LED light
JP?
CHECK INDICATOR LIGHT. loes the combination meter 30 to step 9. 30 to step 38.
‘N” range indicator illuminate?
CHECK “N” RANGE SWITCH. Nhen the “ D range is o
; to step 40. 30 to step 10.
selected, does the “N” range
-ED light up?
1 CHECK “D” RANGE SWITCH. Nhen the “D” range is o; to step 11. 30 to step 41.
selected, does the LED light
Jp?
I CHECK INDICATOR LIGHT. I o e s the combination meter 30 to step 12. 30 to step 44.
‘D” range indicator illuminate?
? CHECK “D” RANGE SWITCH. Nhen the “ 3 range is selected, 30 to step 46. 30 to step 13.
joes the “D” range LED light
Jp?
3 CHECK “3” RANGE SWITCH. When the “ 3 range is selected, 30 to step 14. 30 to step 47.
joes the LED light up?
I CHECK INDICATOR LIGHT. Does the combination meter 30 to step 15. Go to step 50.
‘3” range indicator illuminate?
> CHECK “3” RANGE SWITCH. When the “ 2 range is selected, 30 to step 52. Go to step 16.
does the “ 3 range LED light
up?
5 CHECK “2” RANGE SWITCH. When the “2” range is selected, 30 to step 17. Go to step 53.
does the LED light up?
7 CHECK INDICATOR LIGHT. Does the combination meter 30 to step 18. Go to step 56.
“2” range indicator illuminate?
3 CHECK “2” RANGE SWITCH. When the “1” range is selected, So to step 58. Go to step 19.
does the “2” range LED light
up?
9 CHECK “1” RANGE SWITCH. When the “ I ” range is selected, Go to step 20. Go to step 59.
does the LED light up?
D CHECK INDICATOR LIGHT. Does the combination meter Go to step 21. Go to step 62.
“1” range indicator illuminate?
1 CHECK “1” RANGE SWITCH. When the “P” range is Go to step 64. Go to step Symp-
selected, does the “1” range tom Related Diag-
LED light UP? nostic. <Ref. to A1
127, Symptom
Related Diagnos-
tic.>

AT-I 17
I DIAGNOSTIC PROCEDURE FOR NO-DIAGNOSTIC TROUBLE CODE (DTC)
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

Step Check Yes No

2 CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 Go to step 23. Repair open circui
INHIBITOR SWITCH AND CHASSIS R? in harness
GROUND. between inhibitor
1)Turn the ignition switch to OFF. switch connector
2)Disconnect the connector from inhibitor and chassis
switch. ground, and poor
3)Measure the resistance of harness between contact in cou-
inhibitor switch and chassis ground. pling connector.
Connector & terminal
(T7) No. 5 - Chassis ground:
3 CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 Go to step 24. Repair open circuil
TCM AND INHIBITOR SWITCH. R? in harness
1)Turn the ignition switch to OFF. between TCM and
2)Disconnect the connectors from TCM and inhibitor switch
inhibitor switch. connector, and
3)Measure the resistance of harness between poor contact in
TCM and inhibitor switch connector. coupling connec-
Connector & terminal tor.
Non-turbo model
(655) NO. 23 - (T7) NO. 9
Turbo model
._ (655) NO. 1 - (T?’) NO. 9
4 CHECK INPUT SIGNAL FOR TCM. Is the voltage less than 1 V in Go to step 25. Go to step 65.
1)Turnthe ignition switch to OFF. ‘P” range?
2)Connect the connector to TCM and inhibitor
switch.
3)Turn the ignition switch to ON.
4)Measure the voltage between TCM and
chassis ground.
Connector & terminal
Non-turbo model
(655) No. 23 (+) - Chassis ground (-):
Turbo model
(655) No. 1 (+) - Chassis ground (-):
5 CHECK INPUT SIGNAL FOR TCM. Is the voltage more than 8 V in Go to step 65. Replace the TCM.
Measure the voltage between TCM and chas- 2ther ranges? <Ref. to AT-45,
sis ground. Transmission Con-
Connector & terminal :rol Module
Non-turbo model :TCM).>
(655) No. 23 (+) - Chassis ground (-):
Turbo model
(655) No. 1 (+) - Chassis ground (-):
6 CHECK “P” RANGE INDICATOR LIGHT s the “ P range indicator light Go to step 27. qeplace the “ P
BULB. iulb OK? ange indicator
1)Turn the ignition switch to OFF. ight bulb. <Ref. to
2)Remove the combination meter. DI-11, Combina-
3)Remove the “ P range indicator light bulb ion Meter Assem-
from combination meter. ilY.>
7 CHECKHARNESSCONNECTORBETWEEN s the resistance more than 1 Go to step 65. 3epair open circuit
TCM AND COMBINATION METER. n? n harness
1)Disconnectthe connectors from TCM and ietween TCM con.
combination meter. lector and combi-
2)Measure the resistance of harness between iation meter, and
TCM and combination meter. ioor contact in
Connector & terminal :oupling connec-
Non-turbo model or.
(655) NO.23 -(112) NO. 14:
Turbo model
(655) NO. 1 - (i12) NO. 14:

AT-I 18
DIAGNOSTIC PROCEDURE FOR NO-DIAGNOSTIC TROUBLE CODE (DTC) I
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

Step Check Yes No

CHECK HARNESS CONNECTOR BETWEEN s the resistance less than 1 30 to step 29. lepair ground
TCM AND INHIBITOR SWITCH. AR? ,hart circuit in “ P
1)Turn the ignition switch to OFF. ange circuit.
2)Disconnect the connectors from TCM, inhibi.
tor switch and combination meter.
3)Measure the resistance of harness between
TCM and chassis ground.
Connector & terminal
Non-turbo model
-
(B55) No. 23 Chassis ground:
Turbo model
(B55) No. 1 - Chassis ground:
CHECK HARNESS CONNECTOR BETWEEN s the resistance less than 1 30 to step 30. lepair open circui
TCM AND INHIBITOR SWITCH. 2? I harness
1)Turn the ignition switch to OFF. between TCM anc
2)Disconnect the connectors from TCM and ihibitor switch
inhibitor switch. :onnector,and
3)Measure the resistance of harness between ioor contact in
TCM and inhibitor switch connector. :oupling connec-
Connector & terminal Dr.
Non-turbo model
(B55) NO. 17 - (V) NO. 8:
Turbo model
(B55) NO. 3- (V) NO. 8:
CHECK INPUT SIGNAL FOR TCM. s the voltage less than 1 V in 30 to step 31. ;o to step 65.
1)Turn the ignition switch to OFF. R” range?
2)Connect the connector to TCM and inhibitor
switch.
3)Turn the ignition switch to ON.
4)Measure the voltage between TCM and
chassis ground.
Connector & terminal
Non-turbo model
(B55) No. 17 (+) - Chassis ground (-):
Turbo model
(B55) No. 3 (+)- Chassis ground (-):
CHECK INPUT SIGNAL FOR TCM. s the voltage more than 8 V in 30 to step 65. leplace the TCM.
Measure the voltage between TCM and chas- )ther ranges? :Ref. to AT-45,
sis ground. -ransmissionCon
Connector & terminal rol Module
Non-turbo model TCM).>
(B55) No. 17 (+) - Chassis ground (-):
Turbo model
(B55) No. 3 (+) - Chassis ground (-):
CHECK “R” RANGE INDICATOR LIGHT s the “R” range indicator light 30 to step 33. leplace the “R”
BULB. )ulb OK? ange indicator
1)Turn the ignition switch to OFF. ght bulb. <Ref. tc
2)Remove the combination meter. DI-11, Combina-
3)Remove the “R” range indicator light bulb ion Meter Assem,
from combination meter. )lY.>

AT-I 19
I DIAGNOSTIC PROCEDURE FOR NO-DIAGNOSTIC TROUBLE CODE (DTC)
AUTOMATIC TRANSMISSION (DIAGNOSTICS)
~ ~~ ~~~~

Step Check Yes No

3 CHECK HARNESS CONNECTOR BETWEEN s the resistance less than 1 30 to step 65. Repair open circuii
TCM AND COMBINATION METER. 2? in harness
1)Disconnectthe connectors from TCM and between TCM con
combination meter. nector and combi-
2)Measure the resistance of harness between nation meter, and
TCM and combination meter. poor contact in
Connector & terminal TCM connector.
Non-turbo model
(B55) NO. 17 - (i12) NO. 13:
Turbo model
(B55) NO. 3 - (i12) NO. 13:
4 CHECK HARNESS CONNECTOR BETWEEN s the resistance more than 1 30 to step 35. Repair ground
TCM AND INHIBITOR SWITCH. AR? short circuit in “R”
1)Turn the ignition switch to OFF. range circuit.
2)Disconnect the connectors from TCM, inhibi.
tor switch and combination meter.
3)Measure the resistance of harness between
TCM and chassis ground.
Connector & terminal
Non-turbo model
(B55) No. 17 - Chassis ground:
._ .. Turbo model
(B55) No. 3 - Chassis ground:
5 CHECK HARNESSCONNECTOR BETWEEN s the resistance less than 1 30 to step 36. Repair open circuit
TCM AND INHIBITOR SWITCH. 2? in harness
1)Turn the ignition switch to OFF. between TCM and
2)Disconnect the connectors from TCM and inhibitor switch
inhibitor switch. connector, and
3)Measure the resistance of harness between poor contact in
TCM and inhibitor switch connector, coupling connec-
Connector & terminal tor.
Non-turbo model
(B55) NO. 22 - (T?) NO. IO:
Turbo model
(B55) NO. 14 - (T7) NO. 10:
6 CHECK INPUT SIGNAL FOR TCM. 5 the voltage less than 1 V in 20 to step 37. Go to step 65.
1)Turn the ignition switch to OFF. N” range?
2)Connect the connector to TCM and inhibitor
switch.
3)Turn the ignition switch to ON.
4)Measure the voltage between TCM and
chassis ground.
Connector & terminal
Non-turbo model
(B55) No. 22 (+) - Chassis ground (-):
Turbo model
(B55) No. 14 (+) - Chassis ground (-):
7 CHECK INPUT SIGNAL FOR TCM. 5 the voltage more than 8 V in 20 to step 65. Replace the TCM.
Measure the voltage between TCM and chas- ither ranges? <Ref. to AT-45,
sis ground. Transmission Con-
Connector & terminal trol Module
Non-turbo model (TCM).>
(B55) No. 22 (+) - Chassis ground (-):
Turbo model
(B55) No. 14 (+) - Chassis ground (-):

AT-I 20
 I
DIAGNOSTIC PROCEDURE FOR NO-DIAGNOSTIC TROUBLE CODE (DTC)
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

Step Check Yes No

8 CHECK “N” RANGE INDICATOR LIGHT s the “N” range indicator light i o to step 39. Replace the “N”
BULB. wlb OK? range indicator
1)Turn the ignition switch to OFF. light bulb. <Ref. to
2)Remove the combination meter. IDI-11, Combina-
3)Remove the “N” range indicator light bulb tion Meter Assem-
from combination meter. bly.>
9 CHECK HARNESS CONNECTOR BETWEEN s the resistance less than 1 i o to step 65. Repair open circuit
TCM AND COMBINATION METER. 2? in harness
1)Disconnect the connectors from TCM and between TCM con-
combination meter. nector and combi-
2)Measure the resistance of harness between nation meter, and
TCM and combination meter. poor contact in
Connector & terminal TCM connector.
Non-turbo model
(B55) NO.22 - (i12) NO. 12:
Turbo model
(B55) NO. 14 - (i12) NO. 12:
0 CHECK HARNESS CONNECTOR BETWEEN s the resistance more than 1 30 to step 41. Repair ground
TCM AND INHIBITOR SWITCH. dQ? short circuit in “N”
1)Turnthe ignition switch to OFF. range circuit.
2)Disconnect the connectors from TCM, inhibi-
tor switch and combination meter.
3)Measure the resistance of harness between
TCM and chassis ground.
Connector & terminal
Non-turbo model
(B55) No. 22 - Chassis ground:
Turbo model
(B55) No. 14 - Chassis ground:
,1 CHECK HARNESSCONNECTOR BETWEEN s the resistance less than 1 i o to step 42. Repair open circuit
TCM AND INHIBITOR SWITCH. n? in harness
1)Turn the ignition switch to OFF. between TCM and
2)Disconnect the connectors from TCM and inhibitor switch
inhibitor switch. connector, and
3)Measure the resistance of harness between poor contact in
TCM and inhibitor switch connector. coupling connec-
Connector & terminal tor.
Non-turbo model
(B55) NO. 8 - (T7) NO. 3:
Turbo model
(B55) NO. 4 - (T7) NO. 3:
12 CHECK INPUT SIGNAL FOR TCM. Is the voltage less than 1 V in 30 to step 43. Go to step 65.
1)Turn the ignition switch to OFF. ‘ D range?
2)Connect the connector to TCM and inhibitor
switch.
3)Turn the ignition switch to ON.
4)Measure the voltage between TCM and
chassis ground.
Connector & terminal
Non-turbo model
(B55) No. 8 (+) - Chassis ground (-):
Turbo model
(B55) No. 4 (+) - Chassis ground (-):

AT-I 21
I DIAGNOSTIC PROCEDURE FOR NO-DIAGNOSTIC TROUBLE CODE (DTC)
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

Step Check Yes No

CHECK INPUT SIGNAL FOR TCM. s the voltage more than 8 V in I Go to step 65. 3eplace the TCM.
Measure the voltage between TCM and chas- Ither ranges? :Ref. to AT-45,
sis ground. rransmission Con-
Connector & terminal ro1 Module
Non-turbo model TCM).>
(B55) No. 8 (+) - Chassis groundI)-(
Turbo model
(B55) No. 4 (+) - Chassis ground (-):
CHECK “D” RANGE INDICATOR LIGHT s the “ D range indicator light ;o to step 45. 3eplace the “ D
BULB. lulb OK? ange indicator
1)Turnthe ignition switch to OFF. ight bulb. <Ref. to
2)Remove the combination meter. DI-11, Combina-
3)Remove the “ D range indicator light bulb ion Meter Assem-
from combination meter. llY.>
CHECK HARNESS CONNECTOR BETWEEN s the resistance less than 1 io to step 65. 3epair open circuit
TCM AND COMBINATION METER. 2? n harness
1)Disconnectthe connectors from TCM and letween TCM con-
combination meter. lector and combi-
2)Measure the resistance of harness between ration meter, and
TCM and combination meter. TCM connector.
Connector & terminal
Non-turbo model
(B55) NO. 8 - (i12) NO. 11:
Turbo model
(B55) NO. 4 - (i12) NO. 11:
CHECK HARNESS CONNECTOR BETWEEN s the resistance more than 1 20 to step 47. 3epair ground
TCM AND INHIBITOR SWITCH. dQ? ;hort circuit in “ D
1)Turnthe ignition switch to OFF. ange circuit.
2)Disconnect the connectors from TCM, inhibi-
tor switch and combination meter.
3)Measure the resistance of harness between
TCM and chassis ground.
Connector & terminal
Non-turbo model
(B55) No. 8 - Chassis ground:
Turbo model
(B55) No. 4 - Chassis ground:
CHECK HARNESS CONNECTOR BETWEEN s the resistance less than 1 io to step 48. 3epair open circuit
TCM AND INHIBITOR SWITCH. 2? n harness
1)Turn the ignition switch to OFF. letween TCM and
2)Disconnect the connector from TCM and nhibitor switch
inhibitor switch. :onnector, and
3)Measure the resistance of harness between loor contact in
TCM and inhibitor switch connector. :oupling connec-
Connector & terminal or.
Non-turbo model
(655) NO. 18 - (P) NO. 11:
Turbo model
(655) NO. 5 - (R) NO. 1 1:

AT-I 22
 I
DIAGNOSTIC PROCEDURE FOR NO-DIAGNOSTIC TROUBLE CODE (DTC)
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

3
Step Check
18 CHECK INPUT SIGNAL FOR TCM. s the voltage less than 1 V in 30 to step 49. Go to step 65.
1)Turn the ignition switch to OFF. 3 range?
2)Connect the connector to TCM and inhibitor
switch.
3)Turn the ignition switch to ON.
4)Measure the voltage between TCM and
chassis ground.
Connector & terminal
Non-turbo model
(B55) No. 18 (+) - Chassis ground (-):
Turbo model
(B55) No. 5 (+) - Chassis ground (-):
I9 CHECK INPUT SIGNAL FOR TCM. s the voltage more than 8 V in 30 to step 65. Replace the TCM.
Measure the hvoltage between TCM and chas- )ther ranges? <Ref. to AT-45,
sis ground. Transmission Con-
Connector & terminal trol Module
Non-turbo model (TCM).>
(B55) No. 18 (+) - Chassis ground (-):
Turbo model
(B55) No. 5 (+) - Chassis ground (-):
io CHECK “3” RANGE INDICATOR LIGHT s the “3” range indicator light 30 to step 51. Replace the “ 3
BULB. ulb OK? range indicator
1)Turn the ignition switch to OFF. light bulb. <Ref. to
2)Remove the combination meter. IDI-11, Combina-
3)Remove the “ 3 range indicator light bulb tion Meter Assem-
from combination meter. bly.>
il CHECK HARNESSCONNECTOR BETWEEN s the resistance more than 1 30 to step 65. Repair open circuii
TCM AND COMBINATION METER. 2? in harness
1)Disconnectthe connectors from TCM and between TCM con
combination meter. nector and combi-
2)Measure the resistance of harness between nation meter, and
TCM and combination meter. poor contact in
Connector & terminal TCM connector.
Non-turbo model
(B55) NO. 18 - (i12) NO. 10:
Turbo model
(B55) NO. 5 - (i12) NO. 10:
i2 CHECK HARNESSCONNECTOR BETWEEN s the resistance more than 1 30 to step 53. Repair ground
TCM AND INHIBITOR SWITCH. del? short circuit in “ 3
1)Turn the ignition switch to OFF. range circuit.
2)Disconnect the connectors from TCM, inhibi-
tor switch and combination meter.
3)Measure the resistance of harness between
TCM and chassis ground.
Connector & terminal
Non-turbo model
(B55) No. 18 - Chassis ground:
Turbo model
(B55) No. 5 - Chassis ground:

AT-I 23
I DIAGNOSTIC PROCEDURE FOR NO-DIAGNOSTIC TROUBLE CODE (DTC)
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

Step Check Yes No

13 CHECK HARNESS CONNECTOR BETWEEN s the resistance less than 1 30 to step 54. 3epair open circuit
TCM AND INHIBITOR SWITCH. n? n harness
1)Turn the ignition switch to OFF. letween TCM and
2)Disconnect the connector from TCM and nhibitor switch
inhibitor switch. :onnector, and
3)Measure the resistance of harness between ioor contact in
TCM and inhibitor switch connector. :oupling connec-
Connector & terminal ‘or.
Non-turbo model
(854) NO. 10 - (T7) NO. 4:
Turbo model
(B55) NO. 6 - (T7) NO. 4:
14 CHECK INPUT SIGNAL FOR TCM. s the voltage less than 1 V in o
; to step 55. 30 to step 65.
1)Turn the ignition switch to OFF. ‘2” range?
2)Connect the connector to TCM and inhibitor
switch.
3)Turn the ignition switch to ON.
4)Measure the voltage between TCM and
chassis ground.
Connector & terminal
Non-turbo model
.. .. (854) No. 10 (+) - Chassis groundI)-(
Turbo model
(B55) No. 6 (+) - Chassis groundI)-(
5 CHECK INPUT SIGNAL FOR TCM. s the voltage more than 8 V in 30 to step 65. 3eplace the TCM.
Measure the voltage between TCM and chas- ither ranges? :Ref. to AT-45,
sis ground. rransmission Con-
Connector & terminal rol Module
Non-turbo model TCM).>
(B54) No. 10 (+) - Chassis ground (-):
Turbo model
(B55) No. 6 (+) - Chassis ground (-):
8
6 CHECK “2” RANGE INDICATOR LIGHT s the “2” range indicator light 30 to step 57. 3eplace the “ 2
BULB. iulb OK? ‘ange indicator
1)Turn the ignition switch to OFF. ight bulb. <Ref. to
2)Remove the combination meter. DI-11, Combina-
3)Remove the “2” range indicator light bulb ion Meter Assem-
from combination met,er. ilY.>
7 CHECK HARNESSCONNECTOR BETWEEN s the resistance less than 1 ;o to step 65. 3epair open circuit
TCM AND COMBINATION METER. 2? n harness
1)Disconnectthe connectors from TCM and letween TCM and
combination meter. :ombination
2)Measure the resistance of harness between neter, and poor
TCM and combination meter. :ontact in TCM
Connector & terminal :onnector.
Non-turbo model
(854) No. 10 - (i12) No. 4:
Turbo model
(B55) No. 6 - (i12) No. 4:

AT-I 24
I DIAGNOSTIC PROCEDURE FOR NO-DIAGNOSTIC TROUBLE CODE (DTC)
I
AUTOMATIC TRANSMISSION (DIAGNOSTICS)
~ ~~

Step Check Yes No

3 CHECK HARNESS CONNECTOR BETWEEN s the resistance more than 1 ;o to step 59. Repair ground
TCM AND INHIBITOR SWITCH. do? short circuit in “ 2
1)Turn the ignition switch to OFF. range circuit.
2)Disconnect the connectors from TCM, inhibi
tor switch and combination meter.
3)Measure the resistance of harness between
TCM and chassis ground.
Connector & terminal
Non-turbo model
(B54) No. 10 - Chassis ground:
Turbo model
(B55) No. 6 - Chassis ground:
3 CHECK HARNESS CONNECTOR BETWEEN s the resistance less than 1 ;o to step 60. Repair open circuit
TCM AND INHIBITOR SWITCH. 1? in harness
1)Turn the ignition switch to OFF. between TCM and
2)Disconnect the connectors from TCM and inhibitor switch
inhibitor switch. connector, and
3)Measure the resistance of harness between poor contact in
TCM and inhibitor switch connector. coupling connec-
Connector & terminal tor.
Non-turbo model
(854) NO. 1 - (P) NO. 6:
Turbo model
(B55) NO. 7 - (P) NO. 6:
3 CHECK INPUT SIGNAL FOR TCM. s the voltage less than 1 V in 30 to step 61. Go to step 65.
1)Turnthe ignition switch to OFF. 1” range?
2)Connect the connector to TCM and inhibitor
switch.
3)Turn the ignition switch to ON.
4)Measure the voltage between TCM and
chassis ground.
Connector & terminal
Non-turbo model
(854) No. 1 (+) - Chassis ground (-):
Turbo model
-
(B55) No. 7 (+) Chassis ground (-):
1 CHECK INPUT SIGNAL FOR TCM. s the voltage more than 8 V in ;o to step 65. Replace the TCM.
Measure the voltage between TCM and chas- ither ranges? <Ref. to AT-45,
sis ground. Transmission Con-
Connector & terminal trol Module
Non-turbo model (TCM).>
-
(854) No. 1 (+) Chassis ground (-):
Turbo model
-
(B55) No. 7 (+) Chassis ground (-):
2 CHECK “1” RANGE INDICATOR LIGHT s the “1” range indicator light 20 to step 63. Replace the “1”
BULB. iulb OK? range indicator
1)Turn the ignition switch to OFF. light bulb. <Ref. to
2)Remove the combination meter. IDI-11, Combina-
3)Remove the “1” range indicator light bulb tion Meter Assem-
from combination meter. bly.>

AT-1 25
I DIAGNOSTIC PROCEDURE FOR NO-DIAGNOSTIC TROUBLE CODE (DTC)
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

Step Check Yes No

i3 CHECK HARNESS CONNECTOR BETWEEN s the resistance less than 1RS i o to step 65. Repair open circuit
TCM AND COMBINATION METER. in harnes between
1)Disconnectthe connectors from TCM and TCM and combi-
combination meter. nation meter, poor
2)Measure the resistance of harness between contact in TCM
TCM and combination meter. connector.
Connector & terminal
Non-turbo model
(B54) No. 1 - (i12) No. 5:
Turbo model
(B55) No. 7 - (i12) No. 5:
i4 CHECK HARNESS CONNECTOR BETWEEN s the resistance more than 1 ;o to step 65. Repair ground
TCM AND INHIBITOR SWITCH. dsz? short circuit in “1”
1)Turn the ignition switch to OFF. range circuit.
2)Disconnect the connectors from TCM, inhibi-
tor switch and combination meter.
3)Measure the resistance of harness between
TCM and chassis ground.
Connector & terminal
Non-turbo model
(B54) No. 1 - Chassis ground:
-. Turbo model
(B55) No. 7 - Chassis ground:
i5 CHECK POOR CONTACT. s there poor contact in inhibi- 3epair poor con- Adjust the inhibi-
or switch circuit? act. tor switch and
select cable. <Ref.
to AT-28, ADJUST-
MENT, Inhibitor
Switch.> and
<Ref. to CS-26,
Select Cable.>

AT-I 26
 I
SYMPTOM RELATED DIAGNOSTIC
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

16.Symptom Related Diagnostic

A: INSPECTION
Svmptom Problem parts I
Inhibitor switch
Starter does not rotate when the select lever is in “P” or “N”; Select cable
starter rotates when the select lever is in “R”, “D”, “ 3 or “ 2 . Select lever
Starter motor and harness
~~

Strainer
Transfer duty solenoid
Abnormal noise when the select lever is in “ P or “N” Oil pump
Drive plate
ATF level too high or too low
Strainer
Hissing noise occurs during standing start.
ATF level too high or too low
Noise occurs while driving in “Dl”. Final gear
Planetary gear
Noise occurs while driving in “ 0 2 . Reduction gear
Differential gear oil level too high or too low
Final gear
Low & reverse brake
Noise occurs while driving in “ D 3
Reduction gear
Differential gear oil level too high or too low
Final gear
Low & reverse brake
Noise occurs while driving in ‘ID4 Planetary gear
Reduction gear
Differential gear oil level too high or too low
Control valve
Lock-up damper
Engine stalls while shifting from one range to another.
Engine performance
Input shaft
TCM
Vehicle moves when the select lever is in “N”.
Low clutch
TCM
Harness
Shock occurs when the select lever is moved from “N” to “ D .
Control valve
ATF deterioration
Control valve
Low clutch
Excessive time lag occurs when the select lever is moved from
Line pressure duty solenoid
“N” to “ D .
Seal ring
Front gasket transmission case
TCM
Harness
Shock occurs when the select lever is moved from “N” to “R”.
Control valve
ATF deterioration
Control valve
Low & reverse clutch
Excessive time lag occurs when the select lever is moved from Reverse clutch
“N” to “R”. Line pressure duty solenoid
Seal ring
Front gasket transmission case
Parking brake mechanism
Vehicle does not start in any shift range (engine stalls).
Planetarv aear

AT-127
 I
SYMPTOM RELATED DIAGNOSTIC
AUTOMATIC TRANSMISSION (DIAGNOSTICS)
~~

Symptom ’roblem parts

Strainer
1 Line pressure duty solenoid

I Control valve

1 Drive pinion

1 Hypoid gear

1 Axle shaft

1 Differential gear
Vehicle does not start in any shift range (engine revving up).
1 Oil pump

1 Input shaft

b Output shaft

b Planetary gear
b Drive plate
b ATF level too low

b Front gasket transmission case

b Select cable

Vehicle does not start in “R” range only (engine rewing up).
b

.Select lever
Control valve
b

.Low & reverse clutch

Reverse clutch

,Vehicle does not start in “R” range only (engine stalls).

..
Low clutch
2-4 brake

.
-
Planetary gear
Parking brake mechanism
Low clutch
Vehicle does not start in “D”, “ 3 range only (engine rewing up).
* One-wav clutch
Vehicle does not start in “D”, “ 3or “2” range only (engine rev- Low clutch
vina up).
Vehicle does not start in “D”, “ 3 or “ 2 range only (engine
stalls).
.Reverse clutch

Vehicle starts in “R” range only (engine revving up). Control valve
Control valve
Low clutch
Reverse clutch
Acceleration during standing starts is poor (high stall rpm).
ATF level too low
Front gasket transmission case
Differential gear oil level too high or too low
Oil pump
Acceleration during standing starts is poor (low stall rpm). Torque converter one-way clutch
Engine performance
TCM
Control valve
Acceleration is poor when the select lever is in “D”, “ 3 or “ 2
High clutch
range (normal stall rpm).
2-4 brake
Planetary gear

I
Control valve
Acceleration is poor when the select lever is in “R” (normal stall High clutch
rpm). 2-4 brake
Planetary gear
TCM
Rear vehicle speed sensor
Front vehicle speed sensor
No shift occurs from 1st to 2nd gear. Throttle position sensor
Shift solenoid 1
Control valve
2-4 brake
TCM
Control valve
No shift occurs from 2nd to 3rd gear.
High clutch
Shift solenoid 2
 I
SYMPTOM RELATED DIAGNOSTIC
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

Problem parts
TCM
B Shift solenoid 1
No shift occurs from 3rd to 4th gear. B ATF temperature sensor

r
Control valve
B 2-4 brake

B Inhibitor switch
Engine brake is not effected when the select lever is in “ 3 TCM
range. * Throttle position sensor
* Control valve
‘Engine brake is not effected when the select lever is in “ 3 or “2” 0 Control valve
range.
Engine brake is not effected when the select lever is in “1” * Control valve
range. Low & reverse brake
Inhibitor switch
TCM
Front vehicle speed sensor
Shift characteristics are erroneous. Rear vehicle speed sensor
Throttle position sensor
Control valve
Ground earth
TCM
Throttle position sensor
ATF temperature sensor
Control valve
Lock-up facing
Engine speed signal
m n u brake is not effected. Select cable
Select lever
Shift lever cannot be moved or is hard to move from “P” range. Parkinu mechanism
ATF spurts out. ATF level too high
Differential oil swrts out. Differential gear oil too high
Seal pipe
Differential oil level changes excessively.
Double oil seal
High clutch
2-4 brake
Low & reverse clutch
Odor is produced from ATF supply pipe.
Reverse clutch
Lock-up facing
ATF deterioration
TCM
Throttle position sensor
2-4 brake duty solenoid
ATF temperature sensor
Line pressure duty solenoid
Shock occurs from 1st to 2nd gear.
Control valve
2-4 brake
ATF deterioration
Engine performance
2-4 brake timing solenoid
TCM
Throttle position sensor
2-4 brake duty solenoid
ATF temperature sensor
Line pressure duty solenoid
Control valve
2-4 brake
2-4 brake timing solenoid
Hiah clutch
I
 SYMPTOM RELATED DIAGNOSTIC
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

Symptom Problem parts

TCM
Throttle position sensor
2-4 brake duty solenoid
ATF temperature sensor
Line pressure duty solenoid
Shock occurs from 2nd to 3rd gear. Control valve
High clutch
2-4 brake

r
ATF deterioration
Engine performance
2-4 brake timing solenoid
TCM
Throttle position sensor
2-4 brake duty solenoid
ATF temperature sensor
Slippage occurs from 2nd to 3rd gear. Line pressure duty solenoid
Control valve
High clutch
2-4 brake
2-4 brake timing solenoid
TCM
Throttle position sensor
2-4 brake duty solenoid
ATF temperature sensor
Line pressure duty solenoid
Control valve
2-4 brake timing solenoid
2-4 brake
ATF deterioration
Engine performance
Low clutch timing solenoid
Low clutch
TCM
Throttle position sensor
2-4 brake duty solenoid
ATF temperature sensor
Slippage occurs from 3rd to 4th gear. Line pressure duty solenoid
Control valve
2-4 brake
2-4 brake timing solenoid
TCM
Throttle position sensor
ATF temperature sensor
Line pressure duty solenoid
Shock occurs when the select lever is moved from “ 3 to “ 2 Control valve
2-4 brake duty solenoid
2-4 brake
ATF deterioration
2-4 brake timing solenoid
TCM
Throttle position sensor
ATF temperature sensor
I Shock occurs when the select lever is moved from “ 0to “1” Line pressure duty solenoid
Control valve
range. ATF deterioration
2-4 brake duty solenoid
2-4 brake timing solenoid
Low clutch timinu solenoid

AT-I 30
 SYMPTOM RELATED DIAGNOSTIC
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

3vmPtom Problem parts

TCM
Throttle position sensor
ATF temperature sensor
Line pressure duty solenoid
Shock occurs when the select lever is moved from “2” to “1” Control valve
.ange. Low & reverse clutch
ATF deterioration
2-4 brake duty solenoid
2-4 brake timing solenoid
Low clutch timing solenoid
TCM
Throttle position sensor
ATF temperature sensor
Line pressure duty solenoid
Shock occurs when the accelerator pedal is released at Control valve
nedium speeds. Lock-up damper
Engine performance
2-4 brake duty solenoid
2-4 brake timing solenoid
Low clutch timing solenoid
TCM
Lock-up duty solenoid
Vibration occurs during straight-forwardoperation.
Lock-up facing
Lock-up damper
TCM
Front vehicle speed sensor
Rear vehicle speed sensor
Throttle position sensor
Vibration occurs during turns (tight corner “braking” phenome- ATF temperature sensor
non). Transfer clutch
Transfer valve
Transfer duty solenoid
ATF deterioration
Harness
TCM
Front vehicle speed sensor
Throttle position sensor
ATF temperature sensor
Front wheel slippage occurs during standing starts. Control valve
Transfer clutch
Transfer valve
Transfer pipe
Transfer dutv solenoid
TCM
Transfer clutch
Vehicle is not set in FWD mode.
Transfer valve
Transfer duty solenoid
Select cable
Select lever
Select lever is hard to move.
Detent spring
Manual date
Detent spring
Select lever is too high to move (unreasonable resistance).
Manual plate
Select cable
Select lever slips out of operation during acceleration or while Select lever
driving on rough terrain. Detent spring
Manual plate

AT-1 31
I SYMPTOM RELATED DIAGNOSTIC
I
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

AT-I 32
 MANUAL TRANSMISSION AND
DIFFERENTIAL

MT
Page
1. General Description .................................................................................... 2
2. Transmission Gear Oil .............................................................................. 26
3. Manual Transmission Assembly ............................................................... 27
4. Transmission Mounting System ................................................................ 34
5. Oil Seal ...................................................................................................... 36
6. Switches and Harness .............................................................................. 37
7. Vehicle Speed Sensor ............................................................................... 39
8. Preparation for Overhaul ........................................................................... 40
9. Transfer Case and Extension Case Assembly .......................................... 41
r . 10. Transfer Drive Gear .................................................................................. 45
11. Transfer Driven Gear ................................................................................ 47
12. Center Differential ..................................................................................... 49
13. Reverse Check Sleeve .............................................................................. 50
14. Transmission Case ................................................................................... 54
15. Main Shaft Assembly for Single-Range .................................................... 57
16. Drive Pinion Shaft Assembly ..................................................................... 63
17. Front Differential Assembly ....................................................................... 71
18. Speedometer Gear .................................................................................... 77
19. Reverse Idler Gear .................................................................................... 78
20. Shifter Fork and Rod ................................................................................. 80
21 . General Diagnostic.................................................................................... 84
 GENERAL DESCRIPTION
3
MANUAL TRANSMISSION AND DIFFERENTIAL

1. General Description
A: SPECIFICATIONS
1. MANUAL TRANSMISSION AND DIFFERENTIAL

Sedan Wagon
Type 5-forward speeds with synchromesh and 1-reverse
1st 3.454 3.454
2nd 2.062 1.947
3rd 1.448 1.366
Transmission gear ratio
F I 1.088 I 0.972
15th I 0.780 I 0.738
I Reverse I 3.333
Type of gear Hypoid
Gear ratio 4.1 11 I
3.900
Type of gear Helical
Transfer
Gear ratio 1.ooo 1.100
Rear reduction gear
C. ~
Type of gear Hypoid
Final
Gear ratio 4.1 11 3.900 3.545
Front differential 1 Type and number of gear Straight bevel gear (Bevel pinion: 2, Bevel gear: 2)

Center differential I Type and number of gear

I Straight bevel gear
(Bevel Dinion: 2, Bevel aear: 2 and viscous couplina)
Transmission aear
" .
oil I
GL-5
Transmission aear oil caeacitv I 3.5 8 (3.7 US qt, 3.1 Imp qt)

2. TRANSMISSION GEAR OIL

Recommended oil

Transmission gear oil

API Classification

SAE Viscosity No and Applicable Temperature

(OF) -22 -15

MT-2
 GENERAL DESCRIPTION
3
MANUAL TRANSMISSION AND DIFFERENTIAL

3. TRANSMISSION CASE ASSEMBLY 4. DRIVE PINION ASSEMBLY

Drive pinion shim adjustment Preload adjustment of thrust bearing
Hypoid gear backlash Starting torque
0.13 - 0.18 mm (0.0051 - 0.0071 in) 0.3 - 0.8 N-m (0.03 - 0.08 kgf-m, 0.2 - 0.6 ft-
Drive pinion shim Ib)

Part No.
Thickness
mm (in)
1 Part No.
mm (in) Part No. Thickness mm (in)

32295AA031
I 803025052 I 3.950 (0.1555) I
0.275 803025053
32295AA041

32295AA051 803025055
(0.0079) (0.01 18)

32295AA061 I 32295AAlOl

Selection of main shaft rear plate

I Main shaft rear date I
bimension"Amm (in) I Part No. I Mark I 803025059 3.850 (0.1516)
. . 4.00-4.13
32294AA041 1
(0.1575 - 0.1626)
3.87 - 3.99
32294AA051 2 5. MAIN SHAFT
(0.1524 - 0.1571)

Input shaft holder adjustment Snap ring (Outer-25) to synchronizer hub clear-
ance
I Dimension " D mm (in) I Number of shim I 0.060 - 0.100 mm (0.0024 - 0.0039 in)
52.50 - 53.1 1
(2.0669 - 2.0909)
- I SnaD rina (Outer-25) 1
Thickness Part No, Thickness
52.00 - 52.49 Part No.
1 mm (in) mm (in)
(2.0472 - 2.0665)
- 805025051 2.42 (0.0953) 805025055 2.62 (0.1031)
51.26 - 51.99
2 805025052 2.47 (0.0972) 805025056 2.67 (0.1051)
(2.0181 - 2.0468)
805025053
_________- - - (0.0992)
2.52 ,- ,
805025057 2.72 (0.1071)
1
I

I
- - - - I

805025054 I 2.57 (0.1012) I 805025058 I 2.37 (0.0933)

MT-3
 GENERAL DESCRIPTION
I
MANUAL TRANSMISSION AND DIFFERENTIAL

6. REVERSE IDLER GEAR 7. SHIFTER FORK AND ROD

Adjustment of reverse idler gear position Select suitable shifter forks so that both coupling
Reverse idler gear to transmission case (LH) wall sleeve and reverse driven gear are positioned in
clearance the center of their synchromesh mechanisms.
6.0 - 7.5 mm (0.236 - 0.295 in) Rod end clearance
A: 1st-2nd - 3rd-4th
0.4 - 1.4 mm (0.016 - 0.055 in)
Part No. Mark Remarks
B: 3rd-4th - 5th
0.5 - 1.3 mm (0.020 - 0.051 in)
I 32820AA080 I 8 I Standard I
I 32820AA090 I 9 I Closer to the case wall I I 1st-2nd shifter fork I
I Part No. I Mark I Remarks I
After installing a suitable reverse shifter lever, ad-
just reverse idler gear to transmission case wall I 32804AA060 1 Approach to 1st gear
by 0.2 mm (0.008 in)
clearance to within 0 to 0.5 mm (0 to 0.020 in) using 32804AA070 I No mark I Standard
1
washers.
I
I 32804AA080 I 3 I Approach to 2nd gear
by 0.2 mm (0.008 in) I
I Part No.
I Thickness
mm (in)
I
Washer (20.5 x 26 x t)
Part No, I
y; : ;T I
I

803020151 0.4 (0.016) 803020154 1.9 (0.075) Part No. Mark Remarks
--803020152 1.1 (0.043) 803020155 2.3 (0.091) Approach to 4th gear
32810AA061 1
803020153 1.5 (0.059) - - bv 0.2 mm (0.008 in)
I 32810AA071 I No mark I Standard I
I 32810AA101 I 3 I Approach to 3rd gear
bv 0.2 mm (0.008 in)

I 5th shifter fork (Non-turbo)

I Part No. I Mark I Remarks I
I 32812AA201 I 4 I
Approach to 5th gear
bv 0.2 mm (0.008 in) I
Become distant from
32812AA221 5th gear by 0.2 mm
(0.008 in)

Part No. Mark Remarks

I 32812AA231 I ' 1 Approach to 5th gear

by 0.2 mm (0.008 in) I
32812AA241 No mark Standard
Become distant from
32812AA251 9 5th gear by 0.2 mm
(0.008 in)

MT-4
 GENERAL DESCRIPTION
MANUAL TRANSMISSION AND DIFFERENTIAL

8. TRANSFER CASE 9. EXTENSION ASSEMBLY

Neutral position adjustment Thrust washer (50 x 61 x t) to taper roller bearing
table outer race side clearance
0.2 - 0.3 mm T (0.0008 - 0.012 in T)
Part No. Thickness mm (in)
32190AA000 0.15 (0.0059) NOTE:
T: Tight
I 32190AA010 I 0.30 (0.0118) I

Part No. Thickness mm (in)

Part No. Mark Remarks 803050060 0.50 (0.0197)
Neutral position is 803050061 0.55 (0.0217)
32188AA090 3
closer to 1st.
I 803050062 I 0.60 (0.0236) I
I 32188AA100 I 0 I Standard I 803050063 0.65 (0.0256)
I 32188AA110 I 1 I Neutral position is
closer to reverse aear. I 803050064
803050065
0.70 (0.0276)
0.75 (0.0295)
Reverse check plate adjustment 803050066 0.80 (0.0315)
803050067 0.85 (0.0335)
I -
Reverse check plate I
I Part No. Mark1 Angle
e I I
Remarks
I I
803050068
803050069 I
0.90 (0.0354)
0.95 (0.0374) I
.-.. Arm stops closer to I 803050070 I 1.OO (0.0394) I
32189AA000 0 803050071 1.05 (0.0413)
I I I
280
I
-
5th qear.
I
Arm stops closer to 803050072 1.10 (0.0433)
32189AA010 1
31" 5th gear. 803050073 1.15 (0.0453)
Arm stops in the cen- 803050074 1.20 (0.0472)
33189AA020 2
340 ter. I 803050075 I 1.25 (0.0492) I
Arm stops closer to I 803050076 I 1.30 (0.0512) I
32189AA030 3
370 reverse gear. 803050077 1.35 (0.0531)
I 32189AA040 I 4 I 40" I Arm stops closer to
reverse aear. I 803050078
803050079
1.40 (0.0551)
1.45 (0.0571)

Part No. Thickness mm (in)

I 803036050 I 0.9 (0.035) I
803036054 1.O (0.039)
803036051 1.1 (0.043)
803036055 1.2 (0.047)
803036052 1.3 (0.051 )
803036056 1.4 (0.055)
803036053 1.5 (0.059)
I 803036057 I 1.6 (0.063) I
803036058 1.7 (0.067)

MT-5
 GENERAL DESCRIPTION
MANUAL TRANSMISSION AND DIFFERENTIAL

1O.FRONT DIFFERENTIAL 11.TRANSFER DRIVE GEAR

Snap ring (Outer-30)

Washer (38.1 x 50 x t)
Part No. Thickness mm (in)
Thickness Part No, Thickness
Part No. 805030041 1.53 (0.0602)
mm (in) mm (in)
0.925 - 1.025 - 805030042 1.65 (0.0650)

I I 0.0374) I I 0.0413) I
I
I 803038022
I
I
0.975-
l.ooo
(0.0384-
I
I
- 1
I
- II

Thickness Part No. Thickness

Part No.
mm (in) mm (in)
805028011 I 1.05 (0.0413) 1 805028012 I 1.20 (0.0472)

MT-6
 GENERAL DESCRIPTION
I
MANUAL TRANSMISSION AND DIFFERENTIAL

B: COMPONENT
1. TRANSMISSION CASE

(1) Transmission case ASSY (7) Speedometer shaft (13) Oil level gauge (Non-turbo model)
(2) Gasket (8) Snap ring (Outer) (14) Oil level gauge (Turbo model)
(3) Drain plug (9) Oil seal
(4) Snap ring (Outer) (10) Clamp Tightening torque: N.m (kgf-m, ff-lb)
(5) Speedometer driven gear (11) Pitching stopper bracket T: 44 (4.5, 32.5)
(6) Washer (12) Clip

Size All models Tightening torque: N.m (kgf-m, ft-lb)

8 mm bolt <5> - <I 5> 25 (2.5, 18.1)
< I > - <4>
10 mm bolt 39 (4.0, 28.9)
<16> - <17>

MT-7
I GENERAL DESCRIPTION
MANUAL TRANSMISSION AND DIFFERENTIAL

2. DRIVE PINION ASSEMBLY

/
/’

/
/’

S3M0423B

(1) Drive pinion shaft (15) Baulk ring (29) Locknut

(2) Roller bearing (16) 1st-2nd synchronizer hub (30) Washer
(3) Washer (17) Insert key (31) Thrust bearing
(4) Thrust bearing (18) Reverse driven gear (32) Differential bevel gear sleeve
(5) Needle bearing (19) Outer baulk ring (33) Washer
(6) Driven shaft (20) Synchro cone (34) Lock washer
(7) Key (21) Inner baulk ring (35) Locknut
(8) Woodruff key (22) 2nd driven gear
(9) Drive pinion collar (23) 2nd driven gear bush Tightening torque: N.m (kgf-m, ft-lb)
(10) Needle bearing (24) 3rd-4th driven gear T1: 29 (3.0, 21.7)
(11) Snap ring (Outer) (25) Driven pinion shim T2: 118 (12.0, 86.8)
(12) Washer (26) Roller bearing T3: 265 (27, 195)
(13) Subgear (27) 5th driven gear
(14) 1st driven gear (28) Lock washer

MT-8
 GENERAL DESCRIPTION I
MANUAL TRANSMISSION AND DIFFERENTIAL

3. MAIN SHAFT ASSEMBLY

Oil seal Needle bearing Ball bearing

Needle bearing 4th gear thrust washer Synchro cone stopper
Transmission main shaft Ball bearing Snap ring
Needle bearing 5th gear thrust washer Lock washer
3rd drive gear 5th needle bearing race Lock nut
Inner baulk ring Needle bearing Reverse idler gear shaft
Synchro cone (3rd) Main shaft rear plate Straight pin
Outer baulk ring 5th drive gear Reverse idler gear
Coupling sleeve (3rd-4th) 5th baulk ring Washer
Synchronizer hub (3rd-4th) Shifting insert key (5th-Rev)
Shifting insert key (3rd-4th) Synchronizer hub (5th-Rev) Tightening torque: N.m (kgf-m, ft-lb)
4th baulk ring Coupling sleeve (5th-Rev) T: 118 (12.0, 86.8)
4th drive gear Rev baulk ring
4th needle bearing race Synchro cone (Rev)

MT-9
I GENERAL DESCRIPTION
I
MANUAL TRANSMISSION AND DIFFERENTIAL

4. SHIFTER FORK AND SHIFTER ROD

r-

(1) Shifter arm (9) 3rd-4th fork rod (17) Reverse fork rod arm
(2) 5th shifter fork (10) Interlock plunger (18) Reverse shifter lever
(3) Straight pin (1 1) 1st-2nd fork rod
(4) Reverse fork rod (12) 3rd-4th shifter fork Tightening torque: N-m (kgf-m, ft-lb)
(5) Checking ball plug (13) 1st-2nd shifter fork T: 19.6(2.0, 14.5)
(6) Gasket (14) Ball
(7) Checking ball spring (15) Spring
(8) Ball (16) Snap ring (Outer)

MT-10
 GENERAL DESCRIPTION
I
MANUAL TRANSMISSION AND DIFFERENTIAL

5. TRANSFER CASE AND EXTENSION

I .

TROOO

Oil guide Return spring (31) Transfer drive gear

Gasket O-ring (32) Ball bearing
Transfer case Adjusting select shim (33) Extension
Ball Reverse check sleeve (34) Oil seal
Reverse accent spring Gasket (35) Dust cover
Gasket Neutral switch (36) Shift bracket
Plug Gasket (37) Snap ring
Oil seal Back-up light switch
Snap ring (Inner) Roller bearing Tightening torque: N.m (kgf-myft-lb)
Reverse check plate Transfer driven gear T1: 6.4 (0.65, 4.7)
Reverse check spring Roller bearing T2: lO(1.0, 7.2)
Reverse return spring Adjusting washer T3: 25 (2.5, 18.1)
Reverse check cam Ball bearing T4: 26 (2.7, 20)
Reverse accent shaft Center differential T5: 40 (4.1, 29.7)
Return spring cap Adjusting washer

MT-11
I GENERAL DESCRIPTION I
MANUAL TRANSMISSION AND DIFFERENTIAL

6. FRONT DIFFERENTIAL

H3M1967A

(1) Drive pinion shaft (8) Snap ring (Outer) (15) Retainer lock plate
(2) Hypoid driven gear (9) Roller bearing
(3) Pinion shaft (10) Differentialcase Tightening torque: N.m (kgf-m, ft-lb)
(4) Straight pin (1 1) Oil seal T1: 25(2.5, 18.1)
(5) Washer (12) Differential side retainer T2: 62 (6.3, 45.6)
(6) Differential bevel gear (13) O-ring
(7) Differential bevel pinion (14) Axle drive shaft

MT-12
 GENERAL DESCRIPTION I
MANUAL TRANSMISSION AND DIFFERENTIAL

7. TRANSMISSION MOUNTING

“i, @
I
’\

TROOl:

(1) Pitching stopper (8) Cushion D Tightening torque: N.m (kgf-m, ft-lb)
(2) Spacer (9) Center crossmember T l : 7.5 (0.76, 5.5)
(3) Cushion C (10) Rear plate T2: 35 (3.6,26)
(4) Front plate (1 1) Front crossmember T3: 50 (5.1, 37)
(5) Damper T4: 58 (5.9, 43)
(6) Rear cushion rubber T5: 70 (7.1, 51)
(7) Rear crossmember T6: 140(14.3, 103)

MT-13
I GENERAL DESCRIPTION
MANUAL TRANSMISSION AND DIFFERENTIAL

C: CAUTION Be sure to tighten fasteners including bolts and

Wear working clothing, including a cap, protec-
tive goggles, and protective shoes during opera-
tion.
Remove contamination including dirt and corro-
sion before removal, installation, and disassembly.
Keep the disassembled parts in order and pro-
tect them from dust or dirt.
Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary re-
moval, installation, disassembly and replacement.
When disassembling the case and other light al-
loy parts, use a plastic hammer to force it apart. Do
not pry it apart with a screwdriver or other tool.
Be careful not to burn your hands, because each
part on the vehicle is hot after running.
Use SUBARU genuine gear oil, grease etc. or
the equivalent. Do not mix gear oil, grease etc. with
that of another grade or from other manufacturers.
nuts to the specified torque.
Place shop jacks or safety stands at the specified
points.
Apply gear oil onto sliding or revolution surfaces
before installation.
Replace deformed or otherwise damaged snap
rings with new ones.
Before installing O-rings or oil seals, apply suffi-
cient amount of gear oil to avoid damage and defor-
mation.
Be careful not to incorrectly install or fail to install
O-rings, snap rings and other such parts.
Before securing a part on a vice, place cushion-
ing material such as wood blocks, aluminum plate,
or shop cloth between the part and the vice.
Avoid damaging the mating surface of the case.
Before applying sealant, completely remove the
old seal.

D: PREPARATION TOOL
r. ~

1. SPECIAL TOOLS

ILLUSTRATION I TOOLNUMBER DESCRIPTION REMARKS

398791700 REMOVER Used for removing and installing spring pin (6
mm).

B3M1938
39941 1700 ACCENT BALL Used for installing reverse shifter rail arm.
INSTALLER

B3M1939

MT-14
 GENERAL DESCRIPTION 1
MANUAL TRANSMISSION AND DIFFERENTIAL

--t ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

399527700 'ULLER SET k e d for removing and installing roller bearing
Differential).
1) BOLT (899521412)
2) PULLER (399527702)
3) HOLDER (399527703)
4) ADAPTER (398497701)
5 ) BOLT (899520107)
6) NUT (021008000)

I B3M1940A
399780104 VEIGHT Jsed for measuring preload on roller bearing.

I B3M1941
498077000 3EMOVER Used for removing roller bearing of drive pinion
shaft.

I B3M194;
498077300 CENTER DIFFER- Used for removing the center differential cover
ENTIAL BEARING ball bearing.
REMOVER

I B3M194:

MT-15
I GENERAL DESCRIPTION
MANUAL TRANSMISSION AND DIFFERENTIAL

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

498147000 DEPTH GAUGE Used for adjusting main shaft axial end play.

~~

498247001 MAGNET BASE Used for measuring backlash between side

gear and pinion, and hypoid gear.
Used with DIAL GAUGE (498247100).

-t B3M1945
498247100 31AL GAUGE m Used for measuring backlash between side

.
gear and pinion, and hypoid gear.
Used with MAGNET BASE (498247001).

r--- B3M1946
498427100 STOPPER Jsed for securing the drive pinion shaft assem-
3ly and driven gear assembly when removing the
jrive pinion shaft assembly lock nut.

I B3M1947

MT-16
 GENERAL DESCRIPTION 3
MANUAL TRANSMISSION AND DIFFERENTIAL

ILLUSTRATION TOOL NUMBER DESCRIPTION

_ _ _- I REMARKS
498787100 JlAlN SHAFT Used for removing and installing transmission
;TOPPER main shaft lock nut.

B3M1948
498937000 rRANSMlSSlON Jsed for removing and installing transmission
i0LDER nain shaft lock nut.

B3M1945
499277100 BUSH 1-2 1 Used for installing 1st driven gear thrust plate
INSTALLER and 1st-2nd driven gear bush.
1 Used for installing roller bearing outer races to
jifferential case.

B3M195l
499277200 INSTALLER Used for press-fittingthe 2nd driven gear, roller
bearings, and 5th driven gear onto the driven
shaft.

B3M195

MT-17
 GENERAL DESCRIPTION
MANUAL TRANSMISSION AND DIFFERENTIAL

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

499757002 INSTALLER Used for installing snap ring (OUT 25), and
ball bearing (25 x 26 x 17).
Used for installing bearing cone of transfer
driven gear (extension core side).

B3M1952
499787000 NRENCH ASSY Used for removing and installing differential side
retainer.

B3M1953
499827000 WESS Used for installing speedometer oil seal when
Installing speedometer cable to transmission.

B3M1954
499857000 jTH DRIVEN GEAR Jsed for removing 5th driven gear.
3EMOVER

B3M1955

MT-18
 GENERAL DESCRIPTION I
MANUAL TRANSMISSION AND DIFFERENTIAL

IL
TOOL NUMBER DESCRIPTION L
REMARKS
499877000 3ACE 4-5 1 Used for installing 4th needle bearing race and
NSTALLER ,all bearing onto transmission main shaft.
1 Used with REMOVER (8997141IO).

I
B3M1956
499917500 ]RIVE PINION Used for adjusting drive pinion shim.
3AUGE ASSY

+ B3M1957
499927100 HANDLE Used for fitting transmission main shaft.

I B3M1958
~

499937100 TRANSMISSION Stand used for transmission disassembly and

STAND SET assembly.

I B3M1959

MT-19
 GENERAL DESCRIPTION I
MANUAL TRANSMISSION AND DIFFERENTIAL

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

499987003 SOCKET WRENCH Used for removing and installing driven pinion
(35) lock nut and main shaft lock nut.

B3M1960
499987300 SOCKET WRENCH Used for removing and installing driven gear
(50) assembly lock nut.

...

B3M1961
8997141 10 REMOVER Used for fixing transmission main shaft, drive
pinion, rear drive shaft.

B3M1962
899864100 REMOVER Used for removing parts on transmission main
shaft and drive pinion.

B3M1963

MT-20
 GENERAL DESCRIPTION I
MANUAL TRANSMISSION AND DIFFERENTIAL

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

899884100 iOLDER Jsed for tightening lock nut on sleeve.

B3M1964
899904100 3 EMOVER Used for removing and installing straight pin.

B3M1965
899988608 SOCKET WRENCH Used for removing and installing drive pinion lock
?7) nut.

B3M1966
398497701 ADAPTER Used for installing roller bearing onto differen-
tial case.
Used with INSTALLER (499277100).

B3M1967

MT-21
 GENERAL DESCRIPTION
MANUAL TRANSMISSION AND DIFFERENTIAL

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

499587000 INSTALLER Used for installing driven gears to driven shaft.

B3M1968
899824100 PRESS Used for installing speedometer shaft oil seal.

B3M1969
499987100 SOCKET WRENCH Llsed for removing and installing drive pinion lock
(35) IUt.

B3M1970
899984103 SOCKET WRENCH Jsed for removing and installing drive pinion lock
(35) IUt.

B3M1971

MT-22
 GENERAL DESCRIPTION
I
MANUAL TRANSMISSION AND DIFFERENTIAL

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

498057300 NSTALLER Jsed for installing extension oil seal.

B3M1972
498255400 'LATE Used for measuring backlash.

B3M1973
498077400 REMOVER Used for removing synchronizer cone of main
shaft.
Used for removing 5th driven gear of drive pin-
ion shaft.

B3M1974
41099AA010 ENGINE SUPPORT Used for supporting engine.
BRACKET

B3M1975

MT-23
 GENERAL DESCRIPTION
I
MANUAL TRANSMISSION AND DIFFERENTIAL

r------
ILLUSTRATION TOOL NUMBER
41099AA020
DESC R IPTION
ENGINE SUPPORT
REMARKS
Jsed for supporting engine.

398527700 PULLER ASSY Jsed for removing and installing extension case
*oiler bearing.

I-
B3M1977
398643600 GAUGE Jsed for measuring total end play, extension end
2lay and drive pinion height.

I B3M1978
38177700 INSTALLER 1 Used for installing bearing cone of transfer

driven gear (transfer case side).

1 Used for installing ball bearing of transfer drive

gear.

B3M1905

MT-24
 GENERAL DESCRIPTION
1
MANUAL TRANSMISSION AND DIFFERENTIAL

2. GENERAL PURPOSE TOOLS

TOOL NAME REMARKS

Circuit Tester Used for measuring resistance, voltage and ampere.

MT-25
I TRANSMISSION GEAR OIL
MANUAL TRANSMISSION AND DIFFERENTIAL

2. Transmission Gear Oil B: REPLACEMENT

1) Pull out oil level gauge.
A: INSPECTION 2) Lift-up the vehicle.
1) Park vehicle on a level surface. 3) Drain the transmission gear oil completely.
2) Turn the ignition switch to OFF, and wait until the
CAUTION:
engine cools. Directly after the engine has been running, the
3) Remove the oil level gauge and wipe it clean. transmission gear oil is hot. Be careful not to
4) Reinsert the level gauge all the way. Be sure burn yourself.
that the level gauge is correctly inserted and in the
proper direction. NOTE:
5) Pull out the oil level gauge again and check the Tighten the transmission gear oil drain plug after
oil level on it. If it is below the lower level, add oil draining transmission gear oil.
through the oil level gauge hole to bring the level up Tightening torque:
to the upper level. 44 N.m (4.5 kgf-m, 325 ft-lb)

e' A S3M0470A

(A) Drain plug

(B) Gasket

4) Lower the vehicle.

5 ) Pour the gear oil into the gauge hole.
Recommended gear oil:
Use GL-5 or equivalent.
Gear oil capacity:
3.5 0 (3.7 US 9t, 3.1 Imp 9t)
6 ) Check the level of the transmission gear oil.
CAUTION:
When inserting the level gauge into transmis-
sion gear, align the protrusion on the side of
the top part of the level gauge with the notch in
the gauge hole.
NOTE:
The level should be within the specified range
marked on the gauge.

MT-26
 I
MANUAL TRANSMISSION ASSEMBLY
MANUAL TRANSMISSION AND DIFFERENTIAL

3. Manual Transmission As- (3) Vehicle speed sensor

sembly
A: REMOVAL
1) Open the front hood fully, and support with stay.
2) Disconnect the battery ground terminal.
3) Remove the air intake duct and cleaner case.
(Non-turbo model) <Ref. to IN(S0HC)-7, REMOV-
AL, Air Intake Duct.> and <Ref. to IN(S0HC)-6,
REMOVAL, Air Cleaner Case.>
4) Remove the air cleaner case stay. (Non-turbo
model)
7) Remove the starter. <Ref. to SC-6, REMOVAL,
Starter.>
8) Remove the operating cylinder from the trans-
mission.
Non-turbo model

5 ) Remove the intercooler (Turbo model) <Ref. to

IN(D0HC TURBO)-10, REMOVAL, Intercooler.>
6) Disconnect the following connectors.
(1) Neutral position switch connector
(2) Back-up light switch connector
Non-turbo model Turbo model

9) Remove the pitching stopper.

(A) Neutral switch (Brown)
(B) Back-up light switch (Gray)

Turbo model

MT-27
I MANUAL TRANSMISSION ASSEMBLY
MANUAL TRANSMISSION AND DIFFERENTIAL
10) Separate the clutch release fork from the re- 11) Set ST.
lease bearing. (Turbo model) NOTE:
(1) Remove the clutch operating cylinder from Also is available Part No. 927670000.
the transmission.
ST 41099AA020 ENGINE SUPPORT ASSY
(2) Remove the plug using 10 mm hexagon
wrench.

S2M1935 I 12) Remove the bolt which holds right upper side of
transmission to the engine.
(3) Screw the 6 mm dia. bolt into the release
fork shaft, and remove it.

B2M2791

13) Remove the front and center exhaust pipes.

(Non-turbo model) with OBD <Ref. to EX(S0HC)-
5, REMOVAL, Front Exhaust Pipe.>
14) Remove the center exhaust pipe. (Turbo mod-
el). <Ref. to EX(D0HC TURBO)-8, REMOVAL,
Center Exhaust Pipe.>
15) Remove the rear exhaust pipe and muffler.
CAUTION:
When removing exhaust pipes, be careful each
exhaust pipe does not drop out.
16) Remove the heat shield cover. (If equipped)
S2M1936A 17) Remove the hanger bracket from right side of
transmission.
(A) Shaft
(B) Bolt I I W ' I

(4) Raise the release fork and unfasten the re-

lease bearing tabs to free release fork.
CAUTION:
Step (4) is required to prevent interference with
engine when removing engine from transmis-
sion.

I rJl \\ 0 B2M0032

18) Remove the propeller shaft. <Ref. to DS-14,

REMOVAL, Propeller Shaft.>

MT-28
 1
MANUAL TRANSMISSION ASSEMBLY
MANUAL TRANSMISSION AND DIFFERENTIAL

19) Remove the gear shift rod and stay from trans-
mission.
(1) Disconnect the stay from the transmission.
(2) Disconnect the rod from the transmission.
22) Remove the spring pins and separate front
drive shafts from each side of the transmission.
CAUTION:
Discard removing spring pin. Replace with a
new one.

2M0325
(4 Stay
(6) Rod 23) Remove the nuts which hold lower side of
transmission to the engine.
20) Disconnect the stabilizer link from the trans-
verse link.
2 1 ) Remove the bolt securing ball joint of trans-
verse link to housing.
Except sedan turbo model

B2M2790

24) Place the transmission jack under transmis-

sion.
CAUTION:
G4M0491 Always support transmission case with a trans-
mission jack.
Sedan turbo model
u

G2M0326

MT-29
I MANUAL TRANSMISSION ASSEMBLY
I
MANUAL TRANSMISSION AND DIFFERENTIAL
25) Remove the transmission rear crossmember 6) Tighten the nuts which hold lower side of trans-
from the vehicle. mission to the engine.
Tightening torque:
50 N.m (5.1 kgf-m, 36.9 ft-lb)

26) Remove the transmission.

CAUTION: I 82M2790

Move transmission jack toward rear until main 7) Connect the engine and transmission.
shaft is withdrawn from clutch cover. (1) Install the starter.
27) Separate the transmission assembly and rear <Ref. to SC-7, INSTALLATION, Starter.>
cushion rubber. (2) Tighten the bolt which holds right upper side
of transmission to the engine.
B-:INSTALLATION
1) Install the rear cushion rubber to the transmis- Tightening torque:
sion assembly. 50 N.m (5.1 kgf-m, 36.9 ft-lb)
Tightening torque: I
35 N.m (3.6 kgf-m, 26.3 ft-lb)
2) Install the clutch release lever and bearing onto
the transmission. (Turbo model) <Ref. to CL-15,
INSTALLATION, Release Bearing and Lever.>
3) Install the transmission onto the engine.
(1) Gradually raise the transmission with trans-
mission jack.
(2) Engage them at splines.
CAUTION: B2M2791

Be careful not to strike main shaft against 8) Remove ST.

clutch cover.
4) Install the transmission rear crossmember.
Tightening torque:
T1: 70 N-m (7.1 kgf-m, 51 ft-lb)
T2: 140 N.m (14.3 kgf-m, 103 ft-lb)

5) Take off the transmission jack.

MT-30
 MANUAL TRANSMISSION ASSEMBLY
I
MANUAL TRANSMISSION AND DIFFERENTIAL

9) Push the clutch release lever to fit bearing into 14) Drive the spring
. - .pin into the chamfered hole of

clutch cover. drive shaft.

CAUTION:
Always use a new spring pin.

/
H2M1818

10) Install the plug.

Tightening torque:
44 N.m (4.5 kgf-m, 32.5 ft-lb) 15) Install the ball joints of lower arm into knuckle
arm of housing, and tighten the installing bolts.
Tightening torque:
49 N-m (5.0 kgf-m, 36 ft-lb)

(4 Plug
(B) Transmission ASSY
- B2M3402A
11) Install the pitching stopper.
Tightening torque: (A) Transverse link
T7: 50 Nom(5.7 kgf-m, 37 ft-lb) (B) Ball joint
T2: 58 N.m (5.9 kgf-m, 43 ft-lb)

12) Lift-up the vehicle.

13) Install the front drive shaft into the transmis-
sion.

MT-31
I MANUAL TRANSMISSION ASSEMBLY
MANUAL TRANSMISSION AND DIFFERENTIAL
16) Install the stabilizer link from the transverse (2) Connect the stay to the transmission brack-
link. et.
Except sedan turbo model Tighfening torque:
Tightening torque: 18 N.m (1.8 kgf-m, 13.0 ft-lb)
30 N.m (3.1 kgf-m, 22.1 ft-lb)

(A) Stay
Sedan turbo model (B) Transmission bracket
Tightening torque:
18) Install the propeller shaft. <Ref. to DS-15, IN-
45 N-m (4.6 kgf-m, 33.2 ft-lb)
STALLATION, Prope1ler Shaft.>
19) Install the heat shield cover. (If equipped)
20) Install the rear exhaust pipe and muffler.
21) Install the hanger bracket on the right side of
transmission.

17) Install the gear shift rod and stay.

(1) Connect the rod to the joint.
Tightening torque: (4, B2M0032
18 N-m (1.8 kgf-m, 13.0 ft-lb)
Install the front exhaust .pipe
. and center ex-
haust pipe. (Non-turbo model)
<Ref. to EX(S0HC)-6, INSTALLATION, Front Ex-
haust Pipe.>
23) Install the center exhaust pipe. (Turbo model)
<Ref. to EX(D0HC TURBO)-9, INSTALLATION,
Center Exhaust Pipe.>
24) install the under cover.

MT-32
I MANUAL TRANSMISSION ASSEMBLY 1
MANUAL TRANSMISSION AND DIFFERENTIAL

25) Install the operating cylinder.

Tightening torque:
37 N-m (3.8 kgf-m, 27.5 ft-lb)
Non-turbo model

Turbo model

26) Connect the following connectors.

(1) Transmission ground terminal
Tightening torque:
73 N-m (7.3 kgf-m, 9.4 ft-lb)
(2) Vehicle speed sensor connector
(3) Neutral position switch connector
(4) Back-up light switch connector
27) Install the air cleaner case stay.
Tightening torque:
76 N-m (7.6 kgf-m, 7 7.6 ft-lb)
28) Install the air cleaner case and intake duct.
(Non-turbo model) <Ref. to IN(S0HC)-6, INSTAL-
LATION, Air Cleaner Case.> and <Ref. to IN(S0-
HC)-7, INSTALLATION, Air Intake Duct.>
29) Install the intercooler. (Turbo model)
<Ref. to IN(D0HC TURBO)-1 1, INSTALLATION,
I ntercooler.>
30) Connect the battery ground terminal.
31) Take off the vehicle from lift arms.

MT-33
I TRANSMISSION MOUNTING SYSTEM
I
MANUAL TRANSMISSION AND DIFFERENTIAL

4. Transmission Mounting Sys- 8) Remove the rear crossmember.

tem
A: REMOVAL
1. PITCHING STOPPER
1) Disconnect the battery ground terminal.
2) Remove the air intake duct and cleaner case.
3) Remove the air intake duct (Non-turbo model).
<Ref. to IN(S0HC)-7, REMOVAL, Air Intake Duct.>
4) Remove the air cleaner case (Non-turbo model).
<Ref. to IN(S0HC)-6, REMOVAL, Air Cleaner
7 C J \ ' G2M0831

Case.> 9) Remove the rear cushion rubber.

5) Remove the inter cooler (Turbo model). <Ref. to
IN(D0HC TURBO)-10, REMOVAL, Intercooler.>
B: INSTALLATION
6) Remove the pitching stopper. 1. PITCHING STOPPER
1) Install the pitching stopper.
Tightening torque:
T1: 50 N-m (5.1 kgf-m, 37 ff-lb)
T2: 58 N.m (5.9 kgf-m, 43 ff-lb)

2. CROSSMEMBER AND CUSHION RUB-

BER
1) Disconnect the battery ground terminal.
2) Jack-up the vehicle and support it with sturdy
racks.
2) Install the air intake duct and cleaner case. (Non-
3) Remove the front, center exhaust pipes. (Non-
turbo model)
turbo model)
<Ref. to IN(S0HC)-6, INSTALLATION, Air Cleaner
<Ref. to EX(S0HC)-5, REMOVAL, Front Exhaust
Case.> and <Ref. to IN(S0HC)-7, INSTALLATION,
Pipe.>
Air Intake Duct.>
CAUTION: 3) Install the intercooler. (Turbo model)
When removing exhaust pipes, be careful each <Ref. to IN(D0HC TURBO)-11, INSTALLATION,
exhaust pipe does not drop out. Intercooler.>
4) Remove the center exhaust pipe. (Turbo model) 4) Connect the battery ground terminal.
<Ref. to EX(D0HC TURBO)-8, REMOVAL, Center
Exhaust Pipe.>
5) Remove the rear exhaust pipe and muffler.
6) Remove the heat shield cover. (If equipped)
7) Set the transmissionjack under the transmission
body.
CAUTION:
Always support transmission case with a trans-
mission jack.

MT-34
 TRANSMISSION MOUNTING SYSTEM
I
MANUAL TRANSMISSION AND DIFFERENTIAL

2. CROSSMEMBER AND CUSHION RUB- C: INSPECTION

BER
1) Install for rear cushion rubber.
Tighfening torque:
35 N-m (3.6 kgf-m, 26 ff-lb)
2 ) Install the crossmember.
Tighfening torque:
T I : 70 N.m (7.1 kgf-m, 51 ff-lb)
T2: 140 N-m (14.3 kgf-m, 103 ff-lb)
Repair or replace parts if the results of the inspec-
tion below are not satisfactory.
1. PITCHING STOPPER
Make sure that the pitching stopper is not bent or
damaged. Make sure that the rubber is not stiff,
cracked, or otherwise damaged.
2. CROSSMEMBER AND CUSHION RUB-
BER
Make sure that the crossmember is not bent or
damaged. Make sure that the cushion rubber is not
stiff, cracked, or otherwise damaged.

3) Remove the transmission jack.

4) Install the heat shield cover. (If equipped)
5) Install the front and center exhaust pipes. (Non-
turbo model)
<Ref. to EX(-S0HC)-6, INSTALLATION, Front Ex-
haust Pipe.>
6) Install the center exhaust pipe. (Turbo model)
<Ref. to EX(D0HC TURBO)-9, INSTALLATION,
Center Exhaust Pipe.>
7) Install the rear exhaust pipe and muffler.

MT-35
I OIL SEAL
I
MANUAL TRANSMISSION AND DIFFERENTIAL

5. Oil Seal 7 ) Using ST, install the oil seal.

ST 4$8057300 INSTALLER
A: INSPECTION
Inspect for oil leakage from the oil seal. Replace
the oil seal if the lips is deformed, hardened, dam-
aged, worn or defective if any.
B: REPLACEMENT
1) Clean the transmission exterior.
2) Drain the gear oil completely.
NOTE:
Tighten the drain plug after draining gear oil.
\ B3M1982
Tightening torque:
44 N.m (4.5 kgf-m, 32.5 ff-lb) 8) Install the propeller shaft. <Ref. to DS-15, IN-
STALLATION, Prope1ler Shaft.>
9) Install the heat shield cover. (If equipped)
10) Install the rear exhaust pipe and muffler.
11) Pour the gear oil and check the oil level. <Ref.
to MT-26, Transmission Gear Oil.>

1 g B3M0037

3) Remove the rear exhaust pipe and muffler,

4) Remove the heat shield cover. (If equipped)
5) Remove the propeller shaft. <Ref. to DS-14, RE-
MOVAL, Propeller Shaft.>
6) Using ST, remove the oil seal.
ST 398527700 PULLER ASSY

B3M2135A

(A) Oilseal

MT-36
 SWITCHES AND HARNESS
I
MANUAL TRANSMISSION AND DIFFERENTIAL

6. Switches and Harness 6) Remove the back-up light switch and neutral po-
sition switch with harness.
A: REMOVAL
1. BACK-UP LIGHT AND NEUTRAL POSI-
TION SWITCH
1) Disconnect the connector battery ground termi-
nal.
2) Remove the air intake duct and cleaner case.
(Non-turbo model) <Ref. to IN(S0HC)-6, REMOV-
AL, Air Cleaner Case.> and <Ref. to IN(S0HC)-7,
REMOVAL, Air Intake Duct.>
3) Remove the intercooler (Turbo model). <Ref. to
IN(D0HC TURBO)-I0, REMOVAL, Intercooler.>
(A) Neutral switch (Brown connector)
4) Disconnect the connector back-up light switch
and neutral position switch. (B) Back-up light switch (Gray connector)
Non-turbo model

(A) Neutral switch (Brown)

(B) Back-up light switch (Gray)

Turbo model

5) Lift-up the vehicle.

MT-37
I SWITCHES AND HARNESS
MANUAL TRANSMISSION AND DIFFERENTIAL

B: INSTALLATION C: INSPECTION
1. BACK-UP LIGHT SWITCH AND NEU- 1. BACK-UP LIGHT SWITCH
TRAL POSITION SWITCH Inspect the back-up light switch. <Ref. to LI-6, IN-
1) Install the back-up light switch and neutral posi- SPECTION, Back-up Light System.>
tion switch with harness.
2. NEUTRAL POSITION SWITCH
Tightening torque: 1) Turn the ignition switch to OFF.
24.5 N.m (2.5 kgf-m, 18.1 fi-lb)
2) Disconnect the connector neutral position
switch.
3) Measure the resistance between neutral position
switch terminal.
Non-turbo model
I Gear shift position I Terminal No. I Specified resistance I
Neutral position Less than 1R
1 and2 .
Other positions More than 1MR

Gear shift position Terminal No. Specified resistance

--- (A) Neutral switch
Neutral position
1 and 3
Less than 1R
Other positions More than 1MR
(B) Back-up light switch

2) Connect the connector of back-up light switch

and neutral position switch.
3) Install the air intake duct and cleaner case. (Non-
turbo model) <Ref. to IN(S0HC)-6, INSTALLA-
TION, Air Cleaner Case.> and <Ref. to IN(S0HC)-
7, INSTALLATION, Air Intake Duct.>
4) Install the intercooler. (Turbo model)
<Ref. to IN(D0HC TURBO)-I 1, INSTALLATION,
Intercooler.>
5 ) Connect the battery ground terminal.

Turbo model

TROlOl

4) Replace defective parts.

MT-38
 VEHICLE SPEED SENSOR I
MANUAL TRANSMISSION AND DIFFERENTIAL

7. Vehicle Speed Sensor

A: REMOVAL
1) Disconnect the ground terminal from battery.
2) Lift-up the vehicle.
3) Remove the front and center exhaust pipes.
4) Disconnect the connector from vehicle speed
sensor.
5 ) Turn and remove the vehicle speed sensor.

-8: INSTALLATION
NOTE:
Discard the vehicle speed sensor and after re-
moval, replace with a new one.
Ensure the sensor mounting hole is clean and
free of foreign matter.
Align the tip end of key with key groove on the
end of speedometer shaft during installation.
1) Hand tighten the vehicle speed sensor.
2) Tighten the vehicle speed sensor using suitable
tool.
Tightening torque:
5.9 N-m (0.6 kgf-m, 4.3 ff-lb)
3) Connect the connector to vehicle speed sensor.
4) Install the front and center exhaust pipes.
5 ) Lower the vehicle.
6) Connect the battery ground terminal.
C: INSPECTION
Inspect the vehicle speed sensor.
Non-Turbo model
<Ref. to EN(S0HC)-238, DTC PO500 - VEHICLE
SPEED SENSOR MALFUNCTION -, Diagnostic
Procedure with Diagnostic Trouble Code (DTC).>
Turbo model
<Ref. to EN(D0HC TURBO)-246, DTC PO500 -
VEHICLE SPEED SENSOR MALFUNCTION -,
Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>

MT-39
I PREPARATION FOR OVERHAUL
I
MANUAL TRANSMISSION AND DIFFERENTIAL

8. Preparation for Overhaul

A: PROCEDURE
1) Clean the oil, grease, dirt and dust from trans-
mission.
2) Remove the drain plug to drain oil. After draining,
retighten it as before.
CAUTION:
Replace gasket with a new one.
Tightening torque:
44 N.m (4.5 kgf-m, 32.5 ft-lb)

3) Attach the transmission to ST.

ST 499937100 TRANSMISSION STAND

j G3M0517

4) Rotating parts should be coated with oil prior to

assembly.
5) All disassembled parts, if to be reused, should
be reinstalled in the original positions and direc-
tions.
6) Gaskets, lock washers and lock nut must be re-
placed with new ones.
7) Liquid gasket should be used where specified to
prevent leakage.

MT-40
 TRANSFER CASE AND EXTENSION CASE ASSEMBLY
I
MANUAL TRANSMISSION AND DIFFERENTIAL

2j Remove the bearing cone from the extension

9. Transfer Case and Extension case assemblv, and install to taper roller bearing of
Case Assembly the transfer d h e n gear.
A: REMOVAL
1) Remove the manual transmission assembly
from vehicle. <Ref. to MT-27, REMOVAL, Manual
Transmission Assembly.>
2) Remove the back-up light switch and neutral po-
sition switch. <Ref. to MT-37, REMOVAL, Switches
and Harness.>
3) Remove the transfer case with extension case
assembly.

(A) Bearing cone (Extensioncase)

(B) Extension case

3) While pressing the bearing cone horizontally,

turn the driven shaft ten rotations.
4) Measure the height “W’ between transfer case
and taper roller bearing on the transfer driven gear.

4) Remove the shifter arm.

5) Remove the extension case assembly.

5 ) Measure the depth “X’.

NOTE:
Measure with bearing cone and thrust washer re-
B3M1374 I moved.
B INSTALLATION
1) Install the center differential and transfer driven
gear into transfer case.

6) Calculate space “t” using the following equation:

t = X - W + 0.2 to 0.3 mm (0.008 to 0.012 in)

MT-41
 TRANSFER CASE AND EXTENSION CASE ASSEMBLY
I
MANUAL TRANSMISSION AND DIFFERENTIAL

7) Select the nearest washer in the following table: 10) Measure the depth “T” between extension case
and transfer drive gear.
-
Standard clearance between thrust washer and
taper roller bearing: ST 398643600 GAUGE
0.2 - 0.3 mm T (0.008 - 0.012 in T)
NOTE:
T: Tight
I Thrust washer (50 x 61 x t) I
I Part No. I Thickness” (in) I
803050060 0.50 (0.01 97)
803050061 0.55 (0.0217)
803050062 0.60 (0.0236)
803050063 0.65 (0.0256) 3951
I 803050064 I 0.70 (0.0276) I 11) Calculate the space “U” using the following
803050065
equation: U = S - T
12) Select the suitable washer in the following ta-
803050067 ble:
Standard clearance:
I. 803050070 I 1.OO (0.0394) -10.15 - 0.35 mm (0.0059 - 0.0138 in)
803050071 1.05 (0.041 3) I Thrust washer I
803050072 1.10 (0.0433) Part No. Thickness mm (in)
803050073 1.15 (0.0453) 803036050 0.9 (0.035)
803050074 1.20 (0.0472) 803036054 1.O (0.039)
803050075 1.25 (0.0492) 803036051 1.1 (0.043)
803050076 1.30 (0.0512) 803036055 1.2 (0.047)
I 803050077 I 1.35 (0.0531) 1 803036052 1.3 (0.051)
803050078 1.40 (0.0551) I 803036056 I 1.4 (0.055) ~ -1
803050079 1.45 (0.0571) 803036053 1.5 (0.059)
803036057 1.6 (0.063)
803036058 1.7 (0.067)

407A
-

MT-42
I TRANSFER CASE AND EXTENSION CASE ASSEMBLY I
MANUAL TRANSMISSION AND DIFFERENTIAL

16) Install the extension assembly into the transfer C: DISASSEMBLY

case.
1. TRANSFER CASE
Tightening torque:
40N.m (4.1 kgf-m, 29.7 ff-lb) 1) Remove the reverse check assembly. <Ref. to
MT-50, REMOVAL, Reverse Check Sleeve.>
r 2) Remove the oil guide.

B3M 1374

17) Install the shifter arm to the transfer case. 83M1378

I

2. EXTENSION CASE
1) Remove the transfer drive gear assembly. <Ref.
to MT-45, REMOVAL, Transfer Drive Gear.>
2) Remove the shift bracket.

- w
B3M1396

18) Hang the shifter arm on the 3rd-4th fork rod.

B3M1381

3) Remove the oil seal from the extension case.

<Ref. to MT-36, OIL SEAL, .>

I B3M1397B I
19) Install the transfer case with extension case as-
sembly to the transmission case.
Tightening torque:
25N-m (2.5 kgf-m, 18.1 ff-lb)

/ B3M 1373

MT-43
I TRANSFER CASE AND EXTENSION CASE ASSEMBLY
MANUAL TRANSMISSION AND DIFFERENTIAL

D: ASSEMBLY
1. EXTENSION CASE
1) Using ST, install the oil seal to the extension
case. <Ref. to MT-36, Oil Seal.>
CAUTION:
Use new oil seal.
2) Install the shift bracket to the extension case.
Tightening torque:
25 N-m (2.5 kgf-m, 18.1 ff-lb)

3) Install the transfer drive gear to the extension

case. <Ref. to MT-45, INSTALLATION, Transfer
Drive Gear.>
2. TRANSFER CASE
1) Install the oil guide to the transfer case.
Tightening torque:
6.4 Nom(0.65 kgf-m, 4.7 ff-lb)

B3M137E

2) Install the reverse check sleeve assembly to the

transfer case. <Ref. to MT-50, INSTALLATION,
Reverse Check Sleeve.>

MT-44
 TRANSFER DRIVE GEAR I
MANUAL TRANSMISSION AND DIFFERENTIAL

1O.Transfer Drive Gear C: DISASSEMBLY

1) Remove the snap ring.
A: REMOVAL

@
1) Remove the manual transmission assembly
from vehicle. <Ref. to MT-27, REMOVAL, Manual C
Transmission Assembly.>
2) Remove the back-up light switch and neutral po-
sition switch. <Ref. to MT-37, REMOVAL, Switches
and Harness.>
3) Remove the transfer case with extension case C
assembly. <Ref. to MT-41, REMOVAL, Transfer
Case and Extension Case Assembly.>
4) Remove the extension case assembly. B3M 198E
5) Remove the transfer driven gear.
2) Remove the ball bearing.
6) Remove the transfer drive gear.

B3M1986

INSTALLATION D: ASSEMBLY
1) Set the ST applying to inner race of bearing and
1) Install the transfer drive gear.
instal to drive shaft.
Tightening torque: ST 398177700 INSTALLER
26 N.m (2.7 kgf-m, 20 fi-lb) CAUTION:
Do not apply pressure in excess of 10 kN (1 ton,
1.1 US ton, 1.O Imp ton)

B3M198E

2) Install the transfer driven gear.

3) Install the extension case assembly.
4) Install the transfer case and extension case as- 2) Install the snap ring on transfer drive shaft.
sembly. <Ref. to MT-41, INSTALLATION, Transfer 3) Inspect the clearance between snap ring and in-
Case and Extension Case Assembly.> ner race of ball bearing. <Ref. to MT-46, INSPEC-
5 ) Install the back-up light switch and neutral posi- TION, Transfer Drive Gear.>
tion switch. <Ref. to MT-38, INSTALLATION,
Switches and Harness.>
6) Install the manual transmission assembly from
vehicle. <Ref. to MT-30, INSTALLATION, Manual
Transmission Assembly.>

MT-45
I TRANSFER DRIVE GEAR
MANUAL TRANSMISSION AND DIFFERENTIAL

E: INSPECTION
1) Bearings
Replace bearings in the following cases:
Broken or rusty bearings
Worn or damaged
Bearings that fail to turn smoothly or make ab-
normal noise when turned after gear oil lubrication.
2) Drive gear
Replace drive gear in the following cases:
If their tooth surfaces and shaft are excessively
broken or damaged.
3) Measure the clearance between snap ring and
inner race of ball bearing with a thickness gauge.
Clearance:
0.0 1 - 0.15 mm (0.0004 - 0.0059 in)

B3M1991

If the measurement is not within the specification,

select suitable snap ring.
I Snap ring (Outer-30) I
Part No. Thickness mm (in)
805030041 1.53 (0.0602)
805030042 1.65 (0.0650)
805030043 1.77 (0.0697)

MT-46
 TRANSFER DRIVEN GEAR I
MANUAL TRANSMISSION AND DIFFERENTIAL

11.Transfer Driven Gear B: INSTALLATION

1) Install the bearing cup to extension case and
A: REMOVAL transfer case.
1) Remove the manual transmission assembly
from vehicle. <Ref. to MT-27, REMOVAL, Manual
Transmission Assembly.>
2) Remove the back-up light switch and neutral po-
sition switch. <Ref. to MT-37, REMOVAL, Switches
and Harness.>
3) Remove the transfer case with extension case
assembly. <Ref. to MT-41, REMOVAL, Transfer
Case and Extension Case Assembly.>
4) Remove the extension case assembly.
5) Remove the transfer driven gear.

6) Remove the bearing cup from extension case

and transfer-case. (A) Bearing cup
(B) Bearing cup
(C) Transfer case
(D) Extension case

2) Install the transfer driven gear.

3) Install the transfer case and extension case as-

(A) Bearing cup (transfer case)
(B) Bearing cup (extension case)
sembly.<Ref. to MT-41, INSTALLATION, Transfer
Case and Extension Case Assembly.>
4) Install the back-up light switch and neutral posi-
tion switch. <Ref. to MT-38, INSTALLATION,
Switches and Harness.>
5) Install the manual transmission assembly to ve-
hicle. <Ref. to MT-30, INSTALLATION, Manual
Transmission Assembly.>

MT-47
I TRANSFER DRIVEN GEAR
MANUAL TRANSMISSION AND DIFFERENTIAL

C: DISASSEMBLY D: ASSEMBLY
1) Using ST, remove the roller bearing (extension 1) Using ST, install the roller bearing (extension
case side). case side).
ST 498077000 REMOVER ST1 398177700 INSTALLER
ST2 899864100 REMOVER
CAUTION:
Do not apply pressure in excess of 10 kN (1 ton,
1.1 US ton, 1.0 Imp ton)

(A) Roller bearing

2) Using ST1 and ST2, remove the roller be&,ing

(transfer case side).
ST1 498077000 REMOVER
sJ2 899864100 REMOVER (A) Roller bearing

2) Using ST, install the roller bearing (transfer case

side).
ST 499757002 INSTALLER
CAUTION:
Do not apply pressure in excess of 10 kN (1 ton,
1.1 US ton, 1.O Imp ton)

(A) Roller bearing

(A) Roller bearing

E: INSPECTION
1) Bearings
Replace the bearings in the following cases:
Broken or rusty bearings
Worn or damaged
Bearings that fail to turn smoothly or make ab-
normal noise when turned after gear oil lubrication.
2) Driven gear
Replace drive gear in the following cases:
If their tooth surfaces and shaft are excessively
broken or damaged.

MT-48
 CENTER DIFFERENTIAL I
MANUAL TRANSMISSION AND DIFFERENTIAL

12.Center Differential C: DISASSEMBLY

NOTE:
A: REMOVAL Do not disassemble center differential because it is
1) Remove the manual transmission assembly a non-disassemble part.
from vehicle. <Ref. to MT-27, REMOVAL, Manual
Transmission Assembly.> Remove ball bearing using ST.
2) Remove the transfer case with extension case CAUTION:
assembly.<Ref. to MT-41, REMOVAL, Transfer Do not reuse ball bearing.
Case and Extension Case Assembly.> ST 498077300 CENTER DIFFERENTIAL
3) Remove the extension case assembly. <Ref. to BEARING REMOVER
MT-41, REMOVAL, Transfer Case and Extension 1
Case Assembly.>
4) Remove the transfer driven gear. <Ref. to MT-
47, REMOVAL, Transfer Driven Gear.>
5) Remove the center differential.
B: INSTALLATION
1) Install the center differential into transfer case.
2) Install the transfer driven gear. <Ref. to MT-47,
INSTALLATION, Transfer Driven Gear.>
3) Install the extension case assembly. <Ref. to
“MT-41, INSTALLATION,Transfer Case and Exten-
sion Case Assembly.> D: ASSEMBLY
4) Install the transfer case with extension case as- Install the ball bearing to center differential assem-
sembly. <Ref. to MT-41, REMOVAL, Transfer bly.
Case and Extension Case Assembly.> CAUTION:
5) Install the back-up light switch and neutral posi- Do not apply pressure in excess of 10 kN (1 ton,
tion switch. <Ref. to MT-37, REMOVAL, Switches 1.1 US ton, 1.O Imp ton).
and Harness.>
I
6) Install the manual transmission assembly to ve-
hicle. <Ref. to MT-30, INSTALLATION, Manual
Transmission Assembly.>

B3M13998

(A) Ball bearing

E: INSPECTION
1) Bearings
Replace the bearings in the following cases:
Broken or rusty bearings
Worn or damaged
Bearings that fail to turn smoothly or make ab-
normal noise when turned after gear oil lubrication.
Bearings having other defects
2) Center differential
Replace the center differential assembly in the fol-
lowing case:
Worn or damaged

MT-49
I REVERSE CHECK SLEEVE
I
MANUAL TRANSMISSION AND DIFFERENTIAL

13.Reverse Check Sleeve B: INSTALLATION

1) Install the reverse check sleeve.
A: REMOVAL
1) Remove the manual transmission assembly Tightening torque:
from vehicle. <Ref. to MT-27, REMOVAL, Manual 6.4 N-m (0.65 kgf-m, 4.7 ff-16)
Transmission Assembly.>
2) Remove the transfer case with extension case
assembly. <Ref. to MT-41, REMOVAL, Transfer
Case and Extension Case Assembly.>
3) Remove the shifter arm.
4) Remove the plug, spring washer and reverse
check ball.

B3M 1377 I

2) Install the ball, spring, washer and plug to trans-

fer case.
Tightening torque:
10 N-m (1.0 kgf-m, 7.2 ff-16)

5) Remove the reverse check sleeve.

3) Install the shifter arm to transfer case assembly.

4) Install the transfer case with extension case as-
I
. .
B3M1377 I
sembly. <Ref. to MT-41, INSTALLATION,Transfer
Case and Extension Case Assembly.>
5) Install the manual transmission assembly to ve-
hicle. <Ref. to MT-30, INSTALLATION, Manual
Transmission Assembly.>

MT-50
 REVERSE CHECK SLEEVE I
MANUAL TRANSMISSION AND DIFFERENTIAL

C: DISASSEMBLY D: ASSEMBLY
1) Cover the reverse check sleeve with a rag, and 1) Install the return spring (lst-2nd), return spring
remove snap ring using a screwdriver. cap, reverse accent shaft, check cam, return spring
NOTE: and check spring onto reverse check sleeve.
Replace the snap ring with a new one if deformed NOTE:
or weakened. Be sure the bent section of reverse check spring is
positioned in the groove in check cam.

B3M1383C
I B3M 1384A
(A) Snap ring
(A) Reverse check spring
2) Remove the reverse check plate, reverse check (B) Reverse check cam
‘spring, reverse check cam, return spring (5th-Rev), (C) Return spring (5th-Rev)
reverse accent shaft, return spring cap and return
(D) Reverse accent shaft
spring (1st-2nd).
(E) Return spring cap
I 1 (F) Return spring (1st-2nd)
(G) Reverse check sleeve

2) Hook the bent section of reverse check spring

over reverse check plate.
3) Rotate the cam so that the protrusion of reverse
check cam is at the opening in plate.
4) With cam held in that position, install plate onto
reverse check sleeve and hold with snap ring.
5) Position O-ring in groove in sleeve.
I B3M1384A I
(A) Reverse check plate
(8) Reverse check spring
(C) Return spring (5th-Rev)
(D) Reverse check cam
(E) Reverse accent shaft
(F) Return spring cap
(G) Return spring (1st-2nd)

3) Remove O-ring.
NOTE:
Reverse check sleeve assembly uses an O-ring
which should not be scratched.
Be careful not to break adjustment shim placed
between reverse check sleeve assembly and case.

MT-51
I REVERSE CHECK SLEEVE
MANUAL TRANSMISSION AND DIFFERENTIAL

E: INSPECTION F: ADJUSTMENT
Make sure the cutout section of reverse accent
shaft is aligned with the opening in reverse check 1. NEUTRAL POSITION ADJUSTMENT
sleeve. 1) Shift the gear into 3rd gear position.
Spin cam by hand for smooth rotation. 2) Shifter arm turns lightly toward the lst/2nd gear
Move cam and shaft all the way toward plate and side but heavily toward the reverse gear side be-
release. cause of the function of the return spring, until arm
If the cam does not return properly, replace reverse contacts the stopper.
check spring; if the shaft does not, check for 3) Make adjustment so that the heavy stroke (re-
scratches on the inner surface of sleeve. If the verse side) is a little more than the light stroke (lst/
sleeve is in good order, replace spring. 2nd side).
4) To adjust, remove bolts holding reverse check
sleeve assembly to the case, move sleeve assem-
bly outward, and place adjustment shim (0 to 1 ea.)
between sleeve assembly and case to adjust the
clearance.
CAUTION:
Be careful not to break O-ring when placing
shim(s).
NOTE:
r. - , B3M0048D
When the shim is removed, the neutral position
will move closer to reverse; when the shim is add-
(A) Snap ring ed, the neutral position will move closer to 1st gear.
If the shims alone cannot adjust the clearance,
(6) Reverse check plate
(C) Check spring
replace the reverse accent shaft and re-adjust.
(D) Checkcam

Select a suitable reverse accent shaft and re- Part No. Thickness mm (in)
verse check plate.<Ref. to MT-52, ADJUSTMENT, I 32190AA000 I 0.15 (0.0059) I
Reverse Check Sleeve.> I 32190AA010 I 0.30 (0.0118) I

Part No. Mark Remarks

Neutral position is closer to 1st
32188AA090 3
gear.
-
I 32188AA100 I 0 1 Standard I
1 32188AA110 I 1 I Neutral position is closer to
reverse aear. I

MT-52
 REVERSE CHECK SLEEVE I
MANUAL TRANSMISSION AND DIFFERENTIAL

2. REVERSE CHECK PLATE ADJUST-

MENT
1) Shift the shifter arm to “5th” and then to reverse
to see if reverse check mechanism operates prop-
erly.
2) Also check to see if the arm returns to neutral
when released from the reverse position. If the arm
does not return properly, replace reverse check
plate.
Reverse check plate I
I Part No. (A):
No.
Angle
0
Remarks

Arm stops closer to

32189AA000 0 280
5th gear.
Arm stops closer to
32189AA010 1 310
5th gear.
Arm stops in the cen-
32 189AA020 2 340
ter.
Arm stops closer to
32189AA030 3 370
reverse gear.
Arm stops closer to
32 189AA040 4 400
reverse gear.

B3M00540

MT-53
I TRANSMISSION CASE I
MANUAL TRANSMISSION AND DIFFERENTIAL

14.Transmission Case 7) Separate the transmission case into the right

and left cases by loosening coupling bolts and nuts.
A: REMOVAL
1) Remove the manual transmission assembly
from vehicle. <Ref. to MT-27, REMOVAL, Manual
Transmission Assembly.>
2) Remove the clutch release lever. <Ref. to CL-
15, REMOVAL, Release Bearing and Lever.>
3) Remove the transfer case with extension case
assembly. <Ref. to MT-41, REMOVAL, Transfer
Case and Extension Case Assembly.>
4) Remove the bearing mounting bolts.
1 03M 1359

8) Remove the drive pinion shaft assembly from left

side transmission case.
NOTE:
Use a hammer handle, etc. to remove if too tight.

5 ) Remove the main shaft rear plate.

(A) Main shaft assembly

I I S3M0100C
(A) Main shaft rear plate
6) Put the vinyl tape around splines of the right and
left axle drive shafts to prevent damage to oil seal.
(B) Drive pinion shaft assembly
9) Remove the main shaft assembly.
10) Remove the differential assembly.
CAUTION:
Be careful not to confuse right and left roller
bearing outer races.
Be careful not to damage retainer oil seal.

I I I \\ \
B3M14050

(A) Vinyl tape

MT-54
 TRANSMISSION CASE
I
MANUAL TRANSMISSION AND DIFFERENTIAL

B: INSTALLATION 8) Backlash adjustment of hypoid gear and preload

1) Wipe off grease, oil and dust on the mating sur-
faces of transmission cases with white gasoline.
2) Install the front differential assembly.
3) Install the main shaft assembly.
Install the needle bearing knock pin hole into trans-
mission case knock pin.
4) Install the drive pinion shaft assembly.
Install the roller bearing knock pin hole into trans-
mission case knock pin.
5) Apply the liquid gasket, and then put the case
right side and left side together.
Liquid gasket:
THREE BOND 1215 or equivalent
6) Tighten seventeen bolts with bracket, clip, etc.
as shown in the figure.
NOTE:
Insert the bolts from the bottom and tighten nuts
at the top.
- 0 - Put the cases together so that the drive pinion
shim and input shaft holder shim are not caught up
in between.
Confirm that speedometer gear is meshed.
Tightening torque:
8 mm bolt
25 Nom(2.5 kgf-m, 18.1 ft-16)
*10 mm bolt
39 N.m (4.0 kgf-m, 28.9 ft-lb)
adjustment of roller bearing
NOTE:
Support the drive pinion assembly with ST. (AWD
model)
ST 4984271 00 STOPPER
L - I
B3M1362A
9) Place the transmission with case left side facing
downward and put ST1 on bearing cup.
10) Screw the retainer assembly into left case from
the bottom with ST2. Fit ST3 on the transmission
main shaft. Shift gear into 4th or 5th and turn the
shaft several times. Screw in the retainer while
turning ST3 until a slight resistance is felt on ST2.
This is the contact point of hypoid gear and drive
pinion shaft. Repeat the above sequence several
times to ensure the contact point.
ST1 399780104 WEIGHT
ST2 499787000 WRENCH ASSY
ST3 4999271 00 HANDLE

03M1361A
7) Tighten the ball bearing attachment bolts.
Tightening torque:
29 N-m (3.0 kgf-m, 21.7 ft-16)

MT-55
I TRANSMISSION CASE
MANUAL TRANSMISSION AND DIFFERENTIAL
11) Remove weight and screw in retainer without
O-ring on the upper side and stop at the point
where slight resistance is felt.
NOTE:
At this point, the backlash between the hypoid gear
and drive pinion shaft is zero.
ST 499787000 WRENCH ASSY
12) Fit lock plate. Loosen the retainer on the lower
side by 1-112 notches of lock plate and turn in the
6tainer on the upper side by the same amount in
order to obtain the backlash.
NOTE:
The notch on the lock plate moves by 1/2 notch if
the plate is turned upside down.
13) Turn in the retainer on the upper side addtion-
ally by 1 notch in order to apply preload on taper
roller bearing.
14) Tighten temporarily both the upper and lower
lock plates and mark both holder and lock plate for
later readjustment.
15) Turn the transmission main shaft several times
while tapping around retainer lightly with plastic
hammer.
16) Inspect and adjust backlash and tooth contact
of hypoid gear. <Ref. to MT-74, INSPECTION,
Front Differential Assembly.>
MT-56
17) After checking the tooth contact of hypoid
gears, remove the lock plate. Then loosen the re-
tainer until the O-ring groove appears. Fit O-ring
into the groove and tighten the retainer into the po-
sition where retainer has been tightened in.
Tighten the lock plate.
NOTE:
Carry out this job on both upper and lower retain-
ers.
Tightening torque:
T: 25 N-m (2.5 kgf-m, 18.1 fi-lb)
S3M0014C
18) Selecting of main shaft rear plate <Ref. to MT-
62, ADJUSTMENT, Main Shaft Assembly for Sin-
gle-Range.>
19) Install the clutch release lever and bearing.
<Ref. to CL-15, INSTALLATION, Release Bearing
and Lever.>
20) Install the transfer case with extension case as-
sembly. <Ref. to MT-41, INSTALLATION, Transfer
Case and Extension Case Assembly.>
21) Install the manual transmission assembly into
the vehicle.<Ref. to MT-30, INSTALLATION, Man-
ual Transmission Assembly.>
C: INSPECTION
Check the transmission case for cracks, damage,
and oil leaks.
 MAIN SHAFT ASSEMBLY FOR SINGLE-RANGE
I
MANUAL TRANSMISSION AND DIFFERENTIAL

15.Main Shaft Assembly for Sin- C: DISASSEMBLY

1) Put the vinyl tape around main shaft splines to
gle-Range protet oil seal from damage. Then pull out the oil
A: REMOVAL seal and needle bearing by hand.
1) Remove the manual transmission assembly 2) Remove the lock nut from transmission main
from vehicle. <Ref. to MT-27, REMOVAL, Manual shaft assembly.
Transmission Assembly.> NOTE:
2) Remove the transfer case with extension case Remove the caulking before off lock nut.
assembly. <Ref. to MT-41, REMOVAL, Transfer ST1 499987000 TRANSMISSION HOLDER
Case and Extension Case Assembly.> ST2 498937003 SOCKET WRENCH (35)
3) Remove the transmission case. <Ref. to MT-41,
REMOVAL, Transfer Case and Extension Case
Assembly.>
4) Remove the drive pinion shaft assembly. <Ref.
to MT-63, REMOVAL, Drive Pinion Shaft Assem-
bly.>
5) Remove the main shaft assembly.
B: INSTALLATION
1) Install the needle bearing and oil seal onto the
front of transmission main shaft assembly.
r.

CAUTION:
Wrap clutch splined section with vinyl tape to 3) Remove the 5th-Rev sleeve and hub assembly,
prevent damage to oil seal. baulk ring, 5th drive gear and needle bearing.
Apply grease (Unilube #2 or equivalent) to the
sealing lip of oil seal.
Use a new one. )
2) Install the needle bearing outer race knock pin
hole into transmission case knock pin.
NOTE:
Align the end face of seal with surface (A) when in-
stalling oil seal.
I
A// / 03MQ4378

(A) 5th-Rev sleeve and hub ASSY

(B) Baulk ring
(C) 5th drive gear

4) Remove the snap ring and synchro cone stopper

from 5th-Rev sleeve and hub assembly.

B3M0528A

3) Install the drive pinion assembly. <Ref. to MT-63,

INSTALLATION, Drive Pinion Shaft Assembly.>
4) Install the transmission case. <Ref. to MT-55, IN-
STALLATION, Transmission Case.>
5) Install the transfer case with extension case as-
sembly. <Ref. to MT-41, INSTALLATION, Transfer
Case and Extension Case Assembly.>
6) Install the manual transmission assembly to ve- w B3M0435E
hicle. <Ref. to MT-30, INSTALLATION, Manual
Transmission Assembly.> (A) Synchro cone stopper
(B) Snap ring

MT-57
I MAIN SHAFT ASSEMBLY FOR SINGLE-RANGE
MANUAL TRANSMISSION AND DIFFERENTIAL

5) Using ST1, ST2 and a press, remove the ball 6) Using ST1 and ST2, remove the rest of parts.
bearing, synchro cone and baulk ring (Rev). NOTE:
NOTE: Replace sleeve and hub with new ones. Do not at-
Replace the sleeve and hub with new ones. Do tempt to disassemble because they must engage
not attempt to disassemble because they must en- at a specified point. If they should be disassem-
gage at a specified point. If they should be disas- bled, marking engagement point on splines before-
sembled, mark engagement point on the splines hand.
beforehand. ST1 899864100 REMOVER
Do not reuse the ball bearing. ST2 8997141 10 REMOVER
ST1 499757002 INSTALLER
ST2 498077400 SYNCHRO CONE REMOV- Press
ER n

fl
(A) Ball bearing
(B) Synchro cone
(C) Baulk ring

03MQ035A

MT-58
 I
MAIN SHAFT ASSEMBLY FOR SINGLE-RANGE
MANUAL TRANSMISSION AND DIFFERENTIAL

D: ASSEMBLY 3) Install the 4th needle bearing race onto transmis-

1) Assemble each sleeve and hub assembly.
NOTE:
Position open ends of spring 120" apart.
3rd-4th hub ASSY
sion main shaft using ST1, ST2 and a press.
CAUTION:
Do not apply pressure in excess of 10 kN (1 ton,
1.1 US ton, 1.0 Imp ton).
ST1 8997141 10 REMOVER
ST2 499877000 RACE 4-5 INSTALLER

3rd gear

5th-Rev hub ASSY

- vyY//-'/ B3M0543C

(A) 4th needle bearing race

4) Install the baulk ring, needle bearing, 4th drive

gear and 4th gear thrust washer to the transmission
main shaft.
NOTE:
Align the baulk ring and gear & hub assembly with
B3M1366A
key groove.
2) Install the 3rd drive gear, outer baulk ring, syn-
chro cone, inner baulk ring, sleeve and hub assem-
bly for 3rd needle bearing on the transmission main
shaft.
NOTE:
Align the groove in baulk ring with shifting insert.

S3M0045P

(A) Groove
7 d-r- (B) 4th gear side

(A) 3rd needle bearing

(B) 3rd drive gear
(C) Inner baulk ring
(D) Synchro cone
(E) Outer baulk ring
(F) Sleeve and hub ASSY

MT-59
I MAIN SHAFT ASSEMBLY FOR SINGLE-RANGE
MANUAL TRANSMISSION AND DIFFERENTIAL
5) Drive the ball bearing onto the rear section of 7) Install the bearing onto synchro cone.
transmission main shaft using ST1, ST2 and a 8) Install the baulk ring and synchro cone onto 5th-
press. Rev sleeve and hub assembly using ST and a
CAUTION: press.
Do not apply pressure in excess of 10 kN (1 ton, CAUTION:
1.1 US ton, 1.O Imp ton). Do not apply pressure in excess of 10 kN (1 ton,
ST1 8997141 10 REMOVER 1.1 US ton, 1.0 Imp ton).
ST2 499877000 RACE 4-5 INSTALLER NOTE:
Use new ball bearing.
After press fitting, make sure synchro cone ro-
tates freely.
ST 499757002 INSTALLER

6) Using ST1 and ST2, install the 5th gear thrus

iasher and 5th needle bearing race onto the rear
section of transmission main shaft.
CAUTION:
Do not apply pressure in excess of 10 kN (1 ton, (A) Baulk ring
1.1 US ton, 1.O Imp ton).
(B) Synchro cone
NOTE: (C) Ball bearing
Face the thrust washer in the correct direction.
ST1 8997141 10 REMOVER 9) Install the synchro cone stopper and snap ring to
ST2 499877000 RACE 4-5 INSTALLER 5th-Rev sleeve and hub assembly.

B3M0091D u B3M04358

(A) Face this surface to 5th gear side. (A) Synchro cone stopper
(B) Snap ring

MT-60
 1
MAIN SHAFT ASSEMBLY FOR SINGLE-RANGE
MANUAL TRANSMISSION AND DIFFERENTIAL

10) Install the rest parts to the rear section of trans- E: INSPECTION
mission main shaft. Disassembled parts should be washed clean first
NOTE: and then inspected carefully.
Align the groove in baulk ring with shifting insert. 1) Bearings
Replace the bearings in the following cases:
Bearings whose balls, outer races and inner rac-
es are broken or rusty.
Worn bearings
Bearings that fail to turn smoothly or make ab-
normal noise when turned after gear oil lubrication.
Bearings having other defects
2) Bushing (each gear)
Replace the bushing in the following cases:
When the sliding surface is damaged or abnor-
mally worn.
When the inner wall is abnormally worn.
(A) Needle bearing 3) Gears
(B) 5th drive gear Replace the gears with new ones if their tooth
(C) Baulk ring surfaces are broken, damaged, or excessively
(D) 5th-Rev sleeve and hub ASSY worn.
r. (E) Lock washer Correct or replace if the cone that contacts the
(F) Lock nuts baulk ring is rough or damaged.
Correct or replace if the inner surface or end face
11) Tighten the lock nuts to the specified torque us- is damaged.
ing ST1 and ST2. 4) Baulk ring
NOTE: Replace the ring in the following cases:
Secure the lock nuts in two places after tightening. When the inner surface and end face are dam-
ST1 499987003 SOCKET WRENCH aged.
ST2 498937000 TRANSMISSION HOLDER When the ring inner surface is abnormally or par-
tially worn down.
Tightening torque: When the contact surface of the synchronizer
118 N.m (12.0 kgf-m, 86.8 ff-lb) ring insert is scored or abnormally worn down.
5) Shifting insert key
Replace the insert if deformed, excessively worn,
or defective in any way.

&

S3M0189

6) Oil seal
Replace the oil seal if the lip is deformed, hard-
ened, damaged, worn, or defective in any way.
7) O-ring
Replace the O-ring if the sealing face is deformed,
hardened, damaged, worn, or defective in any way.

MT-61
I MAIN SHAFT ASSEMBLY FOR SINGLE-RANGE
MANUAL TRANSMISSION AND DIFFERENTIAL
8) Gearshift mechanism
Repair or replace the gearshift mechanism if ex-
cessively worn, bent, or defective in any way.
F: ADJUSTMENT
Selection of main shaft rear plate
Using ST, measure the amount (A) of ball bearing
protrusion from transmission main case surface
and select the proper plate in the following table:
NOTE:
Before measuring, tap the end of main shaft with a
plastic hammer lightly in order to make the clear-
ance zero between the main case surface and the
moving flange of bearing.
ST 498147000 DEPTH GAUGE
~ _ _ _ _~

Dimension (A)
Part No. Mark
mm (in)
4.00 - 4.13

I
e*
(0.1575 -
0.1626)
3.87- 3.99
I 32294AA041 I 1

(0.1524 - 32294AA051 2
0.1571)

MT-62
 DRIVE PINION SHAFT ASSEMBLY 3
MANUAL TRANSMISSION AND DIFFERENTIAL

16.Drive Pinion Shaft Assembly 4) Inspection and adjustment of ST

NOTE:
A: REMOVAL Loosen the two bolts and adjust so that the scale
1) Remove the manual transmission assembly indicates 0.5 correctly when the plate end and the
from vehicle. <Ref. to MT-27, REMOVAL, Manual scale end are on the same level.
Transmission Assembly.> Tighten the two bolts.
2) Remove the transfer case with extension case ST 499917500 DRIVE PINION GAUGE
assembly. <Ref. to MT-41, REMOVAL, Transfer ASSY
Case and Extension Case Assembly.>
3) Remove transmission case. <Ref. to MT-54, RE-
MOVAL, Transmission Case.>
4) Remove the drive pinion shaft assembly.
NOTE:
Use a hammer handle, etc. to remove if too tight.

*- (A) Plate
(B) Scale

5 ) Position the ST by inserting the knock pin of ST

into the knock hole in the transmission case.
ST 49991 7500 DRIVE PINION GAUGE
ASSY
(A) Main shaft assembly
6) Slide the drive pinion gauge scale with finger tip
(B) Drive pinion shaft assembly
and read the value at the point where it matches
with the end face of drive pinion.
B: INSTALLATION ST 499917500 DRIVE PINION GAUGE
1) Remove the differential assembly. ASSY
2) Alignment markshumbers on hypoid gear set
The upper number on driven pinion is the match
number for combining it with hypoid driven gear.
The lower number is for shim adjustment. If no low-
er number is shown, the value is zero. The number
on hypoid driven gear indicates a number for com-
bination with drive pinion.

11. B3M0065C I

(A) Adjust clearance to zero without shim.

7) The thickness of shim shall be determined by

adding the value indicated on drive pinion to the
value indicated on the ST. (Add if the number on
G3M0554 drive pinion is prefixed by + and subtract if the num-
ber is prefixed by -.)
3) Place the drive pinion shaft assembly on right
ST 499917500 DRIVE PINION GAUGE
hand transmission main case without shim and
ASSY
tighten the bearing mounting bolts.

MT-63
I DRIVE PINION SHAFT ASSEMBLY
I
MANUAL TRANSMISSION AND DIFFERENTIAL
8) Select one to three shims from the next table for C: DISASSEMBLY
the value determined as described above and take
a shim thickness which is closest to the said value. CAUTION:
Attach a cloth to the end of driven shaft (on the
frictional side of thrust needle bearing) during
Part No. Thickness mm (in) disassembly or reassembly to prevent damage.
I 32295AA031 I 0.1 50 (0.0059) 1) Straighten the lock nut at staked portion. Re-
I 32295AA041 I 0.175 (0.0069) move the lock nut using S T l , ST2 and ST3.
32295AA051 0.200 (0.0079) ST1 899884100 HOLDER
32295AA061 0.225 (0.0089) ST2 4984271 00 STOPPER
32295AA071 0.250 (0.0098) ST3 899988608 SOCKET WRENCH (27)
32295AA081 0.275 (0.0108)
I 32295AA091 I 0.300 (0.0118)
I 32295AA101 I 0.500 (0.0197)

9) Install the differential assembly. <Ref. to MT-71,

INSTALLATION, Front Differential Assembly.>
10) Set the transmission main shaft assembly and
drive pinion assembly in position. (So there is no
clearance between the two when moved all the way
to the front). Inspect the suitable 1st - 2nd, 3rd -
4th and 5th shifter fork so that the coupling sleeve G3M0595
and reverse driven gear are positioned in the cen- 2) Withdraw the drive pinion from driven shaft.
ter of their cynchronizing mechanisms. <Ref. to
Remove the differential bevel gear sleeve, adjust-
MT-68, INSPECTION, Drive Pinion Shaft Assem-
ing washer No. 1, adjusting washer No. 2, thrust
bly.> bearing, needle bearing, drive pinion collar, needle
11) Install the transmission case. <Ref. to MT-55, bearing and thrust bearing.
INSTALLATION, Transmission Case.>
12) Install the transfer case with extension case as-
sembly. <Ref. to MT-41, INSTALLATION,Transfer
Case and Extension Case Assembly.>
13) Install the manual transmission assembly to ve-
hicle.<Ref. to MT-27, Manual Transmission As-
sembly.>

Differential bevel gear sleeve

Washer No. 1 (25 x 37.5 x t)
Thrust bearing (25 x 37.5 x 3)
Washer No. 2 (25 x 37.5 x 4)
Needle bearing (25 x 30 x 20)
Drive pinion collar
Needle bearing (30 x 37 x 23)
Thrust bearing (33 x 50 x 3)

MT-64
 DRIVE PINION SHAFT ASSEMBLY
I
MANUAL TRANSMISSION AND DIFFERENTIAL

3) Remove the roller bearing and washer using ST 7) Remove the roller bearing, 3rd-4th driven gear
and press. using ST1 and ST2.
CAUTION: ST1 499757002 INSTALLER
Do not reuse roller bearing. ST2 8997141 10 REMOVER
ST 498077000 REMOVER
I

G3M060; 8) Remove the key.

9) Remove the 2nd driven gear, inner baulk ring,
4) Straighten the lock nut at staked portion. Re-
synchro cone and outer baulk ring.
move the lock nut using ST1 and ST2.
ST1 499987300 SOCKET WRENCH (50)
ST2 899884100 HOLDER
c.

(A) 2nd driven gear

(B) Inner baulk ring
5) Remove the 5th driven gear using ST. (C) Synchro cone
ST 499857000 5TH DRIVEN GEAR REMOV- (D) Outer baulk ring
ER
10) Remove the 1st driven gear, 2nd gear bushing,
gear and hub using ST1 and ST2.
NOTE:
Replace the gear and hub if necessary. Do not at-
tempt to disassemble if at all possible because they
must engage at a specified point. If they have to be
disassembled, mark the engaging point before-
hand.
STl 499757002 INSTALLER
ST2 8997141 10 REMOVER

6) Remove the woodruff key.

G3M0611

MT-65
I DRIVE PINION SHAFT ASSEMBLY
MANUAL TRANSMISSION AND DIFFERENTIAL

11) Remove the sub gear for 1st driven gear. ST1 499277200 INSTALLER
ST2 499587000 INSTALLER
D: ASSEMBLY
1) Install the sleeve and assembly by matching
alignment marks.
NOTE:
Use the new gear and hub assembly, if the gear
or hub have been replaced.

5) Install the 2nd driven gear, inner baulk ring, syn-

chro cone, outer baulk ring and insert onto driven
shaft.

B3M0077E n n
(A) 1st gear side
-+ (B) 2nd gear side
(C) Flush surface
(D) Stepped surface

2) Install the washer, snap ring and sub gear to 1st

driven gear. ( ) ( S3M0445A
3) Install the 1st driven gear, 1st baulk ring, gear
and hub assembly onto driven shaft.
(A) 2nd driven gear
NOTE: (B) Inner baulk ring
Take care to install gear and hub assembly in (C) Synchro cone
proper direction. (D) Outer baulk ring
Align the baulk ring and gear & hub assembly
with key groove. 6) After installing key on driven shaft, install the
4) Install the 2nd driven gear bushing onto driven 3rd-4th driven gear using ST and press.
shaft using ST1, ST2 and press. CAUTION:
CAUTION: Do not apply pressure in excess of 10 kN (1 ton,
Attach a cloth to the end of driven shaft to 1.1 US ton, 1.0 Imp ton).
prevent damage. NOTE:
Do not apply pressure in excess of 10 kN (1 Align the groove in baulk ring with insert.
ton, 1.1 US ton, 1.0 Imp ton). ST 499277200 INSTALLER
NOTE:
When press fitting, align the oil holes of shaft and
bush.

G3M061.5

MT-66
 DRIVE PINION SHAFT ASSEMBLY il
MANUAL TRANSMISSION AND DIFFERENTIAL

7) Install a set of roller bearings onto the driven NOTE:

shaft using ST and press. Stake the lock nut at two points.
CAUTION: Using spring balancer, check that starting torque
Do not apply pressure in excess of 10 kN (1 ton, of roller bearing is 0.1 to 1.5 N (0.01 to 0.15 kgf,
1.1 US ton, 1.O Imp ton). 0.02 to 0.33ft).
ST 499277200 INSTALLER
I I

G3M0616 10) Install the roller bearing onto drive pinion.

8) Position the woodruff key in groove on the rear of NOTE:
driven shaft. Install 5th driven gear onto drive shaft When installing roller bearing, note its directions
using ST and press. (front and rear) because the knock pin hole in outer
r.

CAUTION: race is offset.

Do not apply pressure in excess of 10 kN (1 ton,
1.1 US ton, 1.O Imp ton).
ST 499277200 INSTALLER

' \
(B) B3M1661A

(A) Roller bearing

(B) Knock pin hole
G3M0617

9) Install the lock washer. Install lock nut and tight- 11) Install the washer using STI, ST2 and press.
en to the specified torque using ST. CAUTION:
ST 499987300 SOCKET WRENCH (50) Discard old lock nuts, replace with new ones.
Tightening torque: Secure lock nut in four places.
265 N.m (27 kgf-m, 195 ff-lb) STI 4992771 00 BUSH 1-2 INSTALLER
ST2 499277200 INSTALLER
I .

(A) Washer

MT-67
I DRIVE PINION SHAFT ASSEMBLY
MANUAL TRANSMISSION AND DIFFERENTIAL
12) Install the thrust bearing and needle bearing. The ball bearing on the rear side of the drive pin-
Install the driven shaft assembly. ion shaft should be checked for smooth rotation be-
fore the drive pinion assembly is disassembled. In
this case, because a preload is working on the

r-:-- bearing, its rotation feels like it is slightly dragging

unlike the other bearings.

B3M0082

13) Install the drive pinion collar, needle bearing,

adjusting washer No. 2, thrust bearing, adjusting
washer No. 1 and differential bevel gear sleeve in
B3M0038E
that order.
NOTE: (A) Drive pinion shaft
Be careful because the spacer must be installed in (B) Ball bearing
proper direction.
r- - I
Bearings having other defects
2) Bushing (each gear)
Replace the bushing in the following cases:
When the sliding surface is damaged or abnor-
mally worn.
When the inner wall is abnormally worn.
3) Gears
Replace gears with new ones if their tooth sur-
faces are broken, damaged, or excessively worn.
Correct or replace if the cone that contacts the
baulk ring is rough or damaged.
Correct or replace if the inner surface or end face
(A) Driven shaft is damaged.
(B) Drive shaft 4) Baulk ring
(C) Drive pinion collar Replace the ring in the following cases:
(D) Needle bearing (25 x 30 x 20) When the inner surface and end face are dam-
(E) Washer No. 2 (25 x 36 x 4) aged.
(F) Thrust bearing (25 x 37.5 x 3) When the ring inner surface is abnormally or par-
(G) Washer No. 1 (25 x 36 x t) tially worn down.
(H) Differential bevel gear sleeve
If the gap between the end faces of the ring and
the gear splined part is excessively small when the
E: INSPECTION ring is pressed against the cone.
Disassembled parts should be washed clean first Clearance (A):
and then inspected carefully. 0.5 - 1.0 mm (0.020 - 0.040 in)
1) Bearings
Replace bearings in the following cases:
Bearings whose balls, outer races and inner rac-
es are broken or rusty.
Worn bearings
/I \

Bearings that fail to turn smoothly or make ab-

normal noise when turned after gear oil lubrication.

I
S3M0188A

MT-68
 DRIVE PINION SHAFT ASSEMBLY I
MANUAL TRANSMISSION AND DIFFERENTIAL

When the contact surface of the synchronizer 2) Using ST1, ST2 and ST3, tighten the lock nut to
ring insert is scored or abnormally worn down. the specified torque.
5) Shifting insert key ST1 899884100 HOLDER
Replace the insert if deformed, excessively worn, ST2 498427100 STOPPER
or defective in any way. ST3 899988608 SOCKET WRENCH (27)
7- I Tightening torque:
118 N.m (12 kgf-m, 86.8 ft-16)

6) Oil seal
Replace the oil seal if the lip is deformed, hard- G3M0626
ened, damaged, worn, or defective in any way.
3) After removing ST2, measure the starting torque
7) O-ring
using torque driver.
&place the O-ring if the sealing face is deformed,
ST1 899884100 HOLDER
hardened, damaged, worn, or defective in any way.
ST3 899988608 SOCKET WRENCH (27)
F: ADJUSTMENT Starting torque:
1. THRUST BEARING PRELOAD 0.3 - 0.8 N-m
(0.03 - 0.08 kgf-m, 0.2 - 0.6 ft-16)
1) After completing the preceding steps 1) through
3), select adjusting washer No. 1 so that the dimen-
sion (H) is zero through visual check. Position
washer (18.3 x 30 x 4) and lock washer (18 x 30 x
2) and install lock nut (18 x 13.5).

4) If starting torque is not within specified limit, se-

lect new adjusting washer No. 1 and recheck start-
ing torque.

\-,
B3M05361

(A) Adjusting washer No.1

(B) Adjusting washer No.2

MT-69
 DRIVE PINION SHAFT ASSEMBLY
I
MANUAL TRANSMISSION AND DIFFERENTIAL

I Adjusting washer No. 1 I

Part No.

803025052 3.950 (0.1555)

803025055 4.025 (0.1585)

803025056 4.050 (0.1594)
803025057 4.075 (0.1604)

I B3M05361

(A) Adjusting washer No. 1

(B) Adjusting washer No. 2

I Starting torque I Dimension H I Washer No. 2 1

I Low I Small I Select thicker one. I

I Part No. I Thickness mm

I 803025059 I 3.850 (0.1516) I
803025054 4.000 (0.1575)
803025058 4.150 (0.1634)

MT-70
 FRONT DIFFERENTIAL ASSEMBLY
1
MANUAL TRANSMISSION AND DIFFERENTIAL

17.Front Differential Assembly B: INSTALLATION

1) Install the differential side retainers using ST.
A: REMOVAL ST 499787000 WRENCH ASSY
1) Remove the manual transmission assembly 2) Install the differential assembly.
from vehicle. <Ref. to MT-27, REMOVAL, Manual
Transmission Assembly.>
Be careful not to fold the sealing lip of oil seal.
2) Remove the transfer case with extension case
assembly. <Ref. to MT-41, REMOVAL, Transfer NOTE:
Case and Extension Case Assembly.> Wrap the left and right splines sections of axle shaft
3) Remove the transmission case. <Ref. to MT-54, with vinyl tape to prevent scratches.
REMOVAL, Transmission Case.>
4) Removes the drive pinion shaft assembly. <Ref.
to MT-63, REMOVAL, Drive Pinion Shaft Assem-
bly.>
5) Remove the main shaft assembly.
<Ref. to MT-57, REMOVAL, Main Shaft Assembly
for Single-Range.>
6) Remove the differential assembly.
CAUTION:
Be careful not to confuse right and left roller
-bearing outer races.
Be careful not to damage retainer oil seal. 3) Install the main shaft assembly. <Ref. to MT-57,
INSTALLATION, Main Shaft Assembly for Single-
Range.>
4) Install the drive pinion assembly. <Ref. to MT-63,
INSTALLATION, Drive Pinion Shaft Assembly.>
5) Install the transmission case. <Ref. to MT-55, IN-
STALLATION, Transmission Case.>
6) Install the transfer case with extension case as-
sembly. <Ref. to MT-41, INSTALLATION,Transfer
Case and Extension Case Assembly.>
7) Install the manual transmission assembly to ve-
hicle. <Ref. to MT-30, INSTALLATION, Manual
Transmission Assembly.>
7) Remove the differential side retainers using ST.
ST 499787000 WRENCH ASSY

MT-71
I FRONT DIFFERENTIAL ASSEMBLY
MANUAL TRANSMISSION AND DIFFERENTIAL

C: DISASSEMBLY 4) Pull out the pinion shaft, and remove the differ-
1) Remove the right and left snap rings from differ- ential bevel pinion and gear and washer.
ential, and then remove the two axle drive shafts.
NOTE:
During reassembly, reinstall each axle drive shaft
in the same place from which it was removed.
2) Loosen the twelve bolts and remove hypoid driv-
en gear.

(A) Pinion shaft

(B) Bevel pinion
(C) Bevel gear
(D) Washer

5) Remove the roller bearing using ST.

ST 399527700 PULLER SET

G3M0668

(A) Snap ring D: ASSEMBLY

(B) Axle drive shaft
1) Install the bevel gear and bevel pinion together
(C) Hypoid driven gear with washers, and insert pinion shaft.
3) Drive out the straight pin from differential assem- NOTE:
bly toward hypoid driven gear. Face the chamfered side of washer toward gear.
ST 899904100 REMOVER

+I
A'L G3M0667
(A) Bevel pinion
(B) Bevel gear
(C) Pinion shaft

MT-72
 FRONT DIFFERENTIAL ASSEMBLY 1
MANUAL TRANSMISSION AND DIFFERENTIAL
2) Measure the backlash between bevel gear and 4) Install the roller bearing to differential case.
pinion. If it is not within specifications, install a suit- CAUTION:
able washer to adjust it. <Ref. to MT-75, ADJUST- Do not apply pressure in excess of 10 kN (1 ton,
MENT, Front Differential Assembly.> 1.1 US ton, 1.O Imp ton).
NOTE: NOTE:
Be sure the pinion gear tooth contacts adjacent Be careful because roller bearing outer races are
gear teeth during measurement. used as a set.
STl 498247001 MAGNET BASE STl 499277100 BUSH 1-2 INSTALLER
ST2 4982471 00 DIAL GAUGE ST2 398497701 ADAPTER
Standard backlash:
0.73 - 0.78 mm (0.0057 - 0.0077 in)
I I

\- / I
I ST2 y
G3M0671

5) Install the hypoid driven gear to differential case

G3M0670 using twelve bolts.
3) Align the pinion shaft and differential case at Tightening torque:
their holes, and drive straight pin into holes from T: 62 N.m (6.3 kgf-m, 45.6 ft-lb)
the hypoid driven gear side, using ST.
I
NOTE:
Lock the straight pin after installing.
ST 899904100 REMOVER

. .
B3M0554C

(A) Hypoid driven gear

(B) Differential case
B3M0609C

(A) Pinion shaft

(B) Differential case
(C) Straight pin

MT-73
I FRONT DIFFERENTIAL ASSEMBLY
MANUAL TRANSMISSION AND DIFFERENTIAL

E: INSPECTION 1. BEVEL PINION GEAR BACKLASH

Repair or replace the differential gear in the follow- Measure the backlash between bevel gear and pin-
ing cases: ion. If it is not within specifications, install a suitable
The hypoid drive gear and drive pinion shaft washer to adjust it.
tooth surface are damaged, excessively worn, or
NOTE:
seized.
Be sure the pinion gear tooth contacts adjacent
The roller bearing on the drive pinion shaft has a
gear teeth during measurement.
worn or damaged roller path.
There is damage, wear, or seizure of the differ- ST1 498247001 MAGNET BASE
ential bevel pinion, differential bevel gear, washer, ST2 498247100 DIAL GAUGE
pinion shaft, and straight pin. Standard backlash:
The differential case has worn or damaged slid-
ing surfaces.
0.13 - 0.18 mm (0.0051 - 0.0071 in)

2. HYPOID GEAR BACKLASH

Set the STI, ST2 and ST3. Insert the needle
through transmission oil drain plug hole so that the
needle comes in contact with the tooth surface at a
right angle and check the backlash.
STI 498247001 MAGNET BASE
ST2 498247100 DIAL GAUGE
ST3 498255400 PLATE
Backlash:
B3M0558C
0.13 - 0.18 mm (0.0051 - 0.0071 in)
(A) Drive pinion shaft
(6) Hypoid driven gear
(C) Pinion shaft
(D) Straight pin
(E) Washer
(F) Differential bevel gear
(G) Differential bevel pinion
(H) Snap ring
(I) Roller bearing
(J) Differential case
NOTE:
If the backlash is outside specified range, adjust it
by turning holder in right side case.

MT-74
 FRONT DIFFERENTIAL ASSEMBLY I
MANUAL TRANSMISSION AND DIFFERENTIAL

3. TOOTH CONTACT OF HYPOID GEAR

Check tooth contact of hypoid gear as follows: Ap-
ply a uniform thin coat of red lead on both tooth sur-
faces of 3 or 4 teeth of the hypoid gear. Move the
hypoid gear back and forth by turning the transmis-
sion main shaft until a definite contact pattern is de-
veloped on hypoid gear, and judge whether face
contact is correct. If it is inaccurate, make adjust-
ment. <Ref. to MT-75, ADJUSTMENT, Front Differ- Thickness mm (in)
Part No.
ential Assembly.>
Tooth contact is correct. I 803038021
1 0.925- 0.950
(0.0364
~~-
\ -
- 0.0374)
~~

0.975- I .OOO
I
803038022
(0.0384- 0.0394)
1.025- 1.050
803038023
(0.0404- 0.0413)

3) Adjust until the specified value is obtained.

Standard backlash:
-
0.13 0.18 mm (0.0051 - 0.0071 in)
2. HYPOID GEAR BACKLASH
Adjust the backlash by turning holder in right side
(A) Toe case.
(B) Coast side
ST 499787000 WRENCH ASSY
(C) Heel I
(D) Drive side

NOTE:
Each time holder rotates one tooth, backlash
changes by 0.05 mm (0.020 in).

MT-75
I FRONT DIFFERENTIAL ASSEMBLY
MANUAL TRANSMISSION AND DIFFERENTIAL

3. TOOTH CONTACT OF HYPOID GEAR The drive pinion shim selected before is too thin.
Increase its thickness.
Adjust until the teeth contact is correct.
Backlash is excessive.
To reduce backlash, loosen holder on the upper
side (case right side) and turn in the holder on the
lower side (case left side) by the same amount.

B3MOQ74

Backlash is insufficient.
To increase backlash, loosen holder on the lower
side (case left side) and turn in the holder on the
upper side (case right side) by the same amount.

B3MQO72

The drive pinion shim selected before is too

thick.
Reduce its thickness.

03M0073

MT-76
 SPEEDOMETER GEAR
18.Speedometer Gear
A: REMOVAL
1) Remove the manual transmission assembly
from vehicle. <Ref. to MT-27, REMOVAL, Manual
Transmission Assembly.>
2) Remove the back-up light switch and neutral po-
sition switch. <Ref. to MT-37, REMOVAL, Switches
and Harness.>
3) Remove the transfer case with extension case
assembly. <Ref. to MT-41, REMOVAL, Transfer
Case and Extension Case Assembly.>
4) Remove the transmission case. <Ref. to MT-54,
REMOVAL, Transmission Case.>
5) Remove the vehicle speed sensor. <Ref. to MT-
39, REMOVAL, Vehicle Speed Sensor.>
6) Remove the outer snap ring and pull out the
speedometer driven gear. Next, remove the oil
seal, speedometer shaft and washer.
r.
/ (A) Outer snap ring
B3M0525C
(A) Outer snap ring
(B) Speedometer driven gear
MT-77
I
MANUAL TRANSMISSION AND DIFFERENTIAL
B: INSTALLATION
1) Install the washer and speedometer shaft, and
press fit oil seal with ST.
CAUTION:
Use new oil seal, if it has been removed.
ST 899824100 or 499827000PRESS
2) Install the vehicle speed sensor. <Ref. to MT-39,
INSTALLATION, Vehicle Speed Sensor.>
3) Install the speedometer driven gear and snap
ring.
CAUTION:
Use new snap ring, if it has been removed.
(B) Speedometer driven gear
4) Install the transmission case. <Ref. to MT-55, IN-
STALLATION, Transmission Case.>
5) Install the transfer case with extension case as-
sembly. <Ref. to MT-41, INSTALLATION, Transfer
Case and Extension Case Assembly.>
6) Install the back-up light switch and neutral posi-
tion switch. <Ref. to MT-38, INSTALLATION,
Switches and Harness.>
7) Install the manual transmission assembly to ve-
hicle.<Ref. to MT-30, INSTALLATION, Manual
Transmission Assembly.>
C: INSPECTION
Check the speedometer gear, oil seal and speed-
ometer shaft for damage. Replace if damaged.
 REVERSE IDLER GEAR
MANUAL TRANSMISSION AND DIFFERENTIAL
19.Reverse Idler Gear
A: REMOVAL
1) Remove the manual transmission assembly
from vehicle. <Ref. to MT-27, REMOVAL, Manual
Transmission Assembly .>
2) Remove the back-up light switch and neutral po-
sition switch. <Ref. to MT-37, REMOVAL, Switches
and Harness.>
3) Remove the transfer case with extension case
assembly. <Ref. to MT-41, REMOVAL, Transfer
Case and Extension Case Assembly.>
4) Remove the transmission case. <Ref. to MT-63,
REMOVAL, Drive Pinion Shaft Assembly.>
5) Remove the drive pinion shaft assembly. <Ref.
to MT-63, REMOVAL, Drive Pinion Shaft Assem-
bly.>
6) Remove the main shaft assembly.
<Ref. to MT-57, REMOVAL, Main Shaft Assembly
for Single-Range.>
7) Remove the differential assembly. <Ref. to MT-
A , REMOVAL, Front Differential Assembly.>
8) Remove the shifter forks and rods. <Ref. to MT-
80, REMOVAL, Shifter Fork and Rod.>
9) Pull out the straight pin, and remove the idler
gear shaft, reverse idler gear and washer.
(A) Straight pin
(8) Idler gear shaft
(C) Idler gear
(D) Washer
IO) Remove the reverse shifter lever.
MT-78
B: INSTALLATION
1) Install the reverse shifter lever, reverse idler gear
and reverse idler gear shaft, and secure with
straight pin.
NOTE:
Be sure to install the reverse idler shaft from the
rear side.
M0526C
(A) Reverse shifter lever
(B) Reverse idler gear
(C) Reverse idler gear shaft
(D) Straight pin
2) Inspect and adjust the clearance between re-
verse idler gear and transmission case wall. <Ref.
to MT-78, INSTALLATION, Reverse Idler Gear.>
and <Ref. to MT-79, ADJUSTMENT, Reverse Idler
Gear.>
3) Install the shifter forks and rods. <Ref. to MT-80,
INSTALLATION,Shifter Fork and Rod.>
4) Install the differential assembly. <Ref. to MT-71,
INSTALLATION, Front Differential Assembly.>
5) Install the main shaft assembly.
<Ref. to MT-57, INSTALLATION, Main Shaft As-
sembly for Single-Range.>
6) Install the drive pinion shaft assembly. <Ref. to
MT-63, INSTALLATION, Drive Pinion Shaft As-
sembly.>
7) Install the transmission case. <Ref. to MT-55, IN-
STALLATION, Transmission Case.>
8) Install the transfer case with extension case as-
sembly. <Ref. to MT-41, INSTALLATION,Transfer
Case and Extension Case Assembly.>
9) Install the back-up light switch and neutral posi-
tion switch. <Ref. to MT-38, INSTALLATION,
Switches and Harness.>
IO) Install the manual transmission assembly to ve-
hicle. <Ref. to MT-30, INSTALLATION, Manual
Transmission Assembly.>
 REVERSE IDLER GEAR I
MANUAL TRANSMISSION AND DIFFERENTIAL

C: INSPECTION
1) Move the reverse shifter rod toward the reverse
side. Inspect the clearance between reverse idler
gear and transmission case wall.
If out of specification, select the appropriate re-
verse shifter lever and adjust.
Clearance A:
6.0 - 7.5 mm (0.236 - 0.295 in)
D: ADJUSTMENT
1) Select the appropriate reverse shifter lever from
the table below, and adjust until the gap between
the reverse idler gear and transmission case wall is
within specification.
Clearance A:
6.0 - 7.5 mm (0.236 - 0.295 in)

2) After installing a suitable reverse shifter lever,

Part No. Mark Remarks
“shift into neutral. Inspect the clearance between re-
32820AA070 7 Further from case wall
verse idler gear and transmission case wall.
If out of specification, select the appropriate washer 32820AA080 8 Standard
and adjust. 32820AA090 9 Closer to case wall

Clearance:
0 - 0.5 mm (0 - 0.020 in)

3) Check the reverse idler gear and shaft for dam-

age. Replace if damaged.

Part No. Thickness mm (in)

803020151 0.4 (0.016)
803020152 1.1 (0.043)
803020153 1.5 (0.059)
803020154 1.9 (0.075)
803020155 2.3 (0.091)

MT-79
I MANUAL TRANSMISSION AND DIFFERENTIAL
SHIFTER FORK AND ROD
20.Shifter Fork and Rod
A: REMOVAL
1) Remove the manual transmission assembly
from vehicle. <Ref. to MT-27, REMOVAL, Manual
Transmission Assembly.>
2) Remove the back-up light switch and neutral po-
sition switch. <Ref. to MT-37, REMOVAL, Switches
and Harness.>
3) Remove the transfer case with extension case
assembly. <Ref. to MT-41, REMOVAL, Transfer
Case and Extension Case Assembly.>
4) Remove the transmission case. <Ref. to MT-54,
REMOVAL, Transmission Case.>
5) Removes the drive pinion shaft assembly. <Ref.
to MT-63, REMOVAL, Drive Pinion Shaft Assem-
bly.>
6) Remove the main shaft assembly.
<Ref. to MT-57, REMOVAL, Main Shaft Assembly
for Single-Range.>
7) Remove the differential assembly. <Ref. to MT-
7.4,~REMOVAL, Front Differential Assembly.>
8) Drive out the straight pin with ST, and 5th shifter
fork.
ST 398791700 STRAIGHT PIN REMOVER
( B: INSTALLATION
B3M03331
(A) Straight pin
(6) 5th shifter fork
9) Remove the plugs, springs and checking balls.
MT-80
10) Drive out the straight pin, and pull out 3-4 fork
rod and shifter fork.
NOTE:
When removing rod, keep other rods in neutral. Al-
so, when pulling out straight pin, remove it toward
the inside of the case so that it does not hit against
the case.
(A) Straight pin
(B) 3-4 fork rod
(C) Shifter fork
11) Drive out the straight pin, and pull out the 1-2
fork rod and shifter fork.
12) Remove the outer snap ring, and pull out re-
verse shifter rod arm from reverse fork rod. Then
take out the ball, spring and interlock plunger from
rod. And then remove the rod.
NOTE:
When pulling out reverse shifter rod arm, be careful
not to let ball pop out of arm.
13) Remove the reverse shifter lever.
1) Install the reverse arm fork spring, ball and inter-
lock plunger to reverse fork rod arm. Insert the re-
verse fork rod into hole in reverse fork rod arm, and
hold it with outer snap ring using ST.
CAUTION:
Apply grease to plunger to prevent it from fall-
ing.
ST 39941 1700 ACCENT BALL INSTALLER
2) Position the ball, spring and gasket in reverse
shifter rod hole, on left side transmission case, and
tighten the checking ball plug.
CAUTION:
Replace gasket with a new one.
3) Install the 1-2 fork rod into 1-2 shifter fork via the
hole on the rear of the transmission case.
 SHIFTER FORK AND ROD I
MANUAL TRANSMISSION AND DIFFERENTIAL

4) Align the holes in rod and fork, and drive straight 9) Position the balls, checking ball springs and gas-
pin into these holes using ST. kets into 3-4 and 1-2 rod holes, and install plugs.
CAUTION: CAUTION:
Replace straight pin with a new one. Replace gasket with a new one.
NOTE:
Set other rods to neutral.
Make sure interlock plunger is on the 3-4 fork rod
side.
ST 398791700 STRAIGHT PIN REMOVER
5) Install the interlock plunger onto 3-4 fork rod.
CAUTION:
Apply a coat of grease to plunger to prevent it
from falling.
6) Install the 3-4 fork rod into 3-4 shifter fork via the 33J
hole on the rear of transmission case.
7) Align the holes in rod and fork, and drive straight (A) 5th shifter fork
pin into these holes. (B) Reverse fork rod
(C) Straight pin
CAUTION:
Replace straight pin with a new one. 10) Install the differential assembly. <Ref. to MT-
** NOTE: 1
71 INSTALLATION, Front Differential Assembly.>
Set the reverse fork rod to neutral. 11) Install the main shaft assembly.
Make sure the interlock plunger (installing be- Single-range model:
fore) is on the reverse fork rod side. <Ref. to MT-57, INSTALLATION, Main Shaft As-
ST 398791700 STRAIGHT PIN REMOVER sembly for Single-Range.>
8) Install the 5th shifter fork onto the rear of reverse 12) Install the drive pinion shaft assembly. <Ref. to
fork rod. Align the holes in the two parts and drive MT-63, INSTALLATION, Drive Pinion Shaft As-
straight pin into place. sembly.>
13) Install the transmission case. <Ref. to MT-55,
CAUTION: INSTALLATION, Transmission Case.>
Replace straight pin with a new one. 14) Install the transfer case with extension case as-
ST 398791700 STRAIGHT PIN REMOVER sembly. <Ref. to MT-41, INSTALLATION, Transfer
Case and Extension Case Assembly.>
15) Install the back-up light switch and neutral po-
( sition switch. <Ref. to MT-38, INSTALLATION,
Switches and Harness.>
16) Install the manual transmission assembly to ve-
hicle. <Ref. to MT-30, INSTALLATION, Manual
Transmission Assembly.>

B3M0333J

(A) 5th shifter fork

(B) Reverse fork rod
(C) Straight pin

MT-81
 SHIFTER FORK AND ROD
MANUAL TRANSMISSION AND DIFFERENTIAL

C: INSPECTION 4) Inspect the clearance between 3rd, 4th drive

1) Check the shift shaft and shift rod for damage. gear and coupling sleeve. If any clearance is not
Replace if damaged. within specifications, replace shifter fork as re-
2) Gearshift mechanism quired.
Repair or replace the gearshift mechanism if ex- Clearance (a) and (b):
cessively worn, bent, or defective in any way. 9.3 mm (0.366 in)
3) Inspect the clearance between lst, 2nd driven
gear and reverse driven gear. If any clearance is
not within specifications, replace the shifter fork as
required.
Clearance (a) and (b):
9.5 mm (0.374 in)

B3M1411A

(A) 3rd drive gear

(B) Coupling sleeve
(C) 4th drive gear
L I
I 3rd-4th shifter fork
I Part No. I Mark I Remarks
(A) 1st driven gear
(B) Reverse driven gear
I 32810AA061 I Approach to 4th gear
by 0.2 mm (0.008 in).
(C) 2nd driven gear 3281OAA071 - Standard
Become distant from
3281OAAI 01 3 3rd gear by 0.2 mm
(0.008 in).

I 32804AA060 I 1 I Approach to 1st gear

by 0.2 mm (0.008 in). I
32804AA070 - Standard
Become distant from
32804AA080 3 2nd gear by 0.2 mm
(0.008 in).

MT-82
 SHIFTER FORK AND ROD
I
MANUAL TRANSMISSION AND DIFFERENTIAL

5) Inspect the clearance between 5th drive gear 6) Inspect the rod end clearances (A) and (B). If any
and coupling sleeve. If any clearance is not within clearance is not within specifications, replace the
specifications, replace shifter fork as required. rod or fork as required.
Clearance (a): Clearance (A):
9.3 mm (0.366 in) 1st -2nd to 3rd - 4th:
0.4 - 1.4 "(0.016 - 0.055 in)
Clearance (B):
3rd - 4th to 5th:
0.5 - 1.3 "(0.020 - 0.051 in)

r
(A) 5th drive gear
S3M0191A

(B) Coupling sleeve

W
B3M0530A
-4- - 5th shifter fork (Non-turbo) I
I Part No. I Mark I Remarks I
I 32812AA201 I 4 I Approach to 5th gear
bv 0.2 mm 10.008 ink I
32812AA211 5 Standard
Become distant from
32812AA221 6 5th gear by 0.2 mm
I (0.068 in).- I
Part No. Mark Remarks

I 32812AA231 1 7 I Approach to 5th gear

by 0.2 mm (0.008 in). I
32812AA241 - Standard
Become distant from
32812AA251 9 5th gear by 0.2 mm
(0.008 in).

MT-83
I GENERAL DIAGNOSTIC
I
MANUAL TRANSMISSION AND DIFFERENTIAL

21 .General Diagnostic
A: INSPECTION
1. MANUAL TRANSMISSION

Symptom Possible cause ~~

Remedv
1. Gears are difficult to intermesh. (a) Worn, damaged or burred chamfer of Replace.
VOTE: internal spline of sleeve and reverse
The cause for difficulty in shifting gears driven gear
:an be classified into two kinds: one is (b) Worn, damaged or burred chamfer of Replace.
malfunction of the gear shift system and spline of gears
:he other is malfunction of the transmis- Redace.
(c) Worn or scratched bushinas
sion. However, if the operation is heavy
and engagement of the gears is difficult, (d) Incorrect contact between synchro- Correct or replace.
jefective clutch disengagement may also nizer ring and gear cone or wear
De responsible. Check whether the clutch
s correctly functioning, before checking
the gear shift system and transmission.
2. Gear slips out. (a) Defective pitching stopper adjustment Adjust.
Gear slips out when coasting on rough (b) Loose engine mounting bolts Tiahten
u or redace.

.-
road.
Gear slips out during acceleration.
(c) Worn fork shifter, broken shifter fork
rail spring
Replace.

Id) Worn or damaaed ball bearina Replace.

3. Unusual noise comes from transmis-
sion.
NOTE:
If an unusual noise is heard when the ve-
hicle is parked with its engine idling and if
the noise ceases when the clutch is disen-
gaged, it may be considered that the
noise comes from the transmission.
(e) Excessive clearance between splines Replace.
of synchronizer hub and synchronizer
sleeve
(f) Worn tooth step of synchronizer hub Replace.
(resDonsible for slipout of 3rd clear)
(9) Worn 1st driven gear, needle bearing Replace.
and race
(h) Worn 2nd driven gear, needle bearing Replace.
and race
Ii) Worn 3rd drive aear and bushinn Replace.
(i) Worn 4th drive gear and bushing Replace.
(k) Worn reverse idler gear and bushing Replace.
(a) Insufficient or improper lubrication Lubricate or replace with specified oil.
(b) Worn or damaged gears and bearings Replace.
NOTE:
If the trouble is only wear of the tooth sur-
faces, merely a high roaring noise will oc-
cur at high speeds, but if any part is
broken, rhythmical knocking sound will be
heard even at low speeds.

MT-84
 GENERAL DIAGNOSTIC
I
MANUAL TRANSMISSION AND DIFFERENTIAL

2. DIFFERENTIAL

Symptom Possible cause Remedy

1 . Broken differential (case, gear, bear-
ng, etc.)
VOTE:
4bnormal noise will develop and finally it
Mill become impossible to continue to run
h e to broken pieces obstructing the gear
,evolution.
(a) Insufficient or improper oil
(b) useof vehicle under Severe con&
tions such as load and
improper use of clutch
(c) Improper adjustment of taper roller
bearing
(d) Improper adjustment of drive pinion
and hvlsoid driven aear
(e) Excessive backlash due to worn dif-
ferential side gear, washer or differential
pinion vehicle under severe operating
conditions
3isassemble differential and replace bro-
ten components and at the same time
:heck other components for any trouble,
3nd replace if necessary.
Readjust bearing preload and backlash
m d face contact of gears.
4djust.
4djust.
4dd recommended oil to specified level.
Do not use vehicle under severe operat-
ng conditions.

2. Differential and hypoid gear noises

I (f) Loose hypoid driven gear clamping
bolts
(a) Insufficient oil
Tighten.

-ubricate.
r
b u b l e s of the differential and hYPoid (b) Improper adjustment of hypoid driven :heck tooth contact.
p a r always appear as nOiSe problems. sear and drive Dinion
rherefore noise is the first indication of I vi I iypuiu ui ivci I ycai ai iu Replace as a set.
:he trouble. However noises from the Readjust bearing preload.
mgine, muffler, tire, exhaust gas, bear-
,e roller bearing Readjust hypoid driven gear to drive pin-
ng, body, etc. are easily mistaken for the
on backlash and check tooth contact.
jifferential noise. Pay special attention to
:he hypoid gear noise because it is easily (e) Distorted hypoid driven gear or differ- Replace.
:onfused with other gear noises. There ential case
we the following four kinds of noises. (f) Worn washer and differential pinion Replace.
1 Gear noise when driving: If noise shaft
ncreases as vehicle speed increases it
nay be due to insufficient gear oil, incor-
Oect gear engagement, damaged gears,
2tc.
1 Gear noise when coasting: Damaged

jears due to maladjusted bearings and

ncorrect shim adjustment
1 Bearing noise when driving or when

:oasting: Cracked, broken or damaged

3earings
1 Noise which mainly occurs when turn-

ng: Unusual noise from differential side

jear, differential pinion, differential pinion
;haft. etc.

MT-85
I GENERAL DIAGNOSTIC
MANUAL TRANSMISSION AND DIFFERENTIAL

MT-86
 a

CLUTCH SYSTEM

CL
Page
1. General Description .................................................................................... 2
2. Clutch Disc and Cover .............................................................................. i1
3. Flywheel .................................................................................................... 14
4. Release Bearing and Lever ....................................................................... 15
5. Operating Cylinder .................................................................................... 18
6. Master Cylinder ......................................................................................... 20
7. Clutch Pipe and Hose ............................................................................... 22
8. Clutch Fluid ............................................................................................... 23
9. Clutch Fluid Air Bleeding ........................................................................... 24
... 10. Clutch Pedal .............................................................................................. 26
11. Clutch Switch ............................................................................................ 30
12. General Diagnostic Table .......................................................................... 31
I GENERAL DESCRIPTION
CLUTCH SYSTEM

1. General Description
A: SPECIFICATIONS
Model NON-TURBO TURBO
Clutch cover Type Push type Pull type
Diaphraam set load ka Ob) 580 (1 -279) 830 (1,830)
Clutch disk I Facinq material I Woven (Non asbestos)
O.D. x I.D. x thickness mm (in) 225 x 150 x 3.5 230 x 150 x 3.5
(8.86 x 5.91 x 0.138) (9.06 x 5.91 x 0.138)
Spline O.D. mm (in) 25.2 (0.992), (No. of teeth: 24)
Clutch release lever ratio 1.6 1.7
I Release bearina Grease-Dacked self-alianina
I Clutch Dedal
I
II Full stroke . ,I
mm (in) 130 - 135 (5.12 - 5.31) I
I Free play mm (in) 1 10 - 20 (0.39 - 0.79) 3 - 13 (0.12 - 0.51)
1

Clutch disk Depth of rivet head mm (in) Standard 1.3 - 1.9 (0.051 - 0.075)
Limit of 0.3 (0.012)
sinking
I Limit for deflection mm (in) I 1.0 (0.039) at R = 107 (4.21) 1 0.8 (0.031) at R = 110 (4.33) I
13.: Inner diameter
O.D.: Outer diameter

cL-2
 I
GENERAL DESCRIPTION
CLUTCH SYSTEM

B: COMPONENT
1. CLUTCH ASSEMBLY FOR NON-TURBO MODEL

TR0533

(1) Clutch release lever sealing (6) Release bearing Tightening torque: N.m (kgf-m, ft-lb)
(2) Retainer spring (7) Clutch cover T1: 15.7(1.6, 11.6)
(3) Pivot (8) Clutch disc T2: 72 (7.3, 52.8)
(4) Release lever (9) Flywheel
(5) Clip

cL-3
 GENERAL DESCRIPTION
CLUTCH SYSTEM

2. CLUTCH ASSEMBLY FOR TURBO MODEL

(8) TR0534

(1) Clutch release lever sealing (6) Clutch cover Tightening torque: N-m (kgf-m, ft-lb)
(2) Release lever shaft (7) Clutch disc T1: 15.7(1.6, 11.6)
(3) Plug (8) Flywheel T2: 44 (4.5, 32.5)
(4) Release lever (9) Spring
(5) Release bearing (10) Bracket

cL-4
 GENERAL DESCRIPTION
I
CLUTCH SYSTEM

3. CLUTCH PIPE AND HOSE FOR NON-TURBO MODEL

(1)’ I

TR0535

(1) Operating cylinder (6) Pipe Tightening torque: N.m (kgf-m, ft-lb)
(2) Washer (7) Master cylinder ASSY T I : 8 (0.8, 5.8)
(3) Clutch hose (8) Clevis pin T2: 15 (1.5, 11)
(4) Bracket (9) Snap pin T3: 18 (1.8, 13.0)
(5) Clip (IO) Lever T4: 37 (3.8,27.5)

CL-5
I GENERAL DESCRIPTION
CLUTCH SYSTEM

4. CLUTCH PIPE AND HOSE FOR TURBO MODEL

TR0536

(1) Operating cylinder (6) Pipe Tightening torque: N.m (kgf-m, ft-lb)
(2) Washer (7) Master cylinder ASSY T I : 8 (0.8, 5.8)
(3) Clutch hose (8) Clevis pin TZ: lS(1.5, 1 1 )
(4) Bracket (9) Snap pin T3: 18 (1.8, 13.0)
(5) Clip (10) Lever T4: 37 (3.8,27.5)

CL-6
 I
GENERAL DESCRIPTION
CLUTCH SYSTEM

5. MASTER CYLINDER
NON-TURBO MODEL

TR0431

(1) Reservoir cap (7) Diaphragm spring Tightening torque: N-m (kgf-m, ft-lb)
(2) Reservoir tank (8) Gasket T I : 10 (1.0, 7)
(3) Oil seal (9) Return spring T2: 46.6 (4.75, 34.4)
(4) Straight pin (10) Piston
(5) Master cylinder (11) Push rod
(6) Seat (12) Piston stop ring

cL-7
 GENERAL DESCRIPTION
I
CLUTCH SYSTEM

TURBO MODEL

TR054!

(1) Reservoir cap (6) Seat Tightening torque: N.m (kgf-m, ft-lb)
(2) Reservoir tank (7) Return spring T: 10 (1.0, 7)
(3) Oil seal (8) Piston
(4) Straight pin (9) Push rod
(5) Master cylinder (10) Piston stop ring

CL-8
I I
GENERAL DESCRIPTION

6. CLUTCH PEDAL

TR0537

(1) Stopper (12) Clutch clevis pin (23) Clutch switch (With cruise control)
(2) Bushing (13) Assist rod A (24) Stop light switch
(3) Spring pin (14) Clip (25) Pedal bracket
(4) Snap pin (15) Assist spring (26) Clutch master cylinder bracket
(5) Brake pedal pad (16) Assist bushing (27) Lever
(6) Brake pedal (17) Assist rod B (28) Clutch switch (Starter interlock)
(7) Clevis pin (18) Spring S
(8) Brake pedal spring (19) Rods Tightening torque: N-m (kgf-m, ft-lb)
(9) Clutch pedal pad (20) Bushing S T1: 8 (0.8, 5.8)
(IO) Clutch pedal (21) O-ring T2: lS(1.8, 13.0)
(11) Bushing C (22) Clip T3: 30 (3.1,22.4)

cL-9
 GENERAL DESCRIPTION
CLUTCH SYSTEM

C: CAUTION Be sure to tighten fasteners including bolts and

Wear working clothing, including a cap, protec-
tive goggles, and protective shoes during opera-
tion.
Remove contamination including dirt and corro-
sion before removal, installation or disassembly.
Keep the disassembled parts in order and pro-
tect them from dust or dirt.
Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary re-
moval, installation, disassembly, and replacement.
Be careful not to burn your hands, because each
part on the vehicle is hot after running.
Use SUBARU genuine fluid, grease etc. or the
equivalent. Do not mix fluid, grease etc. with that of
another grade or from other manufacturers.
D: PREPARATION TOOL
1. SPECIAL TOOLS
nuts to the specified torque.
Place shop jacks or safety stands at the specified
points.
Apply grease onto sliding or revolution surfaces
before installation.
Before installing O-rings or snap rings, apply suf-
ficient amount of fluid to avoid damage and defor-
mation.
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.
Keep fluid away from the vehicle body. If any flu-
id contacts the vehicle body, immediately flush the
area with water.

TOOL NUMBER DESCRlPTtON REMARKS

498497100 CRANKSHAFT Used for stopping rotation of flywheel when Ioos.
STOPPER eninghightening bolt, etc.

I B2M3853
499747100 CLUTCH DISC Used when installing clutch disc to flywheel.
GUIDE

B2M4112

2. GENERAL PURPOSE TOOLS

TOOL NAME REMARKS I

Circuit Tester Used for measuring resistance, voltage and ampere.
Dial Gauge Used for measuring clutch disk run-out.

CL-10
 CLUTCH DISC AND COVER
1
CLUTCH SYSTEM

2. Clutch Disc and Cover 2) Install the clutch cover on flywheel and tighten
bolts to the specified torque.
A: REMOVAL NOTE:
1) Remove the transmission assembly from vehicle When installing the clutch cover on the flywheel,
body. <Ref. to MT-27, REMOVAL, Manual Trans- position the clutch cover so that there is a gap of
mission Assembly.> 120” or more between “0’marks on the flywheel
2) Install the ST on flywheel. and clutch cover. ( “ 0 marks indicate the directions
ST 499747100 CLUTCH DISC GUIDE of residual unbalance.)
Note the front and rear of the clutch disc when in-
stalling.
Temporarily tighten the bolts by hand. Each bolt
should be tightened to the specified torque in a
crisscross method.
Tightening torque:
15.7 N-m (1.6 kgf-m, 11.6 ft-lb)

I I1 1‘ 1
(A) Clutch cover
-. - .

3) Remove the clutch cover and clutch disc.

CAUTION:
Take care not to allow oil on the clutch disc
facing.
Do not disassemble either the clutch cover or
clutch disc.
B: INSTALLATION
1) Insert the ST into the clutch disc and install them
on the flywheel by inserting the ST end into the pi-
lot bearing.
ST 499747100 CLUTCH DISC GUIDE

B2M 1I0118
- -

(A) “ 0marks

3) Remove the ST.

ST 499747100 CLUTCH DISC GUIDE
4) Install the transmission assembly. <Ref. to MT-
G2M0253 30, INSTALLATION, Manual Transmission Assem-
bly.>

CL-11
I CLUTCH DISC AND COVER
1
CLUTCH SYSTEM

C: INSPECTION 4) Deflection on facing:

If deflection exceeds the specified value at the out-
1. CLUTCH DISC er circumference of facing, repair or replace.
1) Facing wear: ST 499747100 CLUTCH DISC GUIDE
Measure the depth of rivet head from the surface of Limit for deflection:
facing. Replace if the facings are worn locally or Non-turbo model:
worn down to less than the specified value. 1.0 mm (0.039 in) at R = 107 mm (4.21 in)
Depth of rivet head: Turbo model:
Limit of sinking 0.8 mm (0.031 in) at R = 110 mm (4.33 in)
0.3 mm (0.012 in)
CAUTION:
Do not wash the clutch disc with any cleaning
fluid.

5) Worn spline, loose rivets and torsion spring fail-

ure:
Replace defective parts.

2) Hardened facing:
Correct by using emery paper or replace.
3) Oil soakage on facing:
Replace the clutch disc and inspect transmission
front oil seal, transmission case mating surface,
engine rear oil seal and other points for oil leakage.

(A) Spline
(B) Rivet
(C) Torsion spring

(A) Facing

CL-12
 CLUTCH DISC AND COVER
I
CLUTCH SYSTEM

2. CLUTCH COVER
NOTE:
Visually check for the following items without disas-
sembling, and replace or repair if defective.
1) Loose thrust rivet.
2) Damaged or worn bearing contact area at the
center of diaphragm spring.

(Bf

(A) Thrust rivet

c.
(B) Diaphragm spring

3) Damaged or worn disc contact surface of pres-

sure plate.
4) Loose strap plate setting bolt.
5) Worn diaphragm sliding surface.

(A) Pressure plate

(B) Strap plate

CL-13
I FLYWHEEL
CLUTCH SYSTEM

3. Flywheel 2) Tighten the flywheel attaching bolts to the spec-

ified torque.
A: REMOVAL NOTE:
1) Remove the transmission assembly. <Ref. to Tighten the flywheel installing bolts gradually. Each
MT-27, REMOVAL, Manual Transmission Assem- bolt should be tightened to the specified torque in
bly.> a crisscross method.
2) Remove the clutch cover and clutch disc. <Ref.
to CL-11, REMOVAL, Clutch Disc and Cover.> Tightening torque:
72 N-m (7.3 kgf-m, 52.8 ft-lb)
CAUTION:
Take care not to allow oil on the clutch disc
facing.
Do not disassemble either the clutch cover or
clutch disc.
3) Using ST, remove the flywheel.
ST 498497100 CRANKSHAFT STOPPER

r.
3) Install the clutch disc and cover. <Ref. to CL-11,
INSTALLATION, INSTALLATION, Clutch Disc and
Cover.>
4) Install the transmission assembly. <Ref. to MT-
30, INSTALLATION, Manual Transmission Assem-
- .
' B2M0332B bly.>
C: INSPECTION
(A) Flywheel
CAUTION:
B: INSTALLATION Since this bearing is grease sealed and is of a
1) Install the flywheel and ST. non-lubrication type, do not wash with gaso-
line or any solvent.
ST 498497100 CRANKSHAFT STOPPER
1) Damage of facing and ring gear:
If defective, replace the flywheel.

(A) Flywheel
(B) Ring gear

2) Smoothness of rotation:
Rotate the ball bearing applying pressure in thrust
direction.
3) If noise or excessive play is noted, replace the
flywheel.

CL-14
 RELEASE BEARING AND LEVER
I
CLUTCH SYSTEM

4. Release Bearing and Lever 4) Remove the clutch release bearing from clutch
cover using a flat-type screwdriver.
A: REMOVAL
1. NON-TURBO MODEL
1) Remove the transmission assembly from vehicle
body.
<Ref. to MT-27, REMOVAL, Manual Transmission
Assembly.>
2) Remove the two clips from clutch release lever
and remove the release bearing.
CAUTION:
Be careful not to deform the clips.
3) Remove the release lever seal. (A) Clutch release bearing

(A) Clutch release lever
(B) Release lever seal
4) Remove the release lever retainer spring from
release lever pivot with a screwdriver by accessing
it through the clutch housing release lever hole.
Then remove the release lever.
B: INSTALLATION
1. NON-TURBO MODEL
CAUTION:
Before or during assembling, lubricate the fol-
lowing points with a light coat of grease.
Contact surface of lever and pivot
Contact surface of lever and bearing
Transmission main shaft spline (Use grease
containing molybdenum disulphide.)
Contact surface of lever and operating cylin-
der
1) While pushing the release lever to pivot and
twisting it to both sides, fit the retainer spring onto
the constricted portion of pivot.
NOTE:
Apply grease (SUNLIGHT 2: P/N 003602010) to
the contact point of release lever and operating cyl-
inder.
Confirm that the retainer spring is securely fitted
by observing it through the main case hole.

(A) Clutch release lever

(B) Screwdriver

2. TURBO MODEL
1) Remove the transmission assembly from vehicle (A) Release lever
body. <Ref. to MT-27, REMOVAL, Manual Trans-
mission Assembly.> 2) Install the release bearing and fasten it with two
2) Remove the clutch release lever from transmis- clips.
sion.
3) Put the clutch release bearing in engine side.

CL-15
I RELEASE BEARING AND LEVER
CLUTCH SYSTEM

3) Install the release lever seal. 3) Apply grease to the specified points:
Spline FX2200
Shaft SUNLIGHT 2

(A) Release lever

(6) Release lever seal
4) Install the transmission assembly.
<Ref. to MT-30, INSTALLATION, Manual Tran
mission Assembly.>
2. TURBO MODEL
#) Install the release bearing on transmission.
2) Insert the release fork into release bearing tab.

S2M1938A

(A) Spline (FX2200)

(6) Shaft (SUNLIGHT 2)

4) Insert the release fork shaft into release fork.

CAUTION:
Make sure the cutout portion of the release fork
S2M1937A shaft contacts spring pin.

(A) Release fork

(6) Release bearing

1845A

(A) Release fork

(B) Release shaft
(C) Spring pin

5 ) Install the transmission assembly. <Ref. to MT-

30, INSTALLATION, Manual Transmission Assem-
bly.>

CL-16
 RELEASE BEARING AND LEVER I
CLUTCH SYSTEM

C: INSPECTION 2. RELEASE LEVER

1. RELEASE BEARING 1) Check the lever pivot portion and the point of
contact with release bearing case for wear.
CAUTION:
Since this bearing is grease sealed and is of a
non-lubrication type, do not wash with gaso-
line or any solvent when servicing the clutch.
1) Check the bearing for smooth movement by ap-
plying force in the radial direction.
Radial direction stroke:
1.4 mm (0.055 in)

S2M1102E

(A) Clutch release lever

(B) Pivot
(C) Clutch release bearing

(A) Bearing case

2) Check the bearing for smooth rotation by apply-

ing pressure in the thrust direction.

(A) Bearing case

3) Check wear and damage of bearing case sur-

face contacting with lever.

CL-17
I OPERATING CYLINDER I
CLUTCH SYSTEM

5. Operating Cylinder 4) Remove the operating cylinder from transmis-

sion.
A: REMOVAL Non-turbo model
1) Remove the air cleaner case and air intake duct
(Non-turbo model). <Ref. to IN(S0HC)-6, REMOV-
AL, Air Cleaner Case.> and <Ref. to IN(S0HC)-7,
REMOVAL, Air Intake Duct.>
2) Remove the intercooler (Turbo model). <Ref. to
IN(D0HC TURBO)-10, REMOVAL, Intercooler.>
3) Remove the clutch hose from operating cylinder.
CAUTION:
Cover the hose joint to prevent clutch fluid from
flowing out.
Non-turbo model
Turbo model

-.
179J
-
(A) Clutch hose
(B) Operating cylinder
Turbo model

(A) Clutch hose

(6) Operating cylinder

CL-18
 OPERATING CYLINDER I
CLUTCH SYSTEM

B: INSTALLATION 2) After bleeding air from the operating cylinder, en-

1) Install in the reverse order of removal.
NOTE:
Before installing the operating cylinder, apply
grease (SUNLIGHT 2: P/N 003602010) to the con-
tact point of release lever and operating cylinder.
Tightening torque:
T1: 18 N.m (1.8 kgf-m, 13.0 ft-lb)
T2: 37 N-m (3.8 kgf-m, 27.5 ft-lb)
Non-turbo model
sure that the clutch operates properly.
<Ref. to CL-24, Clutch Fluid Air Bleeding.>
C: INSPECTION
1) Check the operating cylinder for damage. If the
operating cylinder is damaged, replace it.
2) Check the operating cylinder for fluid leakage or
damage on boot. If any leakage or damage is
found, replace the operating cylinder.

c. .

Turbo model

NOTE:
Be sure to install the clutch hose with the mark
side facing upward.
Be careful not to twist the clutch hose during in-
stallation.

(A) Marking
(B) Clutch hose
(C) Operating cylinder

CL-19
I I
MASTER CYLINDER
CLUTCH SYSTEM

6. Master Cylinder B: INSTALLATION

A: REMOVAL
1) Thoroughly drain the brake fluid from reservoir
tank.
2) Remove the snap pin, clevis pin and separate
the push rod of master cylinder from clutch pedal.
1) Install the master cylinder to body, and install the
clutch pipe to master cylinder.
CAUTION:
Check that the pipe is routed properly.
Tightening torque:
T1: 15 N.m (1.5 kgf-m, 10.8 ff-lb)
T2: 18 N.m (1.8 kgf-m, 13.0 ff-lb)

B4M1189E

(A) Clevis pin

(B) Snap pin 2) Connect the push rod of master cylinder to clutch
-* (C) Push rod pedal, and install the clevis pin and snap pin.
(D) Locknut
NOTE:
3) Remove the air cleaner case and air intake duct Apply grease to the clevis pin.
(Non-turbo model). <Ref. to IN(S0HC)-6, RE-
MOVAL, Air Cleaner Case.> and <Ref. to IN(S0-
HC)-7, REMOVAL, Air Intake Duct.>
4) Remove the intercooler (Turbo model). <Ref. to
IN(D0HC TURBO)-10, REMOVAL, Intercooler.>
5) Remove the clutch pipe from master cylinder.
6) Remove the master cylinder with reservoir tank.
CAUTION:
Be extremely careful not to spill the brake fluid.
Brake fluid spilt on the vehicle body will harm / B4M1189C
the paint surface; wipe it off quickly if spilt.
(A) Clevis pin
(B) Snap pin
(C) Push rod

3) After bleeding air from the system, ensure that

the clutch operates properly.
<Ref. to CL-24, Clutch Fluid Air Bleeding.>
4) Install the air cleaner case and air intake duct
(Non-turbo model). <Ref. to IN(S0HC)-6, INSTAL-
LATION, Air Cleaner Case.> and <Ref. to IN(S0-
HC)-7, INSTALLATION, Air Intake Duct.>
5) Install the intercooler (Turbo model). <Ref. to
(A) Master cylinder IN(D0HC TURBO)-11, INSTALLATION, Intercool-
(B) Clutch pipe er.>

CL-20
 MASTER CYLINDER I
CLUTCH SYSTEM

C: DISASSEMBLY
1) Remove the straight pin and reservoir tank.
D: ASSEMBLY
1) Install the clutch damper. (Non-turbo model)
Tightening torque:
46.6 N.m (4.75 kgf-m, 34.4 ft-lb)
2) Apply a coat of grease to the contacting surfaces
of the push rod and piston before installation.
Grease:
SILICONE GREASE G40M (Part No.
004404003)

(A) Reservoir tank

(B) Straight pin

2) Remove the oil seal.

3) To assemble the master cylinder, reverse the se-

quence of disassembly procedure.
Tightening torque:
10 N-m (1.0 kgf-m, 7 ft-lb)
E: INSPECTION
If any damage, deformation, wear, swelling, rust or
other faults are found on the cylinder, piston, push
(A) Oil seal rod, fluid reservoir, return spring, gasket, clutch
(B) Master cylinder damper and hose replace the faulty part.
3) Move the cylinder boot backward.

TR0475

(A) Master cylinder body

(B) Return spring
(A) Cylinder boot
(C) Piston
(B) Master cylinder
(D) Stop ring
4) Remove the stop ring. (E) Rod ASSY
CAUTION: (F) Clutch damper (Non-turbo model)
Be careful when removing the snap ring to pre-
vent the rod, washer, piston and return spring
from flying out.
5) Remove the clutch damper. (Non-turbo model)

CL-21
I CLUTCH PIPE AND HOSE
CLUTCH SYSTEM

7. Clutch Pipe and Hose B: INSTALLATION

A: REMOVAL
1) Remove the air cleaner case. (Non-turbo model)
<Ref. to IN(S0HC)-6, REMOVAL, Air Cleaner
Case.>
2) Remove the intercooler. (Turbo model) <Ref. to
IN(D0HC TURBO)-IO, REMOVAL, Intercooler.>
3) Drain the clutch fluid. <Ref. to CL-23, Clutch Flu-
id.>
4) Remove the clutch pipe from the clutch hose and
master cylinder.
5) Pull out the clamp, then remove the clutch hose
from bracket I
Install in the reverse order of removal.
NOTE:
Bleed the clutch fluid. <Ref. to CL-24, Clutch Fluid
Air Bleeding.>
Tightening torque:
T1: 15 N.m (1.5 kgf-m, 10.8 ft-lb)
T2: 18 N-m (1.8 kgf-m, 13.0 ft-16)
T3: 25 N-m (2.5 kgf-m, 18.1 ft-16)

'\
'\

(A) Clamp
(B) Clutch hose
6) Remove the hose from operating cylinder.
7) Remove the bracket.

(A) Clutch pipe

(B) Clip
(C) Clutch hose

C: INSPECTION
Check pipes and hoses for cracks, breakage or
damage. Check joints for fluid leakage. If any
cracks, breakage, damage or leakage is found, re-
pair or replace the applicable pipe or hose.

CL-22
 CLUTCH FLUID I
CLUTCH SYSTEM

8. Clutch Fluid B: REPLACEMENT

CAUTION:
A: INSPECTION The FMVSS No. 116, fresh DOT3 or 4 brake
1) Park the vehicle on a level surface. fluid must be used.
2) Inspect the fluid level using the scale on the out- Cover the bleeder with waste cloth, when
side of the reservoir tank. If the level is below “MIN”, loosening it, to prevent brake fluid from being
add fluid to bring it up to “MAX, and also inspect for splashed over surrounding parts.
leakage. Avoid mixing different brands of brake fluid
to prevent degrading the quality of the fluid.
Be careful not to allow dirt or dust to get into
the reservoir tank.
NOTE:
During bleeding operation, keep the clutch reser-
voir tank filled with brake fluid to eliminate entry of
air.
Clutch pedal operating must be very slow.
For convenience and safety, it is advisable to
e have two men working.
The amount of brake fluid required is approxi-
(A) Max. level mately 70 m f2 (2.4 US fl 02, 2.5 Imp fl 02) for total
c.
(B) Min. level clutch system.
(C) Reservoir tank 1) Remove the air cleaner case and air duct.
2) Either jack-up the vehicle and place a safety
stand under it, or lift-up the vehicle.
3) Draw out the brake fluid from reservoir tank with
syringe.
4) Refill the reservoir tank with recommended
brake fluid.
Recommended brake fluid:
FM VSS No. 1 16, fresh DOT3 or 4 brake fluid
5) Drain fluid in the same method as the air bleed-
ing.
6) Refill the brake fluid before reservoir tank be-
comes empty, and drain the contaminated fluid
again.
7) Repeat the above procedure until the contami-
nated fluid is completely drained.

CL-23
I CLUTCH FLUID AIR BLEEDING I
CLUTCH SYSTEM

9. Clutch Fluid Air Bleeding 4) Slowly depress the clutch pedal and keep it de-
pressed. Then open the air bleeder to discharge air
A: PROCEDURE together with the fluid.
Release the air bleeder for 1 or 2 seconds. Next,
NOTE:
with the bleeder closed, slowly release the clutch
Bleed air from the oil line with the help of a co-work-
pedal,
er.
1) Remove the air cleaner case and air intake duct.
(Non-turbo model) <Ref. to IN(S0HC)-6, REMOV-
AL, Air Cleaner Case.> and <Ref. to IN(S0HC)-7,
REMOVAL, Air Intake Duct.>
2) Remove the intercooler. (Turbo model) <Ref. to
IN(D0HC TURBO)-10, REMOVAL, Intercooler.>
3) Fit one end of a vinyl tube into the air bleeder of
operating cylinder and put the other end into a
brake fluid container.

(A) Operating cylinder

(B) Vinyl tube

5 ) Repeat these steps until there are no more air

bubbles in the vinyl tube.
CAUTION:
Cover the bleeder with waste cloth when loos-
ening it, to prevent brake fluid from being
splashed over surrounding parts.
(A) Clutch hose
(B) Air bleeder
(C) Operating cylinder

CL-24
 CLUTCH FLUID AIR BLEEDING I
CLUTCH SYSTEM

6) Tighten the air bleeder.

Tightening torque:
T: 8 N.m (0.8 kgf-m, 5.8 ff-lb)

7) Repeat steps 2) through 4) using the air bleeder

on operating cylinder.
8) Tighten the air bleeder.
Tightening torque:
8 N-m (0.8 kgf-m, 5.8 ff-lb)
9) After depressing the clutch pedal, make sure
that there are no leaks evident in the entire system.
10) After bleeding air from the system, ensure that
the clutch operates properly.

CL-25
I CLUTCH PEDAL I
CLUTCH SYSTEM

1O.Clutch Pedal B: INSTALLATION

A: REMOVAL
1) Remove the steering column. <Ref. to PS-23,
REMOVAL, Tilt Steering Column.>
2) Disconnect the connectors from stop light and
clutch switches.
3) Remove the snap pins which secure lever to
push rod and operating rod.
4) Remove the clevis pins which secure lever to
push rod and operating rod.
1) Install in the reverse order of removal.
CAUTION:
If the cable clamp is damaged, replace it with
a new one.
Never fail to cover outer cable end with boot.
Be careful not to kink the accelerator cable.
Always use a new clevis pins.
2) Adjust the clutch pedal after installation.<Ref. to
CL-27, ADJUSTMENT, Clutch Pedal.>
C: DISASSEMBLY
1) Remove the clutch switches.
2) Remove the clips, assist spring, rod and bush-
ing.

(A) Operating rod

(B) Push rod
(C) Snap pin
02M4115A
(D) Clevis pin
(A) Clip
5 ) Remove the air cleaner case and intake duct.
(Non-turbo model) <Ref. to IN(S0HC)-6, REMOV- (B) Assist spring
AL, Air Cleaner Case.> and <Ref. to IN(S0HC)-7, (C) Assist rod
REMOVAL, Air Intake Duct.> (D) Bushing
6) Remove intercooler. (Turbo model) <Ref. to (E) Clevis pin
IN(D0HC TURBO)-10, REMOVAL, Intercooler.>
7) Remove the nut which secures clutch master 3) Remove the spring pin and lever.
cylinder.

(A) Pin
8) Remove the bolts and nuts which secure brake (B) Lever
and clutch pedals, and remove pedal assembly.

CL-26
 CLUTCH PEDAL I
CLUTCH SYSTEM

4) Remove the clutch pedal and bushings. E: INSPECTION

Move the clutch pedal pads in the lateral direction
with a force of approximately 10 N (1 kgf, 2 Ib) to
ensure the pedal deflection is in specified range.
CAUTION:
If excessive deflection is noted, replace the
bushings with new ones.
Deflection of clutch pedal:
Service limit
5.0 mm (0.197 in) or less
B2M4117A

(A) Clutch pedal

(B) Bushing

5 ) Remove the stopper, clip, O-ring, rod S, and

then remove the spring and bushing S.

(A) Clutch pedal

(B) Brake pedal

F: ADJUSTMENT
1) Turn the lock nuts until clutch pedal full stroke
length is within specifications.
(A) Clip CAUTION:
(B) O-ring Do not attempt to turn the clutch switch to ad-
(C) Bushings just clutch pedal full stroke length.
(D) Spring S NOTE:
(E) Rod S If the lock nuts cannot adjust the clutch pedal full
(F) Stopper stroke length to specifications, turn the master cyl-
inder push rod to adjust it.
6) Remove the stoppers from clutch pedal.
7) Remove the clutch pedal pad. (Non-turbo model) Specified clutch pedal full stroke: A
130 - 135 mm (5.12 - 5.31 in)
D: ASSEMBLY Tightening torque (Clutch switch lock nut):
1) Attach the clutch switch, etc. to pedal bracket T: 8 N.m (0.8 kgf-m, 5.8 ft-16)
temporarily.
2) Clean the inside of bores of clutch pedal and
brake pedal, apply grease, and set bushings into
bores.
3) Align the bores of pedal bracket, clutch pedal
and brake pedal, attach brake pedal return spring,
assist rods, and spring, and bushing.
NOTE:
Clean up inside of bushings and apply grease be-
fore installing the spacer.

CL-27
 CLUTCH PEDAL
CLUTCH SYSTEM

2) Turn the master cylinder push rod so that the cle-
vis pin moves to the left and then to the right. Clevis
pin must move without resistance while it is rattling.
Tightening torque (Push rod lock nut):
T: 10 N.m (1.0 kgf-m, 7 fWb)
6) Push the release lever until operating cylinder
push rod retracts. Ensure that the clutch fluid level
in reservoir tank increases. If the clutch fluid level
increases, hydraulic clutch is properly adjusted; if
fluid level does not increase or push rod does not
retract, replace the master cylinder with a new
one.<Ref. to CL-20, Master Cylinder.>

B4M1189G

1918
(A) Clevis pin
(B) Snap pin (1) Push rod
(C) Push rod (2) Release lever
*. (D) Locknut (3) Operating cylinder
3) Depress and release the clutch pedal 2 to 3 7) Push the release lever until operating cylinder
times to ensure that the clutch pedal and release push rod retracts. Check that the clutch fluid level in
fork operates smoothly. If the clutch pedal and re- reservoir tank increases.
lease fork do not operate smoothly, bleed air from
the clutch hydraulic system. <Ref. to CL-24, Clutch
Fluid Air Bleeding.>
4) Measure the clutch pedal full stroke length again
to ensure that it is within specifications. If it is not,
repeat adjustment procedures again from the be-
ginning.
Specified clutch pedal full stroke:
130 - 135 mm (5.12 - 5.31 in)
5) Move the clevis pin to the left and then to the
right. It should move without resistance while it is 1918

rattling. If resistance is felt, repeat adjustment pro-

cedures again from the beginning. (1) Push rod
(2) Release lever
(3) Operating cylinder

8) If the clutch fluid level increases, hydraulic clutch

play is correct.
9) If the clutch fluid level does not increase or push
rod does not retract, clutch pedal must be readjust-
ed.

CL-28
 CLUTCH PEDAL
I
CLUTCH SYSTEM

10) Check the fluid level on the outside of the res-

ervoir tank. If the level is below “MIN”, add clutch
fluid to bring it up to “MAX.
Recommended clutch fluid:
FMVSS No. 116, fresh DOT 3 or DOT 4 brake
fluid

(A) Max. level

(B) Min. level
c. ~ (C) Reservoir tank

CL-29
I CLUTCH SWITCH
CLUTCH SYSTEM

11.Clutch Switch 2) Check the clutch switch continuity. If continuity is

not as specified, replace the switch.
A: REMOVAL (1) Disconnect the clutch switch connector.
1) Disconnect the ground terminal from battery. (2) Measure the resistance between 1 and 2 of
2) Disconnect the connector from clutch switch. clutch switch terminal.
3) Remove the clutch switch. Terminals/Specified resistance
B: INSTALLATION When clutch pedal depressed:
1) Move the clevis pin of the push rod right and left 1 - ZLess than 1 0
and hold where it moves smoothly, then measure TerminaWSpecified resistance
stroke of clutch pedal. When clutch pedal not depressed:
Specified clutch pedal full stroke:A 1 - ZMore than lMSZ
130 -135 mm (5.12 - 5.31 in) Clutch switch (Starter interlock)
Tightening torque:
T: 8 N-m (0.8 kgf-m, 5.8 ft-lb)

Clutch switch (With cruise control)

04M 119OC

2) If the clutch pedal stroke is out of specification,

adjust the stroke. <Ref. to CL-27, ADJUSTMENT,
Clutch Pedal.>
3) Connect the clutch switch connector.
C: INSPECTION
1) If the clutch switch does not operate properly (or
if it does not stop at the specified position), replace
with a new one.
TR0541
Specified position: L
(3) If not as specified, replace the clutch switch.
P'.5/omm(0.079+0.059/0
in)

I L

G4M0327

CL-30
 GENERAL DIAGNOSTIC TABLE
I
CLUTCH SYSTEM

12.General Diagnostic Table

A: INSPECTION
1. CLUTCH

I Symptom Possible cause Corrective

1. Clutch slippage. (a) Clutch facing smeared by oil Replace.
It is hard to perceive clutch slippage in (bl Worn clutch facina Replace.
the early stage, but pay attention to the (c) Deteriorated diaphragm spring Replace.
following symptoms
(d) Distorted pressure plate or flywheel Sorrect or replace.
Engine speeds up when shifting.
High speeds driving is impossible; (e) Defective release bearing holder Sorrect or replace.
especially rapid acceleration impossible
and vehicle speed does not increase in
proportion to an increase in engine
speed.
Power falls, particularly when ascend-
ing a slope, and there is a smell of burn-
ing of the clutch facing.
Method of testing: Put the vehicle in a
stationary condition with parking brake
.fully applied. Disengage the clutch and
shift the transmission gear into the first.
Gradually allow the clutch to engage
while gradually increasing the engine
speed. The clutch function is satisfactory
if the engine stalls. However, the clutch is
slipping if the vehicle does not start off
and the engine does not stall.
2. Clutch drags. (a) Worn or rusty clutch disc hub spline ReDlaCe clutch disc.
As a symptom of this trouble, a harsh (b) Excessive deflection of clutch disc Correct or replace.
scratching noise develops and control facina
becomes quite difficult when shifting (c) Seized crankshaft pilot needle bear- Replace.
gears. The symptom becomes more inn
apparent when shifting into the first gear.
(d) Cracked clutch disc facing ReDlace.
However, because much trouble of this
sort is due to defective synchronization (e) Sticked clutch disc (smeared by oil or Replace.
mechanism, carry out the test as water)
described after.
Method of testing: <Ref. to CL-32,
DIAGNOSTIC DIAGRAM OF CLUTCH
DRAG, INSPECTION, General Diagnos-
tic Table.>
It may be judged as insufficient disen-
gagement of clutch if any noise occurs
during this test.
3. Clutch chatters. (a) Adhesion of oil on the facing Replace clutch disc.
Clutch chattering is an unpleasant vibra- (bl Weak or broken torsion spring Replace clutch disc.
tion to the whole body when the vehicle is (c) Defective facing contact or excessive Replace clutch disc defection.
just started with clutch partially engaged. disc
(d) Warped pressure plate or flywheel Correct or replace.
(e) Loose disc rivets Replace clutch disc.
(fl Loose enaine mountina Retiahten or replace mounting.
(9) Improper adjustment of pitching stop- Adjustment.
per

CL-31
 GENERAL DIAGNOSTIC TABLE
I
CLUTCH SYSTEM

Symptom Possible cause Corrective

4. Noisy clutch (a) Broken, worn or unlubricated release Replace release bearing.
Examine whether the noise is generated bearing
when the clutch is disengaged, engaged, (b) Insufficient lubrication of pilot bearing Apply grease.
or partially engaged. (c) Loose clutch disc hub Replace clutch disc.
I (d) Loose torsion spring retainer I Replace clutch disc.
(e) Deteriorated or broken torsion spring Replace clutch disc.
5. Clutch grabs. (a) Grease or oil on facing Replace clutch disc.
When starting the vehicle with the clutch (b) Deteriorated cushioning spring Replace clutch disc.
partially the clutch engages (c) Worn or rusted spline of clutch disc or Take off rust, apply grease or replace
suddenly and the vehicle jumps instead main shaft clutch disc or main shaft.
of making a smooth start.
(d) Deteriorated or broken torsion spring Replace clutch disc.
(e) Loose engine mounting Retighten or replace mounting.
(f) Deteriorated diaphragm spring Replace.

2. CLUTCH PEDAL

Trouble Corrective action

Insufficient pedal play Adjust pedal play.
Clutch pedal free play insufficient Adjust pedal free play.
Excessively worn and damaged pedal shaft and/or bushing Replace bushing and/or shaft with new one.

3. DIAGNOSTIC DIAGRAM OF CLUTCH DRAG

Step No
CHECK GEAR NOISE. Clutch is normal.
1)Start the engine. rom the transmission gear?
2)Disengage the clutch and shift quickly from
neutral to reverse in idling condition.
! CHECK GEAR NOISE. Defective trans-
Disengage the clutch at idle and shift from neu- rom the transmission gear? mission or exces-
tral to reverse within 0.5 - 1.O seconds. sive clutch drag
torque.
Inspect Pilot bear-
ing, clutch disc,
transmission and
clutch disc hub
spline.
I CHECK GEAR NOISE. Clutch and fly-
1)Disengage the clutch at idle and shift from wheel seizure.
neutral to reverse within 0.5 - 1.O seconds. Inspect clutch disc, Inspect clutch disc,
2)With the clutch disengaged, shift from N to clutch cover, clutch spline of clutch
R. R to N several times. release, and clutch disc hub.
pedal free play.

CL-32
I a
2002 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX
~~

CHASSIS SECTION

This service manual has been prepared

to provide SUBARU service personnel
with the necessary information and data
for the correct maintenance and repair
of SUBARU vehicles.
This manual includes the procedures
c- .
for maintenance, disassembling, reas-
sembling, inspection and adjustment of
components and diagnostics for guid-
ance of experienced mechanics.
Please peruse and utilize this manual
fully to ensure complete repair work for
satisfying our customers by keeping
their vehicle in optimum condition.
When replacement of parts during
repair work is needed, be sure to use
SUBARU genuine parts.

All information, illustration and specifi-

cations contained in this manual are
based on the latest product information
available at the time of publication
approval.

FUJI HEAVY INDUSTRIES LTD. G18306E5

 FRONT SUSPENSION

FSr
1. General Description .................................................................................... 2
2. Wheel Alignment ......................................................................................... 8
3. Sub Frame ................................................................................................ 16
4. Front Transverse Link ............................................................................... 17
5. Front Ball Joint .......................................................................................... 19
6. Front Strut ................................................................................................. 20
7. Front Stabilizer .......................................................................................... 24
8. Front Crossmember .................................................................................. 25
9. General Diagnostic Table.......................................................................... 26
c- .
I GENERAL DESCRIPTION
FRONT SUSPENSION

1. General Description
A: SPECIFICATIONS
1. STABILIZER
Model Bar diameter.
ALL MODEL 20 mm (0.79 in)

2. WHEEL ALIGNMENT

Sedan Wagon
Model

Caster (common difference: f0'45') 3'35' I

I
3'25' I
I
3'35' I 3'25'
I
II 3'25'
. ~-

0+3 mm (Of0.12 in)

Toe-in
Each toe anale: kO"O7'30 (Total toe anale: fO"15')
I Kingpin angle (tolerance: +0"45') I 14"35' I 14"20' I 13"45' I 13"30' I 13'20'
Wheel arch height 396 mm 406 mm 387 mm 397 mm 402 mm
[tolerance: f 1 2 mm (f0.47 in)] (15.59 in) (15.98 in) (15.24 in) (15.63 in) (15.83 in)
AOTE:
Front and rear toe-ins and front camber can be
adjusted. If the toe-in or camber tolerance exceeds
specifications,adjust toe-in and camber to the mid-
dle value of specification.
The other items indicated in the specification ta-
ble cannot be adjusted. If the other items exceeds
specifications, check suspension parts and con-
nections for deformities; replace with new ones as
required.

B4M2250B

(1) Front
A - B = Positive: Toe-in, Negative: Toe-out
a = Each toe angle

FS-2
I GENERAL DESCRIPTION
FRONT SUSPENSION

c- .

FS-3
 GENERAL DESCRIPTION
FRONT SUSPENSION

B: COMPONENT

FS-4
 GENERAL DESCRIPTION
FRONT SUSPENSION

Front crossmember (17 )Dust seal Tightening torque: N.m (kgf-m, ft-lb)
Bolt ASSY (18) Strut mount T I : ZO(2.0, 14.5)
Housing (19) Spacer T2: 25 (2.5, 18.1) 1

Washer (20) Upper spring seat T3: 30 (3.1,22)

Stopper rubber (Rear) (21) Rubber seat T4: 34 (3.5,25)
Rear bushing (22) Dust cover T5: 40 (4.1, 30)
Stopper rubber (Front) (23) Helper T6: 45 (4.6, 33)
Ball joint (24) Coil spring T7: 50 (5.1, 37)
Transverse link (25) Damper strut T8: 55 (5.6, 41)
Cotter pin (26) Adjusting bolt T9: 71 (7.2, 52)
Front bushing (27) Castle nut T10: 100 (10.2, 74)
Stabilizer link (Except sedan turbo (28) Self-locking nut T11: <Ref. to FS-17, INSPECTION,
model) (29) Sub frame Sub Frame.>
Clamp (30) Cover T12: 175 (17.8, 129)
Bushing (311 Clip T13: 190(19.4, 140)
Stabilizer (32) Stabilizer link (Sedan turbo model) T14: 250 (25.5, 184)
Jack-up plate

.-

FS-5
 GENERAL DESCRIPTION
FRONT SUSPENSION

C: CAUTION
Wear working clothing, including a cap, protec-
tive goggles, and protective shoes during opera-
tion.
Remove contamination including dirt and corro-
sion before removal, installation or disassembly.
Keep the disassembled parts in order and pro-
tect them from dust or dirt.
Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary re-
moval, installation, disassembly, and replacement.
Use SUBARU genuine grease etc. or the equiv-
alent. Do not mix grease etc. with that of another
grade or from other manufacturers.
Be sure to tighten fasteners including bolts and
nuts to the specified torque.
Place shop jacks or safety stands at the specified
points.
Apply grease onto sliding or revolution surfaces
before installation.
c-- Before installing O-rings or snap rings, apply suf-
ficient amount of grease to avoid damage and de-
formation.
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.

FS-6
 GENERAL DESCRIPTION
FRONT SUSPENSION

D: PREPARATION TOOL
1. SPECIAL TOOLS

ILLUSTRATION TOOL NUMBER REMARKS

927380002 sed as an adapter for camber & caster gauge
,hen measuring camber and caster.
I ) 28199AC000 PLATE
2) 28199AC010 BOLT

927680000 NSTALLER & Jsed for replacing transverse link bushing.

3EMOVER SET

84M2385
927760000 STRUT MOUNT Used for disassembling and assembling strut
SOCKET and shock mount.

2. GENERAL PURPOSE TOOLS

TOOL NAME REMARKS

Alignment gauge Used for wheel alignment measurement.
Turning radius gauge Used for wheel alignment measurement.
Toe-in gauge Used for toe-in measurement.
Dial gauge Used for damper strut measurement.

FS-7
 I
WHEEL ALIGNMENT
FRONT SUSPENSION

2. Wheel Alignment
A: INSPECTION
Check, adjust and/or measure wheel alignment in accordance with procedures indicated in figure:

WHEEL ARCH HEIGHT (FRONT AND REAR)

1
CAMBER (FRONT AND REAR)

FRONT TOE-IN

REAR TOE-IN

THRUST ANGLE (REAR)

WHEEL STEERING ANGLE

B4M1OBBA

FS-8
I WHEEL ALIGNMENT I
FRONT SUSPENSION

1. WHEEL ARCH HEIGHT

1) Adjust the tire pressure to specifications.
2) Set the vehicle under “curb weight” conditions. (Empty luggage compartment, install spare tire, jack, ser-
vice tools, and top up fuel tank.)
3) Set the steering wheel in a wheel-forward position.
4) Suspend a thread from wheel arch (point “ A in figure below) to determine the point directly above center
of spindle.
5 ) Measure the distance between measuring point “ A and center of spindle.

E t
m
.-
a,
a,
.-m
a,
..c
c c
c E
2 m
.-c
2 a,
-a, m
a, .c
a, 2
m
c c
3
c
5
L
-a,a,
C m
e aa,
LL f
7 End of spindle;,y//,/

suo009

~
Model

Front
I Turbo ~~

396k12 mm (15.59k0.47in)
Specified wheel arch height
Non-turbo
406kl2 mm (15.98k0.47in)
Sedan
Rear 376k12 mm (14.80k0.47in) 381532 mm (15.0k0.47in)
Front 387k12 mm (15.24k0.47in) 397k12 mm (1 5.63k0.47in)
Wagon
Rear 376+12 mm (14.80k0.47in) 381332 mm (15.0k0.47in)
Front - 402k12 mm (15.83k0.47in)
OUTBACK
I Rear - 386k12 mm (15.20k0.47in)

FS-9
I WHEEL ALIGNMENT
FRONT SUSPENSION

2. CAMBER 2) Turn the camber adjusting bolt so that the cam-

ber is set at the specification.
Inspection
NOTE:
1) Place the front wheel on turning radius gauge. Moving the adjusting bolt by one scale graduation
Make sure the ground contacting surfaces of front changes the camber by approximately 0’10’.
and rear wheels are set at the same height.
2) Set the ST into the center of the wheel, and then
install the wheel alignment gauge.
ST 927380002 ADAPTER

c- ~ (1) Alignment gauge

(2) Turning radius gauge

NOTE:
Refer to the ‘SPECIFICATIONS” for the camber
va Iues.
Front: <Ref. to FS-2, SPECIFICATIONS, General J
Description.>
Rear: <Ref. to RS-2, SPECIFICATIONS, General (1) Strut
Description.> (2) Adjusting bolt
Front camber adjustment (3) Housing
(4) Outer
1) Loosen the two self-locking nuts located at the
(5) Inner
lower front portion of strut.
(6) Camber is increased.
CAUTION: (7) Camber is decreased.
When the adjusting bolt needs to be loos-
ened or tightened, hold its head with a wrench
and turn the self-locking nut.
Discard the loosened self-locking nut and re-
place with a new one.

FS-10
I WHEEL ALIGNMENT I
FRONT SUSPENSION

Left side Right side

Camber is increased.
J @) I
;hte counterclock-
@ Rotate clockwise.

u 04M0190 B4M03Gn

Camber is decreased. @ Rotate clockwise.

@
‘
I
;?:e counterclock-
W
B4M0350 B4M0190

3 ) Tighten the two self-locking nuts. 4. FRONT WHEEL TOE-IN

--Tightening torque:
175 N.m (1 7.8 kgf-m, 129 ft-lb)
3. CASTER
Inspection
1) Place the front wheel on turning radius gauge.
Make sure the ground contacting surfaces of front
and rear wheels are set at the same height.
2) Set the ST into the center of the wheel, and then
install the wheel alignment gauge.
ST 927380002 ADAPTER
Inspection
1) Using a toe gauge, measure the front wheel toe-
in.
Toe-in:
Of3 mm (OdU. 12 in)
2) Mark the rear sides of left and right tires at height
corresponding to the center of spindles and mea-
sure distance “ A between marks.
3) Move the vehicle forward so that the marks line
up with front sides at height corresponding to the
center of spindles.
4) Measure the distance “ 6 between left and the
right marks. Toe-in can then be obtained by the fol-
lowing equation:
A - B = Toe-in

B A

(1) Alignment gauge i i

(2) Turning radius gauge

NOTE:
Refer to the ‘SPECIFICATIONS’ for the caster val-
ues. <Ref. to FS-2, SPECIFICATIONS, General Adjustment
Description.> 1) Loosen the left and right side steering tie-rods
lock nuts.

FS-11
I WHEEL ALIGNMENT
FRONT SUSPENSION

2) Turn the left and right tie rods equal amounts un- 4) Measure the distance “B” between left and right
til the toe-in is at the specification. marks. Toe-in can then be obtained by the follow-
Both the left and right tie-rods are right-hand ing equation:
threaded. To increase toe-in, turn both tie-rods A - B = Toe-in
clockwise equal amounts (as viewed from the in-
side of the vehicle). I

S4M0348A Adjustment
1) Loosen the self-locking nut on inner side of link
(1) Lock nut
rear.
3) Tighten the tie-rod lock nut. CAUTION:
Tightening torque: When loosening or tightening the adjusting
83 N-m (8.5kgf-m, 61.5 ff-lb) bolt, hold the bolt head and turn self-locking
nut.
CAUTION: Discard the loosened self-locking nut and re-
Correct the tie-rod boot, if it is twisted. place with a new one.
NOTE:
Check that the left and right wheel steering angle is
within specifications.
5. REAR WHEEL TOE-IN
Inspection
1) Using a toe-in gauge, measure the rear wheel
toe-in.
Toe-in:
-132 mm (-0.039fo.079 in)
2) Mark the rear sides of left and right tires at height
corresponding to the center of spindles and mea- (1) Adjusting bolt
sure distance “A” between marks. (2) Link rear
3) Move the vehicle forward so the that marks line
up with front sides at height corresponding to the 2) Turn the adjusting bolt head until toe-in is at the
specification.
center of spindles.

FS-12
 WHEEL ALIGNMENT I
FRONT SUSPENSION

NOTE:
When the left and right wheels are adjusted for toe-in at the same time, the movement of one scale gradu-
ation changes toe-in by approximately 1.5 mm (0.12 in).

Left side Right side

~~

Rotate counterclock-
Toe-in is increased. Rotate clockwise.
wise.

B4M0192 B4M0352
~~

c Rotate counterclock-
Toe-in is decreased. Rotate clockwise.
wise.

B4M0352 84M0192

1) Tighten the self-locking nut. Adjus ment

Tightening torque: Turn the tie-rod to adjust the steering angle of both
100 N-m (10.2 kgf-m, 74 ft-lb) inner and outer wheels.
6. STEERING ANGLE CAUTION:
Check the toe-in.
Inspection Correct the boot if it is twisted.
1) Place the vehicle on a turning radius gauge.
2) While depressing the brake pedal, turn the steer-
ing wheel fully to the left and right. With the steer-
ing wheel held at each fully turned position,
-
measure both the inner and outer wheel steering
angle.
Steering angle:
Turbo,sedan and
Model Others
OUTBACK
S4M0348A
I
~~

Outerwheel I 29"35"f1.5" 31"35Y1.5"

(1) Locknut

FS-13
I WHEEL ALIGNMENT
FRONT SUSPENSION

7. THRUST ANGLE 3) When the left and right adjusting bolts are turned
incrementally by one graduation in the same direc-
Inspection
tion, the thrust angle will change approximately 16’
1) Position the vehicle on a level surface. [‘I“ is almost equal to 12 mm (0.472 in)].
2) Move the vehicle 3 to 4 meters directly forward.
Thrust angle:
3) Determine the locus of both front and rear axles.
4) Measure the distance “L” between center line of O”f20’
loci of the axles.
Thrust angle:
Less than 20‘ when “L” is equal to or less
than 15 mm (59 in).

c- .

M S4M0350B

(1) Center line of loci (front axle)

(2) Center line of loci (rear axle)

T S4M0350B
(1) Center line of loci (front axle)
(2) Center line of loci (rear axle)
Adjustment
1) Make the thrust angle adjustments by turning
toe-in adjusting bolts of rear suspension equally in
the same direction.
2) When one rear wheel is adjusted in a toe-in di-
rection, adjust the other rear wheel equally in toe-
out direction, in order to make the thrust angle ad-
justment.
NOTE:
Thrust angle refers to a mean value of left and right
rear wheel toe angles in relation to the vehicle
body center line. Vehicle is driven straight in the
thrust angle direction while swinging in the oblique
direction depending on the degree of the mean
thrust angle.
(11
t

(1) Front
(2) Thrust angle
(3) Body center line

FS-14
I WHEEL ALIGNMENT I
FRONT SUSPENSION

Thrust angle: r = (a- p)/2

a: Right rear wheel toe-in angle
p: Left rear wheel toe-in angle
NOTE:
Here, use only positive toe-in values from each
wheel to substitute for a and p in the equation.

B4M01948

(1) Front
(2) Body center line
c.

FS-15
 SUB FRAME
FRONT SUSPENSION

3. Sub Frame B: INSTALLATION

Install in the reverse order of removal.
A: REMOVAL
NOTE:
1) Lift-up the vehicle.
Replace the M12 bolt with a new one.
2) Remove the under cover.
3) Remove the bolt cover. Tightening torque:
T1: 34 N.m (3.5 kgf-m, 25 ff-lb)
T2: 55 N-m (5.6 kgf-m, 41 ff-lb)
T3: 71 N.m (7.2 kgf-m, 52 ff-lb)
T4: 105 N-m (10.7 kgf-m, 77 ff-lb)

4) Remove the clip.

(1) M8 bolt
(2) M12 bolt (with max)
(3) M12 bolt (with oil)
(4) M10 bolt

5) Remove the sub frame.

NOTE:
Loosen bolt (1) and leave a few threads caught,
then remove the bolts in the order of (2),(3), (4),
(51,and (6).

FS-16
 SUB FRAME
FRONT SUSPENSION

C: INSPECTION
1) Check that there is no damage and distortion at
the sub frame.
2) Check that the bolts are tightened with the spec-
ified torque. If there is looseness, tighten to the
specified torque.
NOTE:
The tightening torque differs by the color for bolt
(3). Always verify the bolt color before checking
tightening torque.
Tightening torque:
T I : 34 N-m (3.5 kgf-m, 25 ff-lb)
T2: 55 N.m (5.6 kgf-m, 41 ff-lb)
T3: 71 N-m (7.2 kgf-m, 52 ff-lb)
T4: Dark green bolt
105 Nom(10.7 kgf-m, 77 ff-lb)
T4: Except dark green bolt
55 N-m (5.6 kgf-m, 41 ff-lb)

FS-17
 SUB FRAME
FRONT SUSPENSION

3. Sub Frame B: INSTALLATION

Install in the reverse order of removal.
A: REMOVAL
NOTE:
1) Lift-up the vehicle.
Replace the M12 bolt with a new one.
2) Remove the under cover.
3) Remove the bolt cover. Tightening torque:
T1: 34 N-m (3.5 kgf-my25 ft-16)
T2: 55 N-m (5.6 kgf-my41 ft-16)
T3: 71 N-m (7.2 kgf-my52 ft-16)

4) Remove the clip.

(1) M8 bolt
(2) M12 bolt
(3) MlO bolt

C: INSPECTION
Check that there is no damage and distortion at the
sub frame.

5 ) Remove the sub frame.

NOTE:
Loosen bolt (1) and leave a few threads caught,
then remove the bolts in the order of (2),(3), (4),
(5),and (6).

FS-16
 I
FRONT TRANSVERSE LINK
FRONT SUSPENSION

4. Front Transverse Link B: INSTALLATION

1) Temporarily tighten the two bolts used to secure
A: REMOVAL the rear bushing of the transverse link to body.
1) Set the vehicle on the lift. NOTE:
2) Disconnect the ground terminal from battery. These bolts should be tightened to such an extent
3) Lift-up the vehicle and remove the wheel. that they can still move back and forth in the oblong
4) Remove the sub frame. <Ref. to FS-16, RE- shaped hole in the bracket (which holds the bush-
MOVAL, Sub Frame.> ing).
5) Disconnect the stabilizer link from transverse
2) Install the bolts used to connect the transverse
link. link to crossmember and temporarily tighten with
6) Remove the bolt securing the ball joint of trans- nut.
verse link to housing.
CAUTION:
Discard the loosened self-locking nut and re-
place with a new one.
3) Insert the ball joint into housing.
4) Connect the stabilizer link to transverse link, and
temporarily tighten bolts.
CAUTION:
Discard the loosened self-locking nut and re-
c.
place with a new one.
S4MOO9(

7) Remove the nut (do not remove bolt.) securing

the transverse link to crossmember.
8) Remove the two bolts securing the bushing
bracket of transverse link to vehicle body at rear
bushing location.

" S4M0090

5) Tighten the following points in the order shown

below when the wheels are in full contact with the
ground and vehicle is curb weight.
(1) Transverse link and stabilizer
Tightening torque:
Sedan Turbo model:
45 N.m (4.6 kgf-m, 33 ft-lb)
9) Extract the ball joint from housing. Except sedan Turbo model:
10) Remove the bolt securing the transverse link to 30 N m (3.1 kgf-m, 22 ft-lb)
crossmember and extract the transverse link from
crossmember. (2) Transverse link and crossmember
Tightening torque:
100 N-m (10.2 kgf-m, 74 ft-lb)
(3) Transverse link rear bushing and body
Tightening torque:
250 N-m (25.5 kgf-m, 184 ff-16)

FS-17
I FRONT TRANSVERSE LINK
FRONT SUSPENSION

NOTE: D: ASSEMBLY
Move the rear bushing back and forth until trans-
verse link-to-rear bushing clearance is established 1. FRONT BUSHING
(as indicated in figure.) before tightening. To reassemble, reverse disassembly procedures.
Unit: mm (in) CAUTION:
Install the front bushing in correct direction, as
.059) shown in the figure.

(1) Rear bushing

6) Install the sub frame. <Ref. to FS-16, INSTALLA- S4M0351A

TION, Sub Frame.>
7) Inspect the wheel alignment and adjust if neces- (1) Face bushing toward center of ball joint
sary. <Ref. to FS-8, Wheel Alignment.> (2) Ball joint

C: DISASSEMBLY 2. REAR BUSHING

1. FRONT BUSHING 1) Install the rear bushing to transverse link and
align the aligning marks scribed on the two.
Using ST, press the front bushing out of place. 2) Tighten the self-locking nut.
ST 927680000 INSTALLER & REMOVER
SET CAUTION:
Discard the loosened self-locking nut and re-
place with a new one.
While holding the rear bushing so as not to
change position of aligning marks, tighten the
self-locking nut.
Tightening torque:
190 N-m (19.4 kgf-m, 140 ff-lb)
E: INSPECTION
1) Check the transverse link for wear, damage and
G4M0494 cracks, and correct or replace if defective.
2) Check the bushings for cracks, fatigue or dam-
2. REAR BUSHING
age.
1) Scribe an aligning mark on the transverse link 3) Check the rear bushing for oil leaks.
and rear bushing.
2) Loosen the nut and remove the rear bushing.

G4M0495 I

FS-18
 I
FRONT BALL JOINT
FRONT SUSPENSION

5. Front Ball Joint C: INSPECTION

1) Measure the play of ball joint by the following
A: REMOVAL procedures. Replace with a new one when the play
1) Remove the front wheel. exceeds the specified value.
2) Pull out the cotter pin from the ball stud, remove (1) With 686 N (70 kgf, 154 Ib) loaded in the di-
the castle nut, and extract the ball stud from the rection shown in the figure, measure dimension
transverse link. e 1.
3) Remove the bolt securing the ball joint to the
housing.

--4)-€xtract the ball joint from the housing.

\
G4M0499
- G4M0500

(2) With 686 N (70 kgf, 154 Ib) loaded in the op-
posite direction shown in the figure, measure di-
mension e,.
B: INSTALLATION
1) Install the ball joint onto the housing. I 4
Torque (Bolt):
50 N-m (5-7 kgf-m, 37 ft-lb)
CAUTION:
Do not apply grease to the tapered portion of
ball stud.
2) Connect the ball joint to transverse link.
Torque (Castle nut): G4M0501

Sedan turbo model: (3) Calculate plays from the following formula.
30 N-m (3.7 kgf-m, 22ft-lb) S= Q2 - 0 1
Except sedan turbo model: (4) When plays are larger than the following val-
45 N.m (4.6 kgf-m, 33ft-lb) ue, replace with a new one.
3) Retighten the castle nut further within 60" until a FRONT BALL JOINT
slot in castle nut is aligned with the hole in ball stud Specified play for replacement: S
end, then insert the new cotter pin and bend it
Less than 0.3 mm (0.012 in)
around castle nut.
4) Install the front wheel. 2) When the play is smaller than the specified val-
ue, visually inspect the dust cover.
3) The ball joint and cover that have been removed
must be checked for wear, damage or cracks, and
any defective part must be replaced.
4) If the dust cover is damaged, replace with a new
ball joint.

FS-19
I FRONT STRUT
FRONT SUSPENSION

6. Front Strut 6) Remove the three nuts securing strut mount to

body.
A: REMOVAL
1) Remove the front wheel.
2) Remove the bolt securing brake hose from strut.

R4Mi78A

3) Scribe an alignment mark on the camber adjust-

ing bolt which secures strut to housing.
4) Remove the bolt securing the ABS sensor har-
ness.

suo011

5 ) Remove the two bolts securing housing to strut.

CAUTION:
While holding the head of adjusting bolt, loosen
self-locking nut.

FS-20
I FRONT STRUT
I
FRONT SUSPENSION

B: INSTALLATION C: DISASSEMBLY
1) Install the strut mount at upper side of strut to 1) Using a coil spring compressor, compress the
body and tighten with nuts. coil spring.
Tightening torque:
20 N-m (2.0 kgf-m, 74.5 ft-lb)
2) Position the aligning mark on camber adjustment
bolt with aligning mark on lower side of strut.
CAUTION:
While holding the head of adjusting bolt,
tighten self-locking nut.
Be sure to use a new self-locking nut.
Tightening torque: S4M0095
775 N-m (77.8 kgf-m, 729 ft-lb)
3 ) Install the ABS sensor harness to strut. 2) Using the ST, remove the self-locking nut.
ST 927760000 STRUT MOUNT SOCKET
Tightening torque:
33 N.m (3.4 kgf-m, 24.3 ft-lb)
4) Install bolts which secure the brake hose to strut.
-_Tightening torque:
33 N-m (3.4 kgf-m, 24.3 ft-lb)
5 ) Install the front wheels.
NOTE:
Check wheel alignment and adjust if necessary.

3) Remove the strut mount, upper spring seat and

rubber seat from strut.
4) Gradually decreasing the compression force,
and remove the coil spring.
5 ) Remove the dust cover and helper spring.

FS-21
I FRONT STRUT
FRONT SUSPENSION

D: ASSEMBLY 5) Set the coil spring correctly so that its end face
1) Before installing the coil spring, strut mount, etc., fits well into the spring seat as shown.
on the strut, check for the presence of air in the
dampening force generating mechanism of the
strut since air prevents proper dampening force
from being produced.
2) Checking for the presence of air:
(1) Place the strut vertically with the piston rod
facing up.
(2) Move the piston rod to the center of its entire
stroke.
(3) While holding the piston rod end with finger-
tips, move the rod up and down. I S4M0353A

(4) If the piston rod moves at least 10 mm (0.39 6) Install the helper and dust cover to the piston
in) in the former step, purge air from the strut. rod.
3) Air purging procedure: 7) Pull the piston rod fully upward, and install the
(1) Place the strut vertically with the piston rod rubber seat and spring seat.
facing up. NOTE:
(2) Fully extend the piston rod. Ensure the upper spring seat is positioned as
(3) With the piston rod fully extended, place the shown in the figure.
-- -piston rod side down. The strut must stand ver-
tically.
(4) Fully contract the piston rod.
(5) Repeat 3 or 4 times from the first step.
NOTE:
After completely purging air from the strut, be sure
to place the strut with the piston rod facing up. If it
is laid down, check for entry of air in the strut as
outlined under “Checking for the presence of air”.
4) Using a coil spring compressor, compress the
coil spring.
4 (1)
S4M0097B

NOTE: (1) Outside of body

Make sure that the vertical installing direction of coil
spring is as shown in the figure.
(2
8) Install the strut mount to the piston rod, and tight-
en the self-locking nut temporarily.
CAUTION:
Be sure to use a new self-locking nut.
9) Using a hexagon wrench to prevent strut rod
from turning, tighten self-locking nut with ST.
ST 927760000 STRUT MOUNT SOCKET
Tightening torque:
55 N.m (5.6 kgf-m, 41 ft-lb)

I B4M0568B I
(1) Fiat (top side)
(2) identificationpaint
(3) inclined (bottom side)

FS-22
 I
FRONT STRUT
FRONT SUSPENSION

10) Loosen the coil spring carefully. 5. HELPER

E: INSPECTION
Check the disassembled parts for cracks, damage
and wear, and replace with new parts if defective.
1. DAMPER STRUT
1) Check for oil leakage.
2) Move the piston rod up and down to check that it
operates smoothly without any binding.
3) Play of piston rod
Measure the play as follows:
Fix the outer shell and fully extend the rod. Set a
dial gauge at the end of the rod: L [ l o mm (0.39
in)], then apply a force of W [20 N (2 kgf, 4 Ib)] to
threaded portion. With the force of 20 N (2 kgf, 4 Ib)
applied, read the dial gauge indication: PI. Apply a
force of 20 N (2 kgf, 4 Ib) in the opposite direction
of “W”, then read the dial gauge indication: P.,
Replace it with a new one if cracked or damaged.
F: DISPOSAL
CAUTION:
On struts which have “GAS FILLED” marked
on the outer housing under spring seat, com-
pletely discharge the gas before disposing, fol-
lowing the methods below.
Do not disassemblethe strut damper or place
into a fire.
Drill holes before disposing of gas filled
struts.
Before handling gas filled struts, be sure to
wear goggles to protect eyes from gas, oil and/
or filings.

GAS FILLED
DO NOT OPEN
DO NOT HEAT
I B4M1201

1) Place the gas filled strut on a flat and level sur-

face with piston rod fully extended.
The free play is determined by the following equa- 2) Using a 2 to 3 mm (0.08 to 0.12 in) dia. drill,
tion: make holes in areas shown in the figure.
Play = PI, P2
Limit of play: I piston rod ,-Strut

Less than 0.8 mm (0.031 in)

If the play is greater, replace the strut.
2. STRUT MOUNT
Check the rubber part for creep, cracks and deteri-
oration, and replace it with a new one if defective.
M (1.57 in)

3. DUSTCOVER B4M1202P
If any cracks or damage are found, replace it with a
new one.
4. COIL SPRING
One having permanent strain should be replaced
with a new one. When the vehicle posture is un-
even, although there are no considerable reasons
like tire puncture, uneven loading, etc., check the
coil spring for its free length referring to specifica-
tions, cracks, etc., and replace it with a new one if
defective.

FS-23
I FRONT STABILIZER
FRONT SUSPENSION

7. Front Stabilizer B: INSTALLATION

A: REMOVAL
Jack-up the front part Of the vehicleand
it with safety stands (rigid racks).
2, Remove the j a c k w plate from lowerpart Of
crossmember.
3) Remove the sub frame. <Ref. to FS-16,RE-
LbVAL, Sub Frame.>
4) Remove the bolt and nut which secure the stabi-
lizer to crossmember.
1) Install in the reverse order of removal.
NOTE:
Install the bushing (on front crossmember side)
while aligning it with paint mark on stabilizer.
Ensure the bushing and stabilizer have the Same
identification colors when installing.

'' suo012

(1) Mark stamped on stabilizer

c- -
(2) Bushing identification color

5 ) Remove the bolts which Secure the stabilizer link
to front transverse link.
2)Always tighten the rubber bushing location when
wheels are in full contact with the ground and ve-
hicle is curb weight.
Tightening torque (Sedan turbo model):
Jack-up plate to crossmember:
20 Nom(2.0 kgf-m, 14.5 ft-lb)
Stabilizer link to front transverse link:
45 N-m (4.6 kgf-m, 33 ft-lb)
Stabilizer to crossmember:
25 N.m (2.5 kgf-m, 18.1 ft-lb)
Tightening torque (Except sedan turbo model):
Jack-up plate to crossmember:
20 N.m (2.0 kgf-m, 14.5 ft-lb)
Stabilizer link to front transverse link:
30 N.m (3.1 kgf-m, 22 ft-lb)
Stabilizer to crossmember:
25 N-m (2.5 kgf-m, 18.1 ft-lb)
3) Install the sub frame. <Ref. to FS-16, INSTALLA-
TION, Sub Frame.>
C: INSPECTION
1) Check the bushing for cracks, fatigue or dam-
age.
2) Check the stabilizer link for deformities, cracks
or damage, and bushing for protrusions from the
hole of stabilizer link.

FS-24
 FRONT CROSSMEMBER
8. Front Crossmember
A: REMOVAL
1) Disconnect the ground terminal from battery.
2) Lift-up the vehicle and remove the front tires and
wheels.
3) Remove the sub frame. <Ref. to FS-16, RE-
MOVAL, Sub Frame.>
4) Remove both stabilizer and jack-up plate.
c.
(1) Front stabilizer
(2) Front crossmember
5) Disconnect the tie-rod end from housing.
6) Remove the front exhaust pipe. (Non-turbo mod-
el) <Ref. to. EX(S0HC)-5, REMOVAL, Front Ex-
haust Pipe.>
7 ) Remove the front transverse link from front
crossmember and body.
8) Remove the nuts attaching engine mount cush-
ion rubber to crossmember.
9) Remove the steering universaljoint. <Ref. to PS-
26, REMOVAL, Steering Gearbox.>
10) Disconnect the power steering pipe from steer-
ing gear box.
11) Lift the engine by approx. 10 mm (0.39 in) by
using a chain block.
FS-25
FRONT SUSPENSION
12) Support the crossmember with a jack, remove
the nuts securing crossmember to body and lower
crossmember gradually along with the steering
gearbox.
CAUTION:
When removing the crossmember downward,
be careful that the tie-rod end does not inter-
fere with SFJ boot.
13) Remove the steering gearbox from crossmem-
ber.
B: INSTALLATION
1) Install in the reverse order of removal.
CAUTION:
Always tighten the rubber bushing when
wheels are in full contact with the ground and
vehicle is curb weight.
Tightening torque:
Transverse link bushing to crossmember:
100 N.m (10.2 kgf-m, 74 ft-lb)
Stabilizer to bushing:
25 N.m (2.5 kgf-m, 18.1 ft-lb)
Tie-rod end to housing:
27.0 N-m (2.75 kgf-m, 19.9 ft-lb)
Front cushion rubber to crossmember:
85 N.m (8.7 kgf-m, 62.7 ft-lb)
Universal joint to pinion shaft:
24 N-m (2.4 kgf-m, 17.4 ff-16)
Crossmember to body:
100 N-m (10.2 kgf-m, 74 ft-lb)
2) Purge air from the power steering system.
NOTE:
Check the wheel alignment and adjust if necessary.
C: INSPECTION
Check the crossmember for wear, damage and
cracks, and correct or replace if defective.
 I
GENERAL DIAGNOSTIC TABLE
FRONT SUSPENSION

9. General Diagnostic Table

A: INSPECTION
1. IMPROPER VEHICLE POSTURE OR IMPROPER WHEEL ARCH HEIGHT
Possible causes Countermeasures

(2) Unsmooth operation of damper strut and/or shock absorber Replace.

(3) Installation of wrong strut and/or shock absorber Replace with proper parts.
(4) Installation of wrong coil spring Replace with proper parts.

ning over bump and/or hump.

1) Large rebound shock
3) Large shock in bumping

I Replace.
(1) Breakage of coil spring
(2) Overinflation pressure of tire
I (3) Improper wheel arch height
I Adjust.
I Adjust or replace coil springs with new ones.
I
I
(4) Fault in operation of damper strut and/or shock absorber Replace.
*(5)Damage or deformation of strut mount and/or shock absorber mount Replace.
(6) Unsuitability of maximum and/or minimum length of damper strut and/or Replace with proper parts.
shock absorber
I ( 7 ) Deformation or loss of bushing I Replace. I
(8) Deformationor damage of helper in strut assembly and/or shock Replace.
absorber
(9) Oil leakaae of damDer strut and/or shock absorber Replace.

Possible causes Countermeasures

(1 ) Wear or damage of damper strut and/or shock absorber component Replace.
parts
(2) Loosenina of suspension link installing bolt I Retighten to the specified torque. I
(3) Deformation or loss of bushing 1 Replace. I
(4) Unsuitability of maximum and/or minimum length of damper strut and/or Replace with proper parts.
shock absorber
(5) Breakaae of coil sprina Replace.
I (6) Wear or damaae of ball ioint I Replace. I
I (7) Deformation of stabilizer clamp I Replace. I

FS-26
REAR SUSPENSION

RS
a
.

Page
1. General Description .................................................................................... 2
2. Wheel Alignment ......................................................................................... 9
3. Rear Stabilizer........................................................................................... 10
4. Rear Trailing Link ...................................................................................... 11
5. Rear Strut .................................................................................................. 15
6. Lateral link ................................................................................................. 16
7. Rear Crossmember ................................................................................... 19
8. General Diagnostic Table .......................................................................... 20
I
GENERAL DESCRIPTION
REAR SUSPENSION

1. General Description
A: SPECIFICATIONS
Sedan Wagon
Item OUTBACK
Turbo I Non-turbo 1 Turbo 1 Non-turbo
I Camber (tolerance: fO"45') I -1"30' I -1"25' I -1'20' I -1'15' I -1"10' I
- I f 2 mm (-0.039k0.079 in)
Toe-in
Each toe-in angle: fO"07'30 (Total toe-in angle 0"+15')
Wheel arch height 376 m m 381 mm 376 m m 381 m m 386 m m
[tolerance:k12 mm (k0.47 in)l (14.80 in) (15.0 in) (14.80 in) (15.0 in) (15.20 in)
I Thrust angle I O"f20' I
20 mm 1 3 mm 17 mm 13mm
Diameter of stabilizer
(0.79 in) (0.51 in) (0.67 in) (0.51 in)
NOTE:
Front and rear toe-ins and front camber can be
adjusted. If the toe-in or camber tolerance exceeds
specifications, adjust the toe-in and camber to the
middle value of specification.
The other items indicated in the specification ta-
%le cannot be adjusted. If the other items exceeds
specifications, check the suspension parts and
connections for deformities; replace with new ones
as required.

B4M2250C

(1) Front
A - B = Positive: Toe-in, Negative: Toe-out
al, a2: Each toe-in angle

RS-2
 3
GENERAL DESCRIPTION
REAR SUSPENSION

c.

RS-3
I GENERAL DESCRIPTION
I
REAR SUSPENSION

B: COMPONENT

P I

SI

RS-4
 GENERAL DESCRIPTION
REAR SUSPENSION

Stabilizer Trailing link bracket Tightening torque: N-m (kgf-m, ft-lb)

Stabilizer bracket Cap (Protection) T1: 20(2.0, 14.5)
Stabilizer bushing Washer T2: 25 (2.5, 18.1)
Clamp Rear crossmember T3: 45 (4.6, 33.2)
Floating bushing Strut mount cap T4: 55 (5.6, 4 1)
Stopper Strut mount T5: 70 (7.1, 52)
Stabilizer link Rubber seat upper T6: 90 (9.2, 66)
Rear lateral link Dust cover T7: 100 (10.2, 74)
Bushing (C) Coil spring T8: 115(11.7, 85)
Bushing (A) Helper T9: 130 (13.3, 96)
Front lateral link Rubber seat lower TlO: 135(13.8, 100)
Bushing (B) Damper strut T11: 220(22.4, 162)
Trailing link rear bushing Self-locking nut
Trailing link Rear differential member rear
Trailing link front bushing

c.

RS-5
I GENERAL DESCRIPTION
REAR SUSPENSION

C: CAUTION
Wear working clothing, including a cap, protec-
tive goggles, and protective shoes during opera-
tion.
Remove contamination including dirt and corro-
sion before removal, installation or disassembly.
Keep the disassembled parts in order and pro-
tect them from dust or dirt.
Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary re-
moval, installation, disassembly, and replacement.
Use SUBARU genuine grease etc. or the equiv-
alent. Do not mix grease etc. with that of another
grade or from other manufacturers.
Be sure to tighten fasteners including bolts and
nuts to the specified torque.
Place shop jacks or safety stands at the specified
points.
Apply grease onto sliding or revolution surfaces
before installation.
-0 Before installing O-rings or snap rings, apply suf-
ficient amount of grease to avoid damage and de-
formation.
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.
Before disposing shock absorbers, be sure to
bleed gas completely. Also, do not throw away in
fire.

RS-6
 I
GENERAL DESCRIPTION
REAR SUSPENSION

D: PREPARATION TOOL
1. SPECIAL TOOLS

I ILLUSTRATION TOOL NUMBER DESCRIPTlON REMARKS

927380002 rDAPTER Jsed as an adapter for camber & caster gauge
vhen measuring camber and caster.
1) 28199ACOOO PLATE
2) 28199AC010 BOLT

1 B4M2378A
927720000 NSTALLER &
3EMOVER
Jsed for replacing front bushing.

I suo014
927730000 NSTALLER & Used for replacing rear bushing.
3EMOVER

I SUOOI!
28099PA100 REMOVER Used for removing DOJ.

RS-7
 I
GENERAL DESCRIPTION
REAR SUSPENSION

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

92770000 INSTALLER & Used for replacing lateral link bushing.
REMOVER

SUO015
927690000 HELPER SOCKET Used for replacing lateral link bushing.
WRENCH

SUO015

2. GENERAL PURPOSE TOOLS

TOOL NAME REMARKS

Alignment gauge Used for wheel alignment measurement.
Turnina radius aauae Used for wheel alianment measurement.
IToe-in aauae I Used for toe-in measurement. I
I Transmission iack I Used for suspension assembly/disassembly. I
I Bearing puller I Used for removing bushings.

RS-8
 I
WHEEL ALIGNMENT
REAR SUSPENSION

2. Wheel Alignment
A: INSPECTION
NOTE:
The front and rear wheel alignment must be mea-
sured and/or adjusted at once to obtain accuracy.
Measure and/or adjust the rear wheel alignment to-
gether with the front. Follow the procedure in "FS"
section "Wheel Alignment" for measurement and/or
adjustment of wheel alignment. <Ref. to FS-8, IN-
SPECTION, Wheel Alignment.>

RS-9
I REAR STABILIZER
REAR SUSPENSION

3. Rear Stabilizer B: INSTALLATION

A: REMOVAL
1) Jack-up the rear part of the vehicle, support it
with safety stands (rigid racks).
2) Remove the bolts which secure stabilizer link to
rear lateral link.
1) Install in the reverse order of removal.
NOTE:
Install the bushing while aligning it with paint
mark on stabilizer.
Ensure that the bushing and stabilizer have the
same identification colors when installing.

3) Remove the bolt which secures stabilizer to sta-

bilizer bracket. (1) Mark stamped on stabilizer
c- - (2) Bushing identification color

2) Always tighten the rubber bushing location when

wheels are in full contact with the ground and vehi-
cle is curb weight.
Tightening torque:
Stabilizer link to rear lateral link
45 N-m (4.6 kgf-m, 33.2 ft-lb)
Stabilizer to stabilizer bracket
25 N.m (2.5 kgf-m, 18.1 ft-lb)
C: INSPECTION
1) Check the bushing for cracks, fatigue or dam-
age.
2) Check the stabilizer links for deformities, cracks,
or damage, and bushing for protrusions from the
hole of stabilizer link.

RS-10
 REAR TRAILING LINK
1
REAR SUSPENSION

4. Rear Trailing Link B: INSTALLATION

A: REMOVAL
1) Loosen the rear wheel nuts.
2)Jack-up the vehicle, SUPPofl it with safety stands
(rigid racks) and remove the rear wheels.
3) Remove both rear parking brake clamp and ABS
sensor harness. (Models equipped with ABS)
4) R~~~~~ the bolt which Secures trailing link to
trailing link bracket.
Install in the reverse order of removal.
CAUTION:
Always tighten the .rubber bushing location
when wheels are in full contact with the ground
and vehicle is at curb weight condition.
NOTE:
Check the wheel alignment and adjust if necessary.

(1) Trailing link

5 ) Remove the bolt which secures trailing link to

rear housing.

RS-11
 REAR TRAILING LINK
REAR SUSPENSION

C: DISASSEMBLY 2. REAR BUSHING

1. FRONT BUSHING 1) Remove the housing. <Ref. to DS-23, REMOV-
AL, Rear Axle.>
Using ST, press the front bushing out of place. 2) Using ST, press the rear bushing out of place.
ST 927720000 INSTALLER & REMOVER ST 927730000 INSTALLER &-REMOVER
SET SET

c- -

(1) Press (1) Press

(2) Trailing link (2) Housing

RS-12
 REAR TRAILING LINK I
REAR SUSPENSION

D: ASSEMBLY 2. REAR BUSHING

1) Using ST, press the bushing into trailing link.
1. FRONT BUSHING
ST 927730000 INSTALLER & REMOVER
Using ST, press the bushing into trailing link. SET
ST 927720000 INSTALLER & REMOVER
NOTE:
SET
If it is difficult to press the bushing into trailing link,
CAUTION: apply water-diluted TIRE LUBE to the inner surface
When installing the bushing, turn ST plunger of ST as a lubricant.
upside down and press it until plunger end sur-
face contacts trailing link end surface. SPE ClFlED lubricant:
TIRE LUBE :water = 1 :3

‘ir
(2)
\
c-

(3)
\

S4M0360E

(1) Press
(1) Press
(2) Front bushing
(3) Trailing link

CAUTION:
Install the front bushing in proper direction, as
shown in the figure.

I
S4M0361A

(1) Front

RS-13
 REAR TRAILING LINK
REAR SUSPENSION

2) Press the ST pluger until bushing flange pro- 3) Turn the trailing link upside down. Press the ST
trudes beyond trailing link. plunger in the direction opposite that outlines in the
ST 927730000 INSTALLER & REMOVER former procedure until bushing is correctly posi-
SET tioned in trailing link.
ST 927730060 INSTALLER & REMOVER
SET

r. .

( 1 ) Plunger
(2) Flange
( 1 ) Press
(2) Plunger

4) Install the housing. <Ref. to DS-26, INSTALLA-

TION, Rear Axle.>
E: INSPECTION
Check the trailing links for bends, corrosion or dam-
age.

RS-14
I REAR STRUT I
REAR SUSPENSION

5. Rear Strut B: INSTALLATION

1) Tighten the self-locking nut used to secure strut
A: REMOVAL mount to car body.
1) Remove the rear seat cushion and backrest. CAUTION:
(Sedan model) Discard the loosened self-locking nut, and re-
2) Remove the strut cap of quarter trim. (Wagon place with a new one.
model)
3) Loosen the rear wheel nuts. Tightening torque:
4) Jack-up the vehicle, support it with safety stands 20 Nom(2.0 kgf-m, 14.5 ft-lb)
(rigid racks) and remove the rear wheels. 2) Tighten the bolts which secure rear strut to hous-
5 ) Remove the brake hose clip and remove the ing.
brake hose from rear strut.
Tightening torque:
220 N.m (22.4 kgf-m, 162 ft-lb)
CAUTION:
Discard the loosened self-locking nut, and re-
place with a new one.
3) Install the brake hose to lower side of strut, then
insert brake hose clip.
CAUTION:
Check that the hose clip is positioned proper-
ly-
Check the brake hose for twisting, or exces-
sive tension.
(1) Brake hose clip
(Model equipped with ABS)
(2) Brake hose
Do not subject the ABS sensor harness to exc-
6) Remove -the bolts which secure rear strut to es-sive tension.
housing. 4) Lower the vehicle and tighten wheel nut.
Tightening torque:
90 N-m (9.2 kgf-m, 66 ft-lb)
5 ) Sedan model:
Install the rear seat backrest and rear seat cushion.
Wagon model:
Install the strut cap to rear quarter trim.
NOTE:
Check wheel alignment and adjust if necessary.
C: DISASSEMBLY
For disassembly of rear strut, refer to procedures
7) Remove the nuts securing strut mount to body. outlined under front strut as a guide. <Ref. to FS-
21, DISASSEMBLY, Front Strut.>
D: ASSEMBLY
Refer to Front Strut as a guide for assembly proce-
dures.
<Ref. to FS-22, ASSEMBLY, Front Strut.>
E: INSPECTION
Refer to Front Strut as a guide for inspection proce-
dures.
<Ref. to FS-23, INSPECTION, Front Strut.>
F: DISPOSAL
Refer to Front Strut as a guide for disposal proce-
dures.<Ref. to FS-23, DISPOSAL, Front Strut.>

RS-15
 LATERAL LINK
REAR SUSPENSION

6. Lateral link
A: REMOVAL
1) Loosen the wheel nuts. Lift-up the vehicle and
remove wheel.
2) Remove the stabilizers. (Turbo model)
3) Remove the ABS sensor harness from trailing
link.
(Models eqipped with ABS)
4) Remove the bolt securing trailing link to housing.

r.

(1) Rear housing

(2) Trailing link

5) Remove the bolts which secure lateral link as-

sembly to rear housing.
6) Remove the DOJ from rear differential using ST.
ST 28099PA100 DRIVE SHAFT REMOVER
NOTE:
The side spline shaft circlip comes out together
with the shaft.
Bushing ST:INSTALLER & REMOVER SET
Bushing A 927700000
Bushina B 927690000
I BushinaC I 927700000 I

(1) Bolt
(2) DOJ

CAUTION:
Be careful not to damage the side bearing re-
tainer. Always use bolt shown in figure, as sup-
porting point for ST during removal.
7) Scribe an alignment mark on the rear lateral link
adjusting bolt and crossmember.

RS-16
 LATERAL LINK
REAR SUSPENSION

D: ASSEMBLY
1) Using ST, press the bushing into place.
CAUTION:
Select the ST according to the type of bushings
used.
NOTE:
Use the same ST as that used during disassem-
bly.
If it is difficult to press the bushing into trailing
link, apply water-diluted TIRE LUBE to the inner
surface of ST as a lubricant.
Specified lubricant:
TIRE LUBE :water = 1 :3

S4MQIQQ

(1) Bushing A
(2) Bushing B
(3) Bushing C
(4) Front
(5) Outside of body

(1) Press
(2) Bushing
(3) Lateral link

S4MQ365

(1) Press
(2) Lateral link

RS-17
I LATERAL LINK
REAR SUSPENSION

2) Press the ST plunger until bushing flange pro-
trudes beyond lateral link.
NOTE:
Use the same ST as that used during disassembly.
3) Turn the lateral link upside down. Press the ST
plunger in the direction opposite that outlined in the
former procedure until bushing is correctly posi-
tioned in trailing link.
NOTE:
Using the same ST as that used during dissassem-
bly.

c. .

(1) Press
(2) Plunger
(3) Lateral link
(4) Flange (1) Press
(2) Plunger
(3) Lateral link

E: INSPECTION
Visually check the lateral links for damage or
bends.

RS-18
I REAR CROSSMEMBER
7. Rear Crossmember
A: REMOVAL
CAUTION:
Do not subject the ABS sensor harness to ex-
cessive tension. (Models equipped with ABS)
1) Separate the front exhaust pipe and rear ex-
haust pipe.
2) Remove the rear exhaust pipe and muffler.
3) Remove the rear differential.
<Ref. to DI-19, REMOVAL, Rear Differential.>
4) Place a transmission jack under rear crossmem-
ber.
5) Remove the bolts securing crossmember to ve-
hicle body, and remove the crossmember.
6) Scribe an alignment mark on the rear lateral link
cam bolt and crossmember.
7) Remove the front and rear lateral links by loos-
ening nuts.
RS-19
I
REAR SUSPENSION
B: INSTALLATION
1) Install in the reverse order of removal.
2) For installation and tightning torque of rear differ-
ential:
<Ref. to DI-20, INSTALLATION, Rear Differential.>
3) Always tighten the rubber bushing when wheels
are in full contact with the ground and vehicle is
curb weight.
NOTE:
Check the wheel alignment and adjust if necessary.
C: INSPECTION
Check the removed parts for wear, damage and
cracks, and correct or replace if defective.
 GENERAL DIAGNOSTIC TABLE
I
REAR SUSPENSION

8. General Diagnostic Table

A: INSPECTION
1. IMPROPER VEHICLE POSTURE OR IMPROPER WHEEL ARCH HEIGHT
Possible causes Countermeasures
(1) Permanent distortion or breakage of coil spring Replace.
(2) Unsmooth operation of damper strut and/or shock absorber Replace.
I (3) Installation of wrong strut and/or shock absorber I Replace with proper parts. I
I (4) Installation of wrong coil spring I Replace with proper parts. I
2. POOR RIDE COMFORT
1) Large rebound shock
2) Rocking of vehicle continues too long after running over bump and/or hump.
3) Large shock in bumping

I (1) Breakage of coil spring I Replace.

I (2) Overinflation Dressure of tire I Adiust.
(3) Improper wheel arch height I
Adjust or replace coil springs with new ones.
44)Fault in operation of damper strut and/or shock absorber
\ ,
II Replace.
'

t(5) Damaae or deformation of strut mount and/or shock absorber mount I Replace.
(6) Unsuitabilityof maximum and/or minimum length of damper strut and/or Replace with proper parts.
shock absorber
(7) Deformation or loss of bushing Replace.
(8) Deformation or damage of helper in strut assembly and/or shock Replace.
absorber
I (9) Oil leakage of damper strut and/or shock absorber 1 Replace.
3. NOISE
Possible causes Countermeasures
(1) Wear or damage of damper strut and/or shock absorber component Replace.
parts
(2) Loosening of suspension link installing bolt I Retighten to the specified torque. I
(3) Deformation or loss of bushing I Replace. I
(4) Unsuitability of maximum and/or minimum length of damper strut and/or Replace with proper parts.
shock absorber
(5)Breakaae of coil sprina Replace.
(6) Wear or damage of ball ioint I Replace. I
I (7) Deformationof stabilizer clamp I Replace. I

RS-20
WHEEL AND TIRE SYSTEM
WT
page
~~ ~

1. General Description .................................................................................... 2

2. Tire .............................................................................................................. 4
3. Steel Wheel ................................................................................................. 5
4. Aluminum Wheel ......................................................................................... 6
5. Wheel Balancing ......................................................................................... 7
6. “T-type” Tire ................................................................................................ 8
7. Full Wheel Cap ............................................................................................ 9
8. General Diagnostics Table ........................................................................ 10
 I
GENERAL DESCRIPTION
WHEEL AND TIRE SYSTEM
~ ~

1. General Description
A: SPECIFICATIONS

S4M0367A

I I P195/60R1587H I 15x6JJ I I I
Front and rear P205/55 R16 89V 16 x 6 1/2JJ 55 (2.17)
.
100 (3.94) Dia.
-*
215/45 R17 87W 17 x 7JJ
T-Type tire T I 35/70 D16 1OOM 16 x 4T 50 (1.97)

Tire size Tire inflation pressure kPa (kg/cm2,psi)

Fr: 220 (2.2, 32)
P I95/60 R15 87H
Rr: 200 (2.0, 29)
Front and rear
P205155 R16 89V Fr: 220 (2.2, 32) Fir: 200 (2.0, 29)
215/45 R17 87W Fr: 230 (2.3, 33) Rr: 220 (2.2, 32)
T-Type tire T135ffO D16 100M 420 (4.2, 60)

WT-2
I GENERAL DESCRIPTION
WHEEL AND TIRE SYSTEM

1. SERVICE DATA B: PREPARATION TOOL

I
~
Item I Axial runout I Radial runout 1 1. GENERAL PURPOSE TOOLS
Steel wheel 1.5 mm (0.059 in)
1.O mm (0.039 in) TOOL NAME REMARKS
Aluminum wheel
Air pressure gauge Used for measuring tire air pressure.
2. ADJUSTING PARTS Dial gauge Used for measuring wheel runout.

I n a m F iunbalance I Less than 5 g (0.18 02) I

Balance weight part number
Weight

I 723141320 I 20 g (0.71 02) I

723141330

723141350

723241380

723241590

Balance weight part number

Weight
(For aluminum wheel)
23141GA462

23141GA482

r 23141GA512 I 30 g (1.06 02) I

I 23141GA522 -I 35 g (1.23 02) I
23141GA532 40 g (1.41 02)
231
~- 41GA542 45 a (15 9 02)
" >

23141GA552 50 g (I.76 02)

- 55 g (1.94 0 2 )
23141GA572 60 g (2.12 02)

WT-3
I TIRE
WHEEL AND TIRE SYSTEM

2. Tire
A: INSPECTION
1) Take stone, glass, nail etc. off the tread groove.
2) Replace the tire:
CAUTION:
When replacing a tire, make sure to use only
the same size, construction and load range as
originally installed.
Avoid mixing radial, belted bias or bias tires
on the vehicle.
(1) when large crack on side wall, damage or
crack on tread is found.
(2) when the “tread wear indicator” appears as
a solid band across the tread.

r. . -
I S4M0377A

(1 ) Tread wear indicator

(2) Tire tread

1. TIRE ROTATION
If tires are maintained at the same positions for a
long period of time, uneven wear results. There-
fore, they should be periodically rotated.
This lengthens service life of tires.
CAUTION:
When rotating tires, replace unevenly worn or
damaged tires with new ones.

WT-4
I STEEL WHEEL I
WHEEL AND TIRE SYSTEM

3. Steel Wheel C: INSPECTION

1) Deformation or damage on the rim can cause air
A: REMOVAL leakage. Check the rim flange for deformation,
1) Apply the parking brake, and position select le- crack or damage, and repair or replace as neces-
ver to “P” or “LOW”. sary.
2) Set the shop jacks or a lift to the specified point, 2) Jack-up the vehicle until wheels clear the floor.
and support the vehicle with its wheels slightly con- 3) Slowly rotate the wheel to check rim “runout” us-
tacting the floor. ing a dial gauge.
3) Loosen the wheel nuts.
4) Raise the vehicle until its wheels take off the
ground using a jack or a lift.
5) Remove the wheel nuts and wheels.
NOTE:
While removing the wheels, prevent hub bolts
from damage.
NOTE:
Place the wheels with their outer sides facing up-
ward to prevent wheels from damage.
/ G4M029E
B: INSTALLATION
--I ) Attach the wheel to the hub by aligning the wheel I-1.5 mm (0.059 in) I
bolt hole with the hub bolt. ~

2) Temporarily attach the wheel nuts to the hub

bolts. (In the case of aluminum wheel, use SUBA-
RU genuine wheel nut for aluminum wheel.)
3) Manually tighten the nuts making sure the wheel
hub hole is aligned correctly to the guide portion of
hub.
4) Tighten the wheel nuts in a diagonal selection to
APP
the specified torque. Use a wheel nut wrench.
Wheel nut tightening torque:
90 N.m (9. I kgf-m, 65.7 ff-lb)
CAUTION: G4M0299
Tighten the wheel nuts in two or three steps
by gradually increasing the torque and working 4) If the rim runout exceeds specifications, remove
diagonally, until the specified torque is the tire from rim and check runout while attaching
reached. For drum brake models, excess tight- dial gauge to positions shown in figure.
ening of wheel nuts may cause wheels to “jud- 5) If the measured runout still exceeds specifica-
der”. tions, replace the wheel.
Do not depress the wrench with a foot; Al-
ways use both hands when tightening.
Make sure the bolt, nut and the nut seating
surface of the wheel are free from oils.
5) If a wheel is removed for replacement or for re-
pair of a puncture, retighten the wheel nuts to the
specified torque after running 1,000 km (600
miles).

WT-5
I ALUMINUM WHEEL
WHEEL AND TIRE SYSTEM

4. Aluminum Wheel
A: REMOVAL
Refer to Steel Wheel for removal procedure of a h -
minum wheels. <Ref. to WT-5, REMOVAL, Steel
Wheel.>
B: INSTALLATION
Refer to Steel Wheel for installation procedure of
aluminum wheels.cRef. to WT-5, INSTALLATION,
Steel Wheel.>
C: INSPECTION
Refer to Steel Wheel for inspection procedure of
aluminum wheels. <Ref. to WT-5, INSPECTION,
Steel Wheel.>
Rim runout:
I Axial runout limit I Radial runout limit I
1.O mm (0.039 in)

D: -CAUTION
Aluminum wheels are easily scratched. To main-
tain their appearance and safety, do the following:
1) Do not damage the aluminum wheels during re-
moval, disassembly, installation, wheel balancing,
etc. After removing the aluminum wheels, place
them on a rubber mat, etc.
2) While the vehicle is being driven, be careful not
to ride over sharp obstacles or allow aluminum
wheels to contact the shoulder of the road.
3) When installing a tire chain, be sure to install it
properly not to have a slack; otherwise it may hit
the wheel while driving.
4) When washing the aluminum wheel, use neutral
synthetic detergent and water. Avoid using the
cleanser including abrasive, hard brushes or an
automatic car washer.

WT-6
 WHEEL BALANCING
I
WHEEL AND TIRE SYSTEM

5. Wheel Balancing B: INSPECTION

1) Proper wheel balance may be lost if the tire is re-
A: REPLACEMENT paired or if it wears. Check the tire for dynamic bal-
1) Remove the balance weights. ance, and repair as necessary.
2) Using the dynamic balancing, measure wheel 2) To check for dynamic balance, use a dynamic
balance. balancer. Drive in the balance weight on both the
3) Select a weight close to the value measured by top and rear sides of the rim.
dynamic balancing. 3) Some types of balancer can cause damage to
the wheel. Use an appropriate balancer when ad-
I Balance weight part number
(For steel wheel)
Weight justing the wheel balance.
4) Use genuine balance weights.
I 723141300 I 10 g (0.35 02) I CAUTION:
I 723141310 I 15 g (0.53 02) I 55 g (1.94 02) weight used with aluminum
723141320 20 g (0.71 02) wheel is not available.
723141330 25 g (0.88 02)
Balance weights are available for use with
any of 14- to 16-inch wheels.
723141340 30 g (1.06 02)
723141350 35 CI (1.23 oz)
I 723141360 I 40 g (1.41 02) I
I 723141370 I 45 g (1.59 02) I
c- ~ 723241380 50 g (1.76 02)
723241580 55 g (1.94 02)
723241590 60 g (2.12 02)

Balance weight part number

Weight
(For aluminum wheel)
23 14 1GA462 5 g (0.18 02).
23141GA472 10 a (0.35 02)

r - 23141GA492 I 20 CI (0.71 02) I

I 23141GA502 I 25 g (0.88 02) I
I 23141GA512 I 30 g (1.06 02) I
23141GA522 35 g (1.23 02)
23141GA532 40 g (1.41 02)
23141GA542 45 g (1.59 02)
23141GA552 50 Q (1.76 02)
I - I 55 g (1.94 02) I B4M0053B
23141GA572 60 g (2.12 02)
(1) Weight for aluminum wheel
(2) Weight for steel wheel

Service limit: A
Weight for steel wheel;
2.16 mm (0.085 in)
Weight for aluminum wheel;
4.5 mm (0.177 in)

WT-7
I “T-TYPE” TIRE
WHEEL AND TIRE SYSTEM

6. “T-type” Tire
A: NOTE
“T-type” tire for temporary use is prepared as a
spare tire.
CAUTION:
Do not use a tire chain with the “T-type” tire.
Because of the smaller tire size, a tire chain will
not fit properly and will result in damage to the
vehicle and the tire.
Do not drive at a speed greater than 80 km/h
(50 MPH).
Drive as slowly as possible and avoid pass-
ing over bumps.
B: REPLACEMENT
Refer to Removal and Installation of Steel Wheel
for removaVinstallation of “T-type” tires. <Ref. to
WT-5, Steel Wheel.>
CAUTION:
Tiepiace with a conventional tire as soon as
possible since the “T-type” tire is only for tem-
porary use.
C: INSPECTION
1) Check the tire inflation pressure.
Specification:
420 kPa (4.2 kg/cn?, 60 psi)
2) Take the stones, glass, nails, etc. out of the tread
groove.
3) Check the tires for deformation, cracks, partial
wear, or wear.
CAUTION:
Replace the tire with a new one.

WT-8
 FULL WHEEL CAP I
WHEEL AND TIRE SYSTEM

7. Full Wheel Cap

A: REMOVAL
Pry off the full wheel cap with a wheel cap remover
inserted between openings in the cap.

B: INSTALLATION
Align the valve hole in the wheel cap with the valve
on the wheel and secure the wheel cap by tapping
*.- . points by hand.
four
C: INSPECTION
1) Check the wheels for missing wheel caps.
2) Check the pawls of wheel caps for damage or
bend.
3) Check the wheel caps for cracks.

WT-9
 3
GENERAL DIAGNOSTICS TABLE
WHEEL AND TIRE SYSTEM

8. General Diagnostics Table

A: INSPECTION

I I Replace
II
Front wheel shimmy

Abnormal tire wear

I
I
Worn or improperly inflated of tire.
Wheel is out of balance.
Improperly inflated of tire.
I Adjustment
I Replace
I
I
I
Sways/pitches Worn or improperly inflated of tire. Replace
Wander/pulls Worn or improperly inflated of tire. Replace

WT-10
 E

DIFFERENTIALS

~~~~~~~~
Dl ~

Page
1. General Description .... ..................................................................... ...........2
2. Differential Gear Oil ................................................................................... 17
3. Front Differential........................................................................................ 18
4. Rear Differential ........................................................................................ 19
5. Rear Differential Front Oil Seal ...................................... .... .......................35
6. Rear Differential Side Oil Seal .................................................................. 37
7. Rear Differential Member .......................................................................... 40
8. General Diagnostic Table .......................................................................... 41
 I
GENERAL DESCRIPTION
DIFFERENTIALS

1. General Description
A: SPECIFICATIONS

II MODEL
I
Waaon Sedan
Non-Turbo

Waaon Sedan
I
MT
Turbo

AT I
Type of gear Hypoid gear
Gear ratio (Number of gear
3.900 (39/10) 4.1 11 (37/9) 4.444 (40/9) 3.545 (39/11) 4.1 11 (37/9)
teeth)
Oil capacity 0.8 0 (0.8 US qt, 0.7 Imp qt)
Rear differential gear oil GL-5

causes the drive line and tires to "drag" or emit

ITEM
abnormal noise when AWD is selected. Rear differential gear oil
API Classification

I \ I tiL-5
SAE Viscosity No. and Application Temperature
("C) -30 -26 -15 -5 0 15 25 30
( O F ) -22 -15 5 23 32 59 77 86
I I I I L ' I

1-2 75W-90
I I I I I I I

f= H3M1272A

DROOOI

1. SERVICE DATA

Front and rear bearing preload at companion New bearing 19.6 - 28.4 (2.0 - 2.9, 4.4 - 6.4)
flange bolt hole N (kgf, Ib) Used bearing 8.34-16.67(0.85-1.7, 1.87-3.75)
Side aear backlash mm (in) 0.10 - 0.20 (0.0039 - 0.0079)
I Side bearina standard width mm (in) I 20.00 (0.7874) I
I Crown gear to drive pinion backlash mm (in) I 0.10 - 0.20 (0.0039 - 0.0079) I
I Crown gear runout on its back surface mm (in) I Less than 0.05 (0.0020) I
2. ADJUSTING PARTS

19.6 - 28.4 N
New bearing
Front and rear bearing preload at com- (2.0 - 2.9 kgf, 4.4 - 6.4 Ib)
panion flange bolt hole 8.34 - 16.67 N
Used bearing
(0.85 - 1.7 kgf, 1.87 - 3.75 Ib)
Part No. Lenath
I 383695201 I 56.2 mm (2.213 in)
I 383695202 I 56.4 mm (2.220 in)
Preload adjusting spacer 383695203 56.6 mm (2.228 in)
383695204 56.8 mm (2.236 in)
383695205 57.0 mm (2.244 in)
383695206 57.2 mm (2.252 in)

DI-2
 GENERAL DESCRIPTION
DIFFERENTIALS

Part No. Length

383705200 2.59 mm (0.1020 in)
383715200 2.57 mm (0.1012 in)
I 383725200 I 2.55 mm (0.1004 in) I

I Preload adjusting washer

..

383575200 3.33 mm (0.131 1 in)

Pinion height adjusting shim 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 (0.141 7 in)
383675200 3.63 mm (0.1429 in)
383685200 3.66 mm (0.1441 in)
Side gear backlash 0.1 - 0.2 mm (0.0039 - 0.0079 in)
Part No. Thickness
t
I

Side gear thrust washer 383445201 II 0.75 - 0.80 mm (0.0295 - 0.0315 in)
(Non-Turbo model) t 383445202 I 0.80 - 0.85 mm (0.0315 - 0.0335 in)

Side bearina standard width - 20.00 mm (0.7874 in)

Part No. Thickness
383475201 0.20 mm (0.0079 in)
383475202 0.25 mm (0.0098 in)
I Side bearing retainer shim 383475203 0.30 mm (0.0118 in)
~

-1 383475204 I 0.40 mm (0.0157 in) I

I 383475205 I 0.50 mm (0.0197 in) I
&own gear to drive pinion backlash 0.10 - 0.20 mm (0.0039 - 0.0079 in)
Limit
Crown gear runout on its back sunface 0.05 mm (0.0020 in)

DI-3
I I
DIFFERENTIALS
B: COMPONENT
1. REAR DIFFERENTIAL WITHOUT LSD
(1) Pinion crown gear set
(2) Pinion height adjusting washer
(3) Rear bearing
(4) Bearing preload adjusting spacer
(5) Bearing preload adjusting washer
.,
(6) Differentialcarrier
(7) Front bearing
(8) Spacer
(9) Pilot bearing
(IO) Front oil seal
(11) Companion flange
(12) Self-locking nut
GENERAL DESCRIPTION
(13) Side bearing
(14) O-ring
(15) Side bearing retainer shim
(16) Side bearing retainer
(17) Side oil seal
(18) .. thrust washer
. , Side aear
(19) Side gear
(20) Pinion mate gear
(21) Pinion mate gear washer
(22) Pinion shaft lock pin
(23) Circlip
(24) Pinion mate shaft
DI-4
(25) Air breather cap
(26) Stud bolt
(27) Oil filler plug
(28) Oil drain plug
(29) Rear cover
(301 Differentialcase
\ I
Tightening torque: N-m (kgf-m, ft-lb)
T1: 10.3 (1.05, 7.6)
T2: 29.4 (3.00,21.7)
T3: 49.0 (5.0, 36.2)
T4: 103.0 (10.50, 75.9)
T5: 181.4 (18.50, 133.8)
 I
GENERAL DESCRIPTION
DIFFERENTIALS

2. REAR DIFFERENTIAL WITH LSD

(1) Pinion crown gear set (12) Self-locking nut (23) Oil filler plug
(2) Pinion height adjusting shim (13) Side bearing (24) Oil drain plug
Rear bearing O-ring
Bearing preload adjusting spacer Side bearing retainer shim Tightening torque: N.m (kgf-m, ft-lb)
Bearing preload adjusting washer Side bearing retainer T1: 10.3 (1.05, 7.6)
Differentialcarrier Side oil seal TZ: 29.4 (3.00,21.7)
Front bearing Gasket T3: 49.0 (5.00, 36.2)
Collar Differential case T4: 103.0 (10.50, 75.9)
Pilot bearing Rear cover T5: 181.4 (18.50, 133.8)
Front oil seal Air breather cap
Companion flange Stud bolt

DI-5
I I
GENERAL DESCRIPTION
DIFFERENTIALS

3. REAR DIFFERENTIAL MOUNTING SYSTEM

DR0002

(1) Differentialfront member (7) Stopper Tightening torque: N-m (kgf-m, ft-I&)
(2) Plate (8) Dynamic damper T1: 20(2.0, 14.5)
(3) Crossmember (9) Differential mount bracket T2: 33 (3.4, 24.3)
(4) Differential rear member (10 ) Differential mount front cover T3: 65 (6.6, 47.9)
(5) Differential mount lower bracket T4: 70 (7.1, 51.6)
(TURBO model) T5: 90 (9.2, 66.4)
(6) Differential mount lower bracket T6: 100 (10.2, 73.8)
(Non-turbo model)

DI-6
 GENERAL DESCRIPTION
DIFFERENTIALS

C: CAUTION
Wear working clothing, including a cap, protec-
tive goggles, and protective shoes during opera-
tion.
Remove contamination including dirt and corro-
sion before removal, installation or disassembly.
Keep the disassembled parts in order and pro-
tect them from dust or dirt.
Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary re-
moval, installation, disassembly, and replacement.
Be careful not to burn your hands, because each
part on the vehicle is hot after running.
Use SUBARU genuine gear oil, grease etc. or
the equivalent. Do not mix gear oil, grease etc. with
that of another grade or from other manufacturers.
Be sure to tighten fasteners including bolts and
nuts to the specified torque.
Place shop jacks or safety stands at the specified
points.
--a- Apply gear oil onto sliding or revolution surfaces
before installation.
Before installing O-rings or snap rings, apply suf-
ficient amount of gear oil to avoid damage and de-
formation.
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.
Avoid damaging the mating face of the case.

DI-7
 GENERAL DESCRIPTION
DIFFERENTIALS

D: PREPARATION TOOL
1. SPECIAL TOOLS

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

398477701 HANDLE Used for installing front and rear bearing cone.

B3M1893
398477702 DRIFT Used for press-fitting the bearing cone of differ-
ential carrier (rear).

B3M1894
398217700 ATTACHMENT SET Stand for rear differential carrier disassembly
and assembly.

B3M1895
498447120 DRIFT Used for installing front oil seal.

B3M1896

DI-8
I GENERAL DESCRIPTION
DIFFERENTIALS

ILLUSTRATION TOOL NUMBER DESCRIPTION IEMARKS

98427200 LANGE WRENCH k e d for stopping rotation of companion flange
vhen loosening and tightening self-lock nut.

B3M1897
I98467700 )RIFT Jsed for removing pinion, pilot bearing and front
iearing cone.

B3M189e ~

a7801 04 VEIGHT Used for installing front bearing cone, pilot bear-
ing companion flange.

B3M189(
899580100 NSTALLER Used for press-fittingthe front bearing cone, pilo
bearing.

B3M190

DI-9
 I
GENERAL DESCRIPTION
DIFFERENTIALS

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

899904100 STRAIGHT PIN Used for driving out differential pinion shaft lock
REMOVER Din.

B3M1901
498247001 MAGNET BASE 1 Used for measuring backlash between side

jear and pinion, and hypoid gear.

1 Used with DIAL GAUGE (498247100).

B3M1902
498247100 DIAL GAUGE 1 Used for measurng backlash between side

gear and pinion, and hypoid gear.

1 Used with MAGNET BASE (498247001).

03M1903
398507704 BLOCK Jsed for adjusting pinion height and preload.

B3M1904

DI-I 0
I GENERAL DESCRIPTION
3
DIFFERENTIALS

ILLUSTRATION TOOL NUMBER DESCRIPTION 3EMARKS

%98177700 VSTALLER Used for installing rear bearing cone.

B3M1905
398457700 UTACHMENT I Used for removing side bearing retainer.

6=:p
B3M1906
398477703 ]RIFT2 1 Used for press-fitting the bearing race (rear) of
differential carrier.

B3M190i
398437700 DRIFT Used for installing side oil seal.

B3M1901

DI-11
 GENERAL DESCRIPTION
DIFFERENTIALS

I ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

398507702 DUMMY SHAFT Used for adjusting pinion height and preload.

398507703 3UMMY COLLAR Used for adjusting pinion height and preload.

I B3M1910
39851 7700 3EPLACER Used for removing rear bearing cone.

398487700 )RIFT 1 Used for press-fitting the side bearing cone.

DI-I 2
I I
GENERAL DESCRIPTION
DIFFERENTIALS

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

398507701 DIFFERENTIAL Used for adjusting pinion height.
CARRIER GAUGE

B3M1913
398527700 PULLEY ASSY Used for removing front oil seal.
Used for removing side bearing cup. (T-type)

B3M1914
399527700 PULLER SET Used for extracting side bearing cone.
(1)BOLT (899521412)
(2)PULLER (399527702)
(3)HOLDER (399527703)
(4)ADAPTER (398497701)
(5)BOLT (899520107)
(6)NUT (021008000)

B3M1915A
398227700 WEIGHT . Used for installing side bearing.

B3M1916

DI-I 3
 GENERAL DESCRIPTION
DIFFERENTIALS

I ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

28099PA090 OIL SEAL PROTEC- Used for installing rear drive shaft into rear dif-
TOR ferential.
For protecting oil seal.

B3M1917
398237700 GAUGE Used for installing side bearing.

I------
B3M1918
28099PA100 DRIVE SHAFT Used for removing rear drive shaft from rear
REMOVER differential.

399703602 WLLEY ASSY Used for removing companion flange

I B3M1930

DI-I 4
I I
GENERAL DESCRIPTION DIFFERENTIALS

ILLUSTRATION TOOL NUMBER DESCRIPTION 3EMARKS

399874100 INSTALLER 1Used for installing companion flange.

B3M193

DI-I 5
 GENERAL DESCRIPTION
DIFFERENTIALS

2. GENERAL PURPOSE TOOLS

I TOOL NAME I REMARKS I

I Transmission jack 1 Used for assembly/disassembly of rear differential. I
Puller Used for removal of side bearing retainer.
Thickness gauge Used for measuring clearance.

DI-16
I DIFFERENTIAL GEAR OIL 1
DIFFERENTIALS

2. Differential Gear Oil 5 ) Fill differential carrier with gear oil to the upper
plug level.
A: INSPECTION CAUTION:
1) Take out the filler plug, and replace gear oil if it is Carefully refill oil while watching the level. Ex-
contaminated or deteriorated. <Ref. to DI-17, RE- cess or insufficient oil must be avoided.
PLACEMENT, Differential Gear Oil.>
2) Check gear oil level is up to the bottom part of fill- Oil capacity:
er bolt. If the level is low, refill up to the bottom of 0.8 Q (0.8 US qf, 0.7 Imp qt)
filler bolt.
I 1

I . . , . . . , I I
1
DUO017 I (A) Filler plug
.
r-
(A) Filler plug ( 6 ) Drain plug
( 6 ) Drain plug
6) Install the filler plug.
B: REPLACEMENT NOTE:
Apply fluid packing to the filler plug.
1) Disconnect the ground terminal from battery.
2) Jack-up the vehicle and support it with sturdy Fluid packing:
racks. THREE BOND 1105 or equivalent
3) Remove the oil drain plug and filler plug, and Tightening torque:
drain the gear oil.
49.0 N.m (5.0 kgf-m, 36.2 ff-lb)
CAUTION:
Be careful not to burn your hands, because
gear oil becomes extremely hot after running.

(A) Filler plug

(B) Drain plug

4) Tighten the oil drain plug.

NOTE:
Apply fluid packing to the drain plug.
Fluid packing:
THREE BOND I105 or equivalent
Tightening torque:
49.0 N.m (5.0 kgf-m, 36.2 ff-lb)

DI-17
 FRONT DIFFERENTIAL
DIFFERENTIALS

3. Front Differential
A: NOTE
1. AT MODEL
Refer to AUTOMATIC TRANSMISSION in sepa-
rate publication “AUTOMATIC TRANSMISSION”
for Front Differential. <Pub. No. G0853ZE>
2. MTMODEL
For front differential of manual transmission, refer
to “MT” section. <Ref. to MT-71, Front Differential
Assembly.>

DI-18
 REAR DIFFERENTIAL I
DIFFERENTIALS

4. Rear Differential 14) Remove the DOJ of rear drive shaft from rear
differential using ST. <Ref. to DI-37, REPLACE-
A: REMOVAL MENT, Rear Differential Side Oil Seal.>
1) Set the vehicle on the lift. ST 28099PA100 DRIVE SHAFT REMOVER
2 ) Disconnect the ground terminal from battery.
3) Move the select lever or gear shift lever to “N”.
4) Release the parking brake.
5) Loosen the wheel nuts.
6) Jack-up the vehicle and support it with sturdy
racks.
7) Remove the wheels.
8) Remove the rear exhaust pipe and muffler.
Non-turbo model:
<Ref. to EX(S0HC)-9, REMOVAL, Rear Exhaust
Pipe.> and <Ref. to EX(S0HC)-11, REMOVAL,
Muffler.>
(A) Bolt
Turbo model:
<Ref. to EX(D0HC TURBO)-13, REMOVAL, Rear 15) Secure the rear drive shaft to rear crossmem-
Exhaust
- PiDe.> and <Ref. to EX(D0HC TURBO)- ber using wire.
14, REMOVAL, Muffler.>
r9) Remove the rear differential protector. (If
.

equipped)
10) Remove the front cover of rear differential
mount.

S3M0500

16) Remove the lower differential bracket.

11) Remove the propeller shaft. <Ref. to DS-14,

REMOVAL, Propeller Shaft.>
12) Remove the heat shield cover.
13) Remove the clamps and bracket of parking
brake cable.

0
S3M0529

17) Support the rear differential with transmission

jack.

DI-I 9
I REAR DIFFERENTIAL
DIFFERENTIALS

18) Remove the self-locking nuts and bolts. 22) Remove the rear differential from front mem-
ber, and remove rear member.

G3M1030
19) Remove the bolts which secure rear differential
front member to body. B: INSTALLATION
Loosen bolt A first, then remove bolts B. To install, reverse the removal sequence.
NOTE: 1) Install the air breather cap tapping with a plastic
Support the front member with the use of a helper hammer.
to prevent it from dropping. CAUTION:
Be sure to install a new air breather cap.
- 2) Position the front member on body by passing it
c- - under parking brake cable and securing to rear dif-
ferential.
NOTE:
\ When installing the rear differential front member,
do not confuse the installation sequence of the up-
per and lower stoppers.
3) Install the DOJ of drive shaft into rear differen-
\ ' 'B3M0657C 1 tial.<Ref. to DI-37, REPLACEMENT, Rear Differ-
ential Side Oil Seal.>
(A) Bolt A ST 28099PA090 SIDE OIL SEAL PROTEC-
(B) Bolt B TOR
20) Remove bolt A.
21) While slowly lowering the transmission jack,
move rear differential forward and remove front
member and rear differential from body.

4) Install in the reverse order of removal.

5 ) After installation, fill the differential carrier with
gear oil to the filler plug level. <Ref. to DI-17, Differ-
. . I
' G3M1029
ential Gear Oil.>

DI-20
 REAR DIFFERENTIAL
DIFFERENTIALS

C: DISASSEMBLY 4) Remove the rear cover by loosening retaining

To detect the real cause of trouble, inspect the fol- bolts.
lowing items before disassembling.
Tooth contact of crown gear and pinion, and
I
backlash
Runout of crown gear at its back surface
Turning resistance of drive pinion
1) Set the ST on vise and install the differential as-
sembly to ST.
ST 398217700 ATTACHMENT
I

(A) Rear cover

(B) Differential carrier

5) Make right and left side bearing retainers in or-

der to identify them at reassembly. Remove the

- ST I
G3M1031 1
side bearing retainer attaching bolts, set the ST to
differential case, and extract right and left side
bearing retainers with a puller.
2) Drain the gear oil by removing plug. CAUTION:
3) Remove the air breather cap. Each shim, which is installed to adjust the side
NOTE: bearing preload, should be kept together with
Do not attempt to replace the air breather cap un- its mating retainer.
less necessary. ST 398457700 ATTACHMENT

S3M0530A

6) Pull out the differential case assembly from dif-

(A) Air breather cap ferential carrier.
(B) Rear cover
CAUTION:
Be careful not to hit the teeth against the case.

S3M0533

DI-21
I I
REAR DIFFERENTIAL
DIFFERENTIALS

7) When replacing the side bearing, pull the bear- 10) Drive out the pinion shaft lock pin from crown
ing cup from side bearing retainer using ST. gear side. (Without LSD)
ST 398527700 PULLER ASSY NOTE:
The lock pin is staked at the pin hole end on the dif-
ferential carrier; do not drive it out forcibly before
unstaking it.
ST 899904100 STRAIGHT PIN REMOVER

,
S3M05341:

8) Extract the bearing cone with ST.

CAUTION:
Do not attempt to disassemble the parts unless
necessary.
NOTE: 11) Draw out the pinion mate shaft and remove pin-
Set the puller so that its claws catch the edge of ion mate gears, side gears and thrust washers.
+he bearing cone. (Without LSD)
Never mix up the right and left hand bearing rac- NOTE:
es and cones. The gears as well as thrust washers should be
ST 398527700 PULLER SET marked or kept separated right and left, and front
and rear.

(C)

S3M051OP
9) Remove the crown gear by loosening crown
gear bolts.
(A) Sidegear
CAUTION: (B) Pinion mate gear
Further disassembling is not allowed. (C) Thrust washer
(D) Differential case
(E) Pinion mate shaft

S3M0509

DI-22
I I
REAR DIFFERENTIAL
DIFFERENTIALS

12) Hold the companion flange with ST and remove 15) Remove the rear bearing cone from drive pin-
drive pinion nut. ion 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

13) Extract the companion flange with a puller.

S3MOS

16) Remove the front oil seal from differential carri-

er using ST.
ST 398527700 PULLER ASSY

14) Press the end of drive pinion shaft and extract it

together with rear bearing cone, preload adjusting
spacer and washer.
NOTE: S3M0513
Hold the drive pinion so as not to drop it.
ST 398467700 DRIFT 17) Remove the pilot bearing together with front
bearing cone using ST.
ST 398467700 DRIFT

G3M0078

S3M0514A

(A) Pinion bearing

(B) Front bearing
(C) Rear bearing cup

DI-23

I REAR DIFFERENTIAL
DIFFERENTIALS
18) When replacing the bearings, tap front bearing
cup and rear bearing cup in this order out of case
by using a brass bar.
(A) 2 cutouts along diagonal lines
(6) Tap alternately with brass bar.
c.
DI-24
I
D: ASSEMBLY
1) Precautions for assembling:
Assemble in the reverse order of disassembling.
Check and adjust each part during assembly.
Keep the shims and washers in order, so that
they are not misinstalled.
Thoroughly clean the surfaces on which the
shims, washers and bearings are to be installed.
Apply gear oil when installing the bearings and
thrust washers.
Be careful not to mix up the right and left hand
races of the bearings.
Replace the oil seal with a new one at every dis-
assembly. Apply chassis grease between the lips
when installing the oil seal.
2) Adjusting preload for front and rear bearings:
Adjust the bearing preload with spacer and washer
between front and rear bearings. Pinion height ad-
justing washer are not affected by this adjustment.
The adjustment must be carried out without oil seal
inserted.
m
(1) Press the rear bearing race into differential
carrier with STI and ST2.
ST1 398477701 HANDLE
ST2 398477703 DRIFT 2
G3M1037
(2) Insert the ST1 into carrier with pinion height
adjusting washer and rear bearing cone fitted
onto it.
CAUTION:
Re-use the used washer if not deformed.
Use a new rear bearing cone.
 REAR DIFFERENTIAL I
DIFFERENTIALS

(3) Then install the preload adjusting spacer
and washer, front bearing cone, ST2, compan-
ion flange, and washer and drive pinion nut.
ST1 398507702 DUMMY SHAFT
ST2 398507703 DUMMY COLLAR
Front and rear bearing preload
For new bearing:
19.6- 28.4N (2.0- 2.9kgf, 4.4- 6.4Ib)
at companion flange bolt hole
For used bearing:
8.34- 16.67N (0.85- 1.7 kgf, 1.87- 3.75Ib)
at cotmanion flanae bolt hole

S3M0516A

(A) Pinion height adjusting shim

(8) Preload adjusting spacer

---
(C) Preload adjusting washer
(4) Turn the STI with hand to make it seated,
1 Part NO. 1 Thickyiy mm
. . II
I

and tighten the drive pinion nut while measuring 383705200 I 2.59 (0.1020)
the preload with spring balance. Select the pre- 383715200 [ 2.57(0.1012)
load adjusting washer and spacer so that the 383725200 I 2.55(0.1004)
specified preload is obtained when nut is tight- 383735200 1 2.53 10.0996) I
ened to the specified torque.
CAUTION: 383755200
Use a new lock nut. ’reload adjusting
Masher
1
I

NOTE: 383775200 1 2.45 (0.0965)

f
Be careful not to give excessive preload. 383785200 2.43 (0.0957)
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)
ST1 398507704 BLOCK 383815200 2.37 (0.0933)
ST2 398507702 DUMMY SHAFT 383825200 2.35(0.0925)
Tightening torque:
r- 383835200 I 2.33(0.0917) I
181 N.m (18.5 kgf-m, 134 ft-lb)
I 383845200 I 2.31 (0.0909) I
Part No.

383695202 56.4(2.2201
Preload adjusting
383695203 56.6(2.228)
spacer
383695204 56.8 (2.236)
383695205 1 57.0(2.244)
383695206 I 57.2 (2.252)

U
G3M1038

DI-25
I REAR DIFFERENTIAL
DIFFERENTIALS

3) Adjusting drive pinion height: (2) Measure the clearance N between the end
Adjust the drive pinion height with shim installed of ST2 and the end surface of STI by using a
between rear bearing cone and the back of pinion thickness gauge.
gear. NOTE:
(1) Install STl, ST2 and ST3, as shown in the Make sure there is no clearance between the case
figure, and apply the specified preload on the and ST2.
bearings.
ST1 398507702 DUMMY SHAFT
Front and rear bearing preload ST2 398507701 DIFFERENTIAL CARRIER
For new bearing: GAUGE
19.6 - 28.4 N (2.0 - 2.9 kgf, 4.4 - 6.4 Ib)
at companion flange bolt hole
For used bearing:
8.34-l6.67N(0.85-l1.7kgf, 1.87-3.75Ib)
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. H3M1309B
ST1
.
398507702 DUMMY SHAFT
c-
ST2 398507701 DIFFERENTIAL CARRIER (3) Obtain the thickness of pinion height adjust-
GAUGE ing shim to be inserted from the following formu-
ST3 398507703 DUMMY COLLAR la, and replace the temporarily installed shim
with this one.
T = To + N - (H x 0.01) - 0.20 mm (0.0079 in)
NOTE:
-I Use copies of this page.
T Thickness of shim temporarily inserted
mm (in)
To Thickness of pinion height adjusting
I shim mm (in) I
N I
Reading of thickness gauge mm (in) I
S3M0518B
H I Figure marked on drive pinion head I
Memo:
(A) Pinion height adjusting shim

(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.

DI-26
I REAR DIFFERENTIAL
DIFFERENTIALS

5) Insert the drive pinion into differential carrier, in-

I Pinion height adjusting shim i stall the previously selected bearing preload adjust-
ing spacer and washer.
383495200
I

3.15 (0.1240)
383525200 3.18 (0.1 252)

383545200 3.24 (0.1276)

383555200 3.27 (0.1287)
383565200 3.30 (0.1299)
383575200 3.33 (0.1311)
383585200 3.36 (0.1323)
383595200 3.39 (0.1335)
383605200 3.42 (0.1346)
(A) Drive pinion
383615200 3.45 (0.1358)
(B) Bearing adjusting spacer
383625200 3.48 (0.1370)
(C) Washer
383635200 3.51 (0.1382)
(D) Differential carrier
383645200 3.54 (0.1394)
383655200 3.57 (0.1 406) 6) Press-fit the front bearing cone into case with
c- - ST1, ST2 and ST3.
383665200 3.60 (0.1417)
383675200 3.63 (0.1429) ST1 398507703 DUMMY COLLAR
383685200 3.66 (0.1441) ST2 399780104 WEIGHT
ST3 899580100 INSTALLER

ST 398177700 INSTALLER

7) Insert the spacer, then press-fit pilot bearing with

ST1 and ST2.
S3M0519A
ST1 399780104 WEIGHT
ST2 899580100 INSTALLER

DI-27
I REAR DIFFERENTIAL
DIFFERENTIALS

8) Fit a new oil seal with ST. 11) Assembling differential case:
NOTE: Install the side gears and pinion mate gears, with
Press-fit until end of oil seal is 1 mm (0.04 in) in- their thrust washers and pinion mate shaft, into dif-
ward from end of carrier. ferential case. (Without LSD)
Apply grease between the oil seal lips. CAUTION:
ST 498447120 DRIFT Apply gear oil on both sides of the washer
and on the side gear shaft before installing.
Insert the pinion mate shaft into the differen-
tial case by aligning the lock pin holes.

9) Press-fit the companion flange with ST1 and

ST2.
GAUTION:
Be careful not to damage the bearing.
ST1 899874100 INSTALLER
ST2 399780104 WEIGHT

G3M0089

(1) Measure the side gear backlash.

Side gear back clearance:
S3M0521A 0.10 - 0.20 mm (0.0039 - 0.0079 in)
10) Install the self-locking nut. Then tighten it with
ST.
ST 498427200 FLANGE WRENCH
Tightening torque:
181 N-m (18.5 kgf-m, 134 fWb)

DI-28
 1
REAR DIFFERENTIAL
DIFFERENTIALS

14) Adjusting the side bearing retainer shims:

(1) The driven gear backlash and side bearing
preload can be determined by the side bearing
retainer shim thickness.
Part No. Thickness mm (in)
(2) Installthe differential case assembly into dif-
I 383445201 I 0.75- 0.80(0.0295- 0.0315) I ferential carrier in the reverse order of disas-
383445202 0.80- 0.85(0.0315 - 0.0335) sembly.
383445203 0.85- 0.90(0.0335- 0.0354)

(3) Install the side retainer shims and O-rings to

the left and right retainers from which they were
removed.
NOTE:
Replace the broken or cracked O-ring with a new
one.
Replace the broken or corroded side retainer
shim with a new one of same thickness.

Part No. Thickness mm (in)

383475201 0.20 (0.0079)
I 383475202 I 0.25(0.0098) I
383475203 0.30(0.0118)
383475204 0.40(0.0157)
3a3475205 0.50(0.0197)

S3M0509 I
- cone onto differential
13) Press the side bearing
case with ST.
ST 398487700 DRIFT

w
(A) Arrow mark

01-29
I REAR DIFFERENTIAL
DIFFERENTIALS

(5) Tighten the side bearing retainer bolts. 15) Recheck the crown gear-to-pinion backlash.
CAUTION: Backlash:
Before tightening the two side bearing retainer 0.10 - 0.20 mm (0.0039 - 0.0079 in)
bolts, apply Lock Tite to bolt threads.
+Lock Tite:
-
THREE BOND 1 105 or equivalent
Tightening torque:
10.3 N.m (1.05 kgf-m, 7.6 ft-16)

G3M1047

16) Check the crown uear runout on its back sur-

face, and make sure pinion and crown gear rotates
smoothIy .
Limit of runout:
S3M0173 Less than 0.05 mm (0.0020 in)
(6) Measure the crown gear-to-drive pinion
backlash. Set the magnet base on differential
carrier. Align the contact point of dial gauge with
tooth face of crown gear, and move crown gear
while holding drive pinion still. Read the value in-
dicated on dial gauge.
Backlash:
0.10 - 0.20 mm (0.0039 - 0.0079 in)

1 1 4 S3M0525

17) Checking and adjusting the tooth contact of

G3M1047
(7) At the same time, measure the turning resis-
tance of drive pinion. Compared with the resis-
tance when differential case is not installed, if
the increase of the resistance is not within the
specified range, readjust side bearing retainer
shims.
crown gear:
(1) Apply an even coat of red lead on both sides
of three or four teeth on the the crown gear.
Check the contact pattern after rotating the
crown gear several revolutions back and forth
until a definite contact pattern appears on the
crown gear.
(2) When the contact pattern is incorrect, read-
just according to the instructions given in
“TOOTH CONTACT PATTERN”.
NOTE:
Be sure to wipe off red lead completely after adjust-
ment is completed.

Turning resistance increase:

2 . 9 - l 0 . 8 N ( 0 . 3 - l 1 . 1 kgf,O.7-2.4Ib)

DI-30
I REAR DIFFERENTIAL
18) If proper tooth contact is not obtained, once
again adjust the drive pinion height changing RH
and LH side bearing retainer shims and the hypoid
gear
- backlash.
(1) Drive pinion height
STl 398507702 DUMMY SHAFT
ST2 398507701 DIFFERENTIAL CARRIER
GAUGE
T = To + N - (H x 0.01) - 0.20 (mm)
Condition
Correct tooth contact
Tooth contact pattern slightly shifted
towards toe under no load rotation.
(When loaded, contact pattern moves
toward heel.)
Face contact
Backlash is too large.
Flank contact
Backlash is too small.
DIFFERENTIALS
Where:
T = Thickness of pinion height adjusting shim
(">
To = Thickness of shim temDorarilv inserted
N = Reading of thickness gauge (mm)
H = Figure marked on drive pinion head
(2) Hyp6id gear backlash
Backlash:
0.10 -
0.20 mm (0.0039 - 0.0079 in)
H3M13098
) G3M104i
TOOTH CONTACT PATTERN
Contact pattern Adjustment
-
Heel side
G3M0098A
This may cause noise and chipping at Increase thickness of drive pinion height
tooth ends. adjusting shim in order to bring drive pin-
ion closer to crown gear center.
- G3M0098B
This may cause noise and stepped wear
V
G3M0098F
Reduce thickness of drive pinion height
on surfaces. adjusting shim in order to move drive pin-
ion away from crown gear.
- G3M0098C G3M0098G
DI-31
I I
REAR DIFFERENTIAL
DIFFERENTIALS

TOOTH CONTACT PATTERN

Condition Contact pattern Adjustment
Toe contact rhis may cause chipping at toe ends. Adjust as for flank contact.
Contact area is small.

I
G3M0098D G3M0098G
Heel contact rhis may cause chipping at heel ends. Adjust as for face contact.
Contact area is small.

V
G3M0098E G3M0098F
I): Adjusting direction of drive pinion
: Adjusting direction of crown gear

DI-32
 REAR DIFFERENTIAL
DIFFERENTIALS

19) Install the rear cover and tighten bolts to spec- 1. SIDE GEAR BACKLASH
ified torque. Using a dial gauge, check the backlash of the side
CAUTION: gear.
Securely connect the ground terminal of rear
differential temperature sensor. Side gear backlash:
0.1 - 0.2 mm (0.004 - 0.008 in)
Tightening torque: If the side gear backlash is not within the specifica-
29 N-m (3.0 kgf-m, 2 1.7 ff-lb) tion, adjust clearance as specified by selecting side
gear thrust washer.

1934
E: INSPECTION
‘-Wash all the disassembled parts clean, and exam- 2. CROWN GEAR BACKLASH
ine them for wear, damage or other defects. Repair
Using a dial gauge, check the backlash of the
or replace defective parts as necessary.
crown gear.
1) Crown gear and drive pinion:
If abnormal tooth contact is evident, find out the Crown gear backlash:
cause and adjust to give correct tooth contact at as- 0.1 - 0.2 mm (0.004 - 0.008 in)
sembly. Replace the gear if excessively worn or in- If the crown gear backlash is not within the specifi-
capable of adjustment. cation, adjust the side bearing preload or repair if
If crack, score or seizure is evident, replace as a necessary.
set. Slight damage of tooth can be corrected by oil
stone or the like.
2) Side gear and pinion mate gear:
Replace if crack, score or other defects are evi-
dent on tooth surface.
Replace if thrust washer contacting surface is
worn or seized. Slight damage of the surface can
be corrected by oil stone or the like.
3) Bearing:
Replace if seizure, peeling, wear, rust, dragging
during rotation, abnormal noise or other defect is I 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 dis-
assembling.
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-33
I
REAR DIFFERENTIAL
DIFFERENTIALS

3. CROWN GEAR RUNOUT F: ADJUSTMENT

Using a dial gauge, check the crown gear runout.
Crown gear runout:
Less than 0.05 mm (0.0020 in)
If the crown gear runout exceeds 0.05 mm (0.0020
in), replace the crown gear.
1. SIDE GEAR BACKLASH
Adjust the side gear backlash.
<Ref. to DI-24, ASSEMBLY, Rear Differential.>
2. CROWN GEAR BACKLASH
Adjust the crown gear backlash.
<Ref. to DI-24, ASSEMBLY, Rear Differential.>
3. TOOTH CONTACT BETWEEN CROWN
GEAR AND DRIVE PINION
Adjust the tooth contact between crown gear and
drive pinion gear.
<Ref. to DI-24, ASSEMBLY, Rear Differential.>

-9
4. TOOTH CONTACT BETWEEN CROWN
S3M0525
4. TOTAL PRELOAD
Adjust the side bearing shim.
<Ref. to DI-24, ASSEMBLY, Rear Differential.>
GEAR AND DRIVE PINION
r.

Inspect the tooth contact between crown gear and

driven pinion. <Ref. to DI-24, ASSEMBLY, Rear
Differential.>
5. TOTAL PRELOAD
Using a gauge, check the turning resistance in-
crease.
Total preload:
2.9-l0.8N.m(0.3-l1.1 kgf,O.7-2.4Ib)
If the increase of the resistance is not within the
specification, adjust the side bearing retainer
shims.

B3M 1935

DI-34
 I
REAR DIFFERENTIAL FRONT OIL SEAL
DIFFERENTIALS

5. Rear Differential Front Oil 11) Extract the companion flange using ST.
ST 399703602 PULLEY ASSY
Seal
.
A: INSPECTION
Make sure that there is no oil leakage from front oil
seal.
If there is any oil leakage, replace the oil seal.
B: REPLACEMENT
1 ) Set the vehicle on the lift.
2) Disconnect the ground terminal from battery.
3) Move the select lever or gear shift lever to “N”.
6448
4) Release the parking brake.
5) Remove the oil drain plug, and drain gear oil. 12) Remove the oil seal using ST.
ST 499705401 PULLER ASSY

--- .

/
(A) Filler plug
DR0003
i: B3M1609B

13) Fit a new oil seal using ST

(B) Drain plug
ST 498447120 DRIFT
6) Install the oil drain plug.
NOTE:
Apply fluid packing to drain plug.
Tightening torque:
49 N.m (5.0 kgf-m, 36.2 ft-lb)
7) Remove the rear exhaust pipe and muffler.
8) Remove the rear differential protector. (If
equipped)
9) Remove the propeller shaft from body. <Ref. to
DS-14, REMOVAL, Propeller Shaft.> G3M0037
IO) Remove the self-locking nut while holding com- 14) Install the companion flange.
panion flange with ST.
ST 498427200 FLANGE WRENCH NOTE:
Use a plastic hammer to install companion flange.

I / / \ \ G3M0034

DI-35
I
REAR DIFFERENTIAL FRONT OIL SEAL
DIFFERENTIALS

15) Tighten the self-locking nut within the specified

torque range so that the turning resistance of com-
panion flange becomes the same as that before re-
placing oil seal.
ST 498427200 FLANGE WRENCH
NOTE:
Use a new self-locking nut.
Tightening torque:
181.4 N-m (18.50 kgf-m, 133.8 ff-lb)

r. .
\ \ G3M0034

16) Reassembling procedure hereafter is the re-

verse of the disassembling.
17) Fill the differential carrier with gear oil to the fill-
er plug level. <Ref. to DI-17, Differential Gear Oil.>

DI-36
 1
REAR DIFFERENTIAL SIDE OIL SEAL
DIFFERENTIALS

6. Rear Differential Side Oil Seal (3) Remove the ABS sensor cable clamp and
parking brake cable guide from the trailing link.
A: INSPECTION
Make sure that there is no oil leakage from side oil
seal.
If there is any oil leakage, replace the oil seal.
B: REPLACEMENT
1) Disconnect the ground terminal from battery.
2) Move the select lever or gear shift lever to “N”.
3) Release the parking brake.
4) Loosen both wheel nuts.
5 ) Jack-up the vehicle and support it with rigid
racks.
6) Remove the wheels. (A) ABS sensor cable clamp
7) Remove the rear exhaust pipe and muffler. (B) Parking brake cable guide
Non-turbo model:
<Ref. to EX(S0HC)-9, REMOVAL, Rear Exhaust (4) Remove the rear stabilizer link.
-
Pipe.> and <Ref. to EX(S0HC)-11, REMOVAL,
Muffler.>
Turbo model:
*<Ref. to EX(D0HC TURBO)-13, REMOVAL, Rear
Exhaust Pipe.> and <Ref. to EX(D0HC TURBO)-
14, REMOVAL, Muffler.>
8) Remove the DOJ of rear drive shaft from rear dif-
ferential.
(1) Remove the ABS sensor cable clamp and
parking brake cable clamp from bracket.
17

(5) Remove the bolts which secure the trailing

link to the housing.

(A) ABS sensor cable clamp

(B) Parking brake cable guide \\ G3M0042

(2) Remove the ABS sensor cable clamp from (6) Remove the bolts which secure the front
the trailing link. and rear lateral link to the rear housing.

DI-37
I REAR DIFFERENTIAL SIDE OIL SEAL
DIFFERENTIALS

(7) Remove the DOJ from the rear differential 10) Remove the nut of protector.
by using ST. ST 398527700 PULLER ASSY
CAUTION:
When removing the DOJ from the rear differen-
tial, fit ST to the bolts as shown in figure so as
not to damage the side bearing retainer.
ST 208099PA100 DRIVE SHAFT REMOVER

G3M1023

11) Drive in a new side oil seal with ST.

CAUTION:
Apply chassis grease between the oil seal lips.
ST 398437700 DRIFT
I

1024
DR0006
12) Insert the DOJ into rear differential.
(A) Bolt
(1) Install the ST to rear differential.
, I

ST 28099PA090 SIDE OIL SEAL PROTEC-

9) Remove the rear drive shaft to rear crossmem- TOR
ber using wire.

S3M050C

DI-38
 1
REAR DIFFERENTIAL SIDE OIL SEAL
DIFFERENTIALS
_ _ _ ~ ~

(2) Install the spline shaft until the spline portion

is inside the side oil seal using ST.
ST 28099PA090 SIDE OIL SEAL PROTEC-
TOR

(3) Remove ST.

ST 28099PA090 SIDE OIL SEAL PROTEC-
TOR
13) Hereafter, reassemble in the reverse order of
disassembly.
-44)-Fill differential carrier with gear oil to the filler
plug level. <Ref. to DI-17, Differential Gear Oil.>

DI-39
I REAR DIFFERENTIAL MEMBER
DIFFERENTIALS
7. Rear Differential Member
A: REMOVAL
1) Set the vehicle on the lift.
2) Disconnect the ground terminal from battery.
3) Move the selector lever or gear shift lever to “N”.
4) Release the parking brake.
5) Loosen the wheel nuts.
6) Jack-up the vehicle and support it with study
racks.
7) Remove the wheels.
8) Remove the rear exhaust pipe and muffler.
Non-turbo model:
<Ref. to EX(S0HC)-9, REMOVAL, Rear Exhaust
Pipe.> and <Ref. to EX(S0HC)-11, REMOVAL,
Muffler.>
Turbo model:
<Ref. to EX(D0HC TURBO)-13, REMOVAL, Rear
Exhaust Pipe.> and <Ref. to EX(D0HC TURBO)-
14, REMOVAL, Muffler.>
9). Remove the rear differential protector. (If
r-
equipped)
10) Remove the rear differential front member.
NOTE:
When removing the rear differential front member,
work the removal procedure as rear differential.
<Ref. to DI-19, REMOVAL, Rear Differential.>
11) Remove the differential rear member.
DI-40
B: INSTALLATION
To install, reverse the removal sequence.
1) Position the front member on body by passing it
under parking brake cable and securing to rear dif-
ferential.
NOTE:
When installing the rear differential front member,
do not confuse the installation seqence of the stop-
per.
I I
’ G3M1029
2) Insert the DOJ of rear drive shaft into rear differ-
ential.<Ref. to DI-37, REPLACEMENT, Rear Dif-
ferential Side Oil Seal.>
CAUTION:
Before inserting, replace the differential side oil
seal with a new one.
ST 28099PA090 SIDE OIL SEAL PROTEX-
TOR
1026
3) Installing procedure hereafter is in the reverse
order of removal.
C: INSPECTION
1) Check the rear differential member for damage,
bend or corrosion.
If damage, bend or corrosion is excessive, replace
the rear differential member.
2) Check bushings of rear differential member for
cracking, hardening or damage.
If cracking, hardening or damage is excessive, re-
place rear differential member.
I GENERAL DIAGNOSTIC TABLE
DIFFERENTIALS

8. General Diagnostic Table

A: INSPECTION
Symptom or trouble Possible cause Remedy
1. Oil leakage (1) Worn, scratched, or incorrectly seated Repair or replace.
front or side oil seal. Scored, battered or
excessively worn sliding surface of com-
panion flange.
(2) Clogged or damaged air breather. Clean, repair or replace.
(3) Loose bolts on differential spindle or Tighten bolts to specified torque. Replace
side retainer or incorrectlv fitted 0-rina. 0-rina.
(4) Loose rear cover attaching bolts or
damaged gasket.
(5) Loose oil filler or drain plug.
1 Tighten bolts to specified torque. Replace
gasket and apply liquid packing.
Retighten and apply liquid packing.
(6) Wear, damage or incorrectly fitting for Repair or replace.
sDindle. side retainer and oil seal.
2. Seizure (1) Insufficient backlash for hypoid gear. Readjust or replace.
NOTE: (2) Excessive preload for side, rear or Readjust or replace.
Seized or damaged parts should be re- front bearing,
placed, and Other parts should be
(3) insufficient or improper oil used, Replace seized part and fill with specified
thoroughly checked for any defect and
oil to specified level.
should be repaired or replaced as re-
quired.
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 bearina.
1
Other parts should be thoroughly (3) Excessive backlash f& differential
checked for any defect and should be re- ycai.
~~~"
I
Replace gear or thrust washer.
paired or replaced as required.
(4) Loose bolts and nuts such as crown I 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:
Noises may be caused by differential 1 near
a---..
as- (3) Insufficient preload for front or rear
sembly, universal joint, wheel bearing, cIU---:--
~dlIlly.
Readjust.
etc. Find out what is-actuallymaking noise
before disassemblv. (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.
(31Broken Dinion mate shaft. Redace.
1 (4) Seized or damaaed side bearing. I Replace.

DI-41
I GENERAL DIAGNOSTIC TABLE
DIFFERENTIALS

I SvmDtom or trouble
6. Gear noises
NOTE:
Since noises from engine, muffler, trans-
mission, propeller shaft, wheel bearings,
tires, and body are sometimes mistaken
for noises from differential assembly, be
careful in checking them. Inspection
methods to locate noises include coast-
ing, accelerating, cruising, and jacking-up
all four wheels. Perform these inspections
according to condition of trouble. When
listening to noises, shift gears into four
wheel drive and fourth speed position, try-
ing to pick up only differential noise.
(1) Improper tooth contact of hypoid gear. I Readjust or replace hypoid gear set.
(2) Improper backlash for hypoid gear. I Readiust.
(3) Scored or chipped teeth of hypoid Replace hypoid gear set.
gear.
(4) Seized hypoid gear. Replace hypoid gear set.
(5) Improper preload for front or rear Readjust.
bearings.
(6) Seized, scored or chipped front or Replace.
rear bearing.
(7) Seized, scored or chipped side bear- Replace.
ina.
(8) Vibrating differential carrier. I Replace. I

DI-42
TRANSFER CASE

TC
Page
1. General Description .................................................................................... 2
2. Transfer Case and Extension for MT .......................................................... 3
3. Transfer Clutch and Extension for AT ......................................................... 4
4. Oil Seal ........................................................................................................ 5
5. Transfer Drive Gear (MT) ............................................................................ 6
6. Transfer Driven Gear (MT) .......................................................................... 7
7. Reduction Drive Gear without VTD ............................................................. 8
8. Reduction Drive Gear with VTD .................................................................. 9
9. Reduction Driven Gear without VTD ......................................................... 10
.
c 10. Reduction Driven Gear with VTD .............................................................. 11
11. Center Differential ..................................................................................... 12
12. Transfer Clutch Pressure Test .................................................................. 13
13. Transfer Duty Solenoid and Valve Body ................................................... 14
I GENERAL DESCRIPTION
TRANSFERCASE

1. General Description
A: NOTE
For removal, installation and inspection work, refer
to “AT” or “MT” section.
AT model:
<Ref. to AT-2, General Description.>
MT model:
<Ref. to MT-2, General Description.>

TC-2
 I
TRANSFER CASE AND EXTENSION FOR MT
TRANSFERCASE

2. Transfer Case and Extension

for MT
A: NOTE
For removal, installation and inspection work, refer
to “MT” section. <Ref. to MT-41, Transfer Case and
Extension Case Assembly.>

c.

TC-3
 I
TRANSFER CLUTCH AND EXTENSION FOR AT
TRANSFERCASE

3. Transfer Clutch and Exten-

sion for AT
A: NOTE
For removal, installation and inspection work, refer
to “AUTOMATIC TRANSMISSION’’ (a separate
publication: Pub. No. G0853ZE).

TC-4
I OIL SEAL
TRANSFERCASE

4. Oil Seal
A: NOTE
For removal, installation and inspection work, refer
to “AT” or “MT” section.
AT model:
<Ref. to AT-27, Extension Case Oil Seal.>
MT model:
<Ref. to MT-36, Oil Seal.>

TC-5
 TRANSFER DRIVE GEAR (MT)
TRANSFERCASE

5. Transfer Drive Gear (MT)

A: NOTE
For removal, installation and inspection work, refer
to “MT” section. <Ref. to MT-45, Transfer Drive
Gear.>

TC-6
I TRANSFER DRIVEN GEAR (MT)
TRANSFERCASE

6. Transfer Driven Gear (MT)

A: NOTE
For removal, installation and inspection work, refer
to "MT" section. <Ref. to MT-47, Transfer Driven
Gear.>

TC-7
I REDUCTION DRIVE GEAR WITHOUT VTD
TRANSFERCASE

7. Reduction Drive Gear without

VTD
A: NOTE
For removal, installation and inspection work, refer
to “AUTOMATIC TRANSMISSION” (a separate
publication: Pub. No. G0853ZE).

TC-8
I REDUCTION DRIVE GEAR WITH VTD
TRANSFERCASE

8. Reduction Drive Gear with

VTD
A: NOTE
For removal, installation and inspection work, refer
to “AUTOMATIC TRANSMISSION’’ (a separate
publication: Pub. No. G0853ZE)

TC-9
I REDUCTION DRIVEN GEAR WITHOUT VTD
TRANSFERCASE

9. Reduction Driven Gear with-

out VTD
A: NOTE
For removal, installation and inspection work, refer
to “AUTOMATIC TRANSMISSION’’ (a separate
publication: Pub. No. G0853ZE).

TC-10
I REDUCTION DRIVEN GEAR WITH VTD
TRANSFERCASE

1O.Reduction Driven Gear with

VTD
A: NOTE
For removal, installation and inspection work, refer
to “AUTOMATIC TRANSMISSION” (a separate
publication: Pub. No. G0853ZE)

TC-11
 CENTER DIFFERENTIAL
TRANSFERCASE

11.Center Differential
A: NOTE
For removal, installation and inspection work, refer
to “AUTOMATIC TRANSMISSION’’ (a separate
publication) or “MT” section.
AT model:
Pub No. G0853ZE
MT model:
<Ref. to MT-49, Center Differential.=.

TC-12
I TRANSFERCLUTCHPRESSURETEST
TRANSFERCASE

12.Transfer Clutch Pressure

Test
A: NOTE
For inspection work, refer to “AT” section. <Ref. to
AT-18, Transfer Clutch Pressure Test.>

TC-13
I I
TRANSFER DUTY SOLENOID AND VALVE BODY
TRANSFERCASE

13.Transfer Duty Solenoid and

Valve Body
A: NOTE
For removal, installation and inspection work, refer
to “AUTOMATIC TRANSMISSION’’ (a separate
publication: Pub. No. G0853ZE) or “AT” section.
<Ref. to AT-39, Shift Solenoids, Duty Solenoids
and ATF Temperature Sensor.>

r. .

TC-14
DRIVE SHAFT SYSTEM

DS
Page
1. General Description .................................................................................... 2
2. Propeller Shaft .......................................................................................... 14
3. Front Axle .................................................................................................. 17
4. Rear Axle .................................................................................................. 23
5. Front Drive Shaft ....................................................................................... 32
6. Front Drive Shaft Boots ............................................................................. 38
7. Rear Drive Shaft........................................................................................ 39
8. Rear Drive Shaft Boots ............................................................................. 44
9. General Diagnostic Table.......................................................................... 46
 GENERAL DESCRIPTION
DRIVE SHAFT SYSTEM
~ ~ ~~

1. General Description
A: SPECIFICATIONS
1. PROPELLER SHAFT

[ Model I Turbo I Non-turbo I

Propeller shaft type DOJ type UJ type
AT 579 (22.79) 584 (22.99)
Front propeller shaft Joint-to-jointlength: L1 mm (in)
MT 638 (25.12) 643 (25.32)
Rear propeller shaft Joint-to-jointlength: L, mm (in) 713 (28.07) 708 (27.87)
D1 63.5 (2.500)
Outside diameter of tube: mm (in)
D2 57.0 (2.244)

Di D2

Di Dz

DR0008

(A) UJtYPe (B) DOJ type

DS-2
 a
GENERAL DESCRIPTION
DRIVE SHAFT SYSTEM

2. FRONT DRIVE SHAFT ASSEMBLY

2 ,

Except turbo MT model 26 mm (1.02 in)

EBJ87+SFJ82
Ttirbo MT model 28 mm (1.10 in)

B4M2218l

(A) EBJ87+SFJ82 (B) Measuring point

DS-3
 GENERAL DESCRIPTION
DRIVE SHAFT SYSTEM

3. REAR DRIVE SHAFT ASSEMBLY

Type of drive shaft assembly Model No. of identification L1 +D

protrusion on shaft (") (") ,

EBJ8WDOJ82 RH 2 (Two) 363 24

Sedan Turbo
EBJ8WDOJ82 LH 1 (One) 353 24
BJ79/DOJ79 RH 2 (Two) 368 23
Sedan Non-turbo
BJ79/DOJ79 LH I . ,
1 (One) 358 23
EBJ8WDOJ82 RH 2 (Two) 353 24
Wagon Turbo
EBJ82/DOJ82 LH 1 (One) 343 24
BJ79/DOJ79 RH 2 (Two) 358 23
Wagon Non-turbo
BJ79/DOJ79 LH 1 (One) 348 23

I DR0013

11) Identification protrusion

DS-4
 GENERAL DESCRIPTION
DRIVE SHAFT SYSTEM

B: COMPONENT
1. PROPELLER SHAFT

DROOlk

(1) Propeller shaft (Turbo model) (4) Bush Tightening torque: N.m (kgf-m, ft-lb)
(2) Propeller shaft (Non-Turbo model) (5) Bush T I : 31 (3.2,23.1)
(3) Rear differential T2: 52 (5.3, 38.3)

DS-5
I
GENERAL DESCRIPTION
DRIVE SHAFT SYSTEM

2. FRONTAXLE

04M2213A

(1) Baffle plate (SFJ) (9) Boot (SFJ) (17) Housing

(2) Spring pin (10) Boot (EBJ) (18) Oil seal (OUT)
(3) Outer race (SFJ) (11) EBJASSY (19) Hub bolt
(4) Snap ring (12) Tone wheel (With ABS) (20) Hub
(5) Trunnion (13) Baffle plate (21) Axle nut
(6) Free ring . . Oil seal (IN)
(14) ~I

(7) Circlip (15) Snap ring Tightening torque: N-m (kgf-m,

. - ft-lb)
(8) Boot band (16) Bearing T: l S S ( 1 9 , 137)

DS-6
 GENERAL DESCRIPTION
DRIVE SHAFT SYSTEM

3. REARAXLE

Baffle plate (DOJ) Baffle plate Tightening torque: N.m (kgf-m, ft-lb)
Outer race (DOJ) Oil seal (IN. No. 2) T1: 13 (1.3, 9.4)
Snap ring Oil seal (IN. No. 3) 12: lSS(19, 137)
Inner race Housing
Ball Bearing ASSY * Non-Turbo model: BJ
Cage Snap ring Turbo model: EBJ
Circlip Oil seal (OUT)
Boot band Tone wheel (With ABS)
Boot (DOJ) Hub bolt
Boot (*) Hub
Non-Turbo: BJ ASSY Axle nut
Turbo: EBJ ASSY

DS-7
 GENERAL DESCRIPTION
DRIVE SHAFT SYSTEM

C: CAUTION
Wear working clothing, including a cap, protec-
tive goggles, and protective shoes during opera-
tion.
Remove contamination including dirt and corro-
sion before removal, installation or disassembly.
Keep the disassembled parts in order and pro-
tect them from dust or dirt.
Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary re-
moval, installation, disassembly, and replacement.
Be careful not to burn your hands, because each
part on the vehicle is hot after running.
Use SUBARU genuine grease etc. or the equiv-
alent. Do not mix grease etc. with that of another
grade or from other manufacturers.
Be sure to tighten fasteners including bolts and
nuts to the specified torque.
Place shop jacks or safety stands at the specified
points.
Apply grease onto sliding or revolution surfaces
before installation.
Before installing O-rings or snap rings, apply suf-
ficient amount of grease to avoid damage and de-
formation.
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.

DS-8
 GENERAL DESCRIPTION
DRIVE SHAFT SYSTEM

D: PREPARATION TOOL
1. SPECIAL TOOLS

ILLUSTRATION TOOL NUMBER DESCRIPTION 3EMARKS

122431000 4XLE SHAFT 1 Used for installing axle shaft into housing.

NSTALLER 1 Used with ADAPTER (927390000).

B4M2386
325091000 3ANDTIGHTENING Used for tightening boot band. (Except front
rooL axle housing side)
(A) Jig for band
(B) Ratchet wrench

B4N2387P
326470000 AXLE SHAFT Used for removing axle shaft.
PULLER

B4M238f
927060000 HUB REMOVER Used for removing front hub.
Used with HUB STAND (927080000).

B4M238!

DS-9
 GENERAL DESCRIPTION
DRIVE SHAFT SYSTEM

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

927420000 HUB REMOVER Used for removing rear hub.
Used with HUB STAND (927080000).

H5M0981
927080000 HUB STAND Used for disassembling and assembling hub bolt
in hub.

B4M2390
927100000 3EARING PULLER Used for disassembling and assembling front
housing bearing.
Used with HOUSING STAND (927400000).

B4M2391
927140000 4XLE SHAFT Same as plate 2 included in AXLE SHAFT
WLLER PLATE PULLER (926470000).

B4M2392

DS-10
 GENERAL DESCRIPTION
DRIVE SHAFT SYSTEM

t
ILLUSTRATION TOOL NUMBER
)27390000
INSTALLER (922431000).

I B4M2393
327400000 -1OUSING STAND Used for disassembling and assembling front
housing bearing.
Used with BEARING PULLER (927100000).

04M2394
327410000 OIL SEAL Used for installing oil seal into front housing.
INSTALLER Used with HOUSING STAND (927400000).

r B4M2395
927430000 HOUSING STAND Used for disasembling and assembling rear
housing bearing.
Used with BEARING PULLER (927440000).

H5M098;

DS-11
I GENERAL DESCRIPTION
DRIVE SHAFT SYSTEM

I ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

927120000 HUB INSTALLER Used for installing hub.

927440000 BEARING * Used for disassembling and assembling rear

REMOVER housing bearing.
Used with HOUSING STAND (927430000).

927460000 31L SEAL 1 Used for installing outer bearing and sub bear-
NSTALLER ng into houding.
1 Used with HOUSING STAND (927430000).

I H5M0984
327450000 W B INSTALLER 1Used for installing hub unit into hub ASSY.
1Used with BEARING SPACER (28499AE000)
md HUB STAND (927080000).

DS-12
 GENERAL DESCRIPTION
DRIVE SHAFT SYSTEM

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

28OBPAO90 OIL SEAL PROTEC- Used for installing rear drive shaft into rear dif-
TOR ferential.
For potecting oil seal.

B4M2401
28099PA100 DRIVE SHAFT Used for removing rear drive shaft from rear dif-
REMOVER ferential.

B4M2402
28099ACOOO BOOT BAND PLI- Used for tightening front EBJ boot band. (Front
ERS axle housing side)

84M2403

2. GENERAL PURPOSE TOOLS

TOOL NAME REMERKS

Puller Used for removing ball joint from knuckle arm.
Dial aauae Used for insDectinQ DroDeller shaft run-out.
lSnaD riniiliers ~
I Used for installing and removing snap ring. I

DS-13
 PROPELLER SHAFT
DRIVE SHAFT SYSTEM

2. Propeller Shaft 9) Remove the four bolts which hold propeller shaft
to rear differential.
A: REMOVAL NOTE:
NOTE: Put matching mark on affected parts before re-
Before removing propeller shaft, wrap metal moval.
parts with a cloth or rubber material. Remove all but one bolt.
In case of DOJ type, before removing propeller
shaft, wrap metal parts (installed at the rubber boot
of center DOJ) with a cloth or rubber material, as
shown in the figure. Rubber boot may be damaged
due to interference with adjacent metal parts while
bending the DOJ during removal.

(A) Matching mark

10) Remove the two bolts which hold center bear-

lt3“‘ ing to the vehicle body.
S3M0030

1) Set the vehicle on a lift.

2) Disconnect the ground terminal from battery.
3) Move the select lever or gear shift lever to “N”.
4) Release the parking brake.
5) Jack-up the vehicle and support it with the safety
stands. (rigid racks)
6) Remove the rear exhaust pipe and muffler.
7) Remove the rear differential protector.
(If equipped) I S3M0028

8) Remove the differential mount front cover.

I S3M0026

DS-14
 PROPELLER SHAFT
DRIVE SHAFT SYSTEM

11) Remove the propeller shaft from the transmis- B: INSTALLATION

sion. 1) Insert the sleeve yoke into the transmission and
CAUTION: attach center bearing to body.
not to damage oil seals and frictional surface Tightening torque:
of sleeve yoke. 52 N-m (5.3 kgf-m, 38.3 ff-lb)
Cover the center exhaust pipe with a cloth to
keep off any ATF or oil spilled from transmis-
sion when removing propeller shaft.
NOTE:
Be sure to use an empty oil can to catch oil flow-
ing out when removing propeller shaft.
Be sure to plug the opening in transmission after
removal of propeller shaft.

, ... i'
-
S3M0028

2) Align the matching marks and connect the flange

yoke and rear differential.
Tightening torque:
37 N-m (3.2 kgf-m, 23.7 ff-lb)

12) Install the extension cap to transmission.

NOTE:
If extension cap is not available, place vinyl bag
over opening and fasten with string to prevent gear
oil or ATF from leaking.

(A) Matching mark

3) Install the differential mount front cover.

Tightening torque:
88 N.m (9.0kgf-m, 65 ff-lb)

(A) Extension cap

S3MO026

4) Install the rear differential protector. (If equipped)

5) Install the rear exhaust pipe and muffler.

DS-15
 PROPELLER SHAFT
DRIVE SHAFT SYSTEM

C: INSPECTION 3. RUNOUT OF PROPELLER SHAFT

NOTE: 1) Remove the rear exhaust pipe and muffler.
Do not disassemble propeller shaft. Check the fol- 2) Remove the heat shield cover. (If equipped)
lowing and replace if necessary. 3) Turn the rear wheels by hand to check for
1) Tube surfaces for dents or cracks “runout” of propeller shaft.
2) Splines for deformation or abnormal wear NOTE:
3) Joints for non-smooth operation or abnormal Measure runout with a dial gauge at the center of
noise front and rear propeller shaft tubes.
4) Center bearing for free play, noise or non-
Runout:
smooth operation
Limit 0.6 mm (0.024 in)
5 ) Oil seals for abnormal wear or damage
6) Center bearing for breakage
Check the following points with propeller shaft in-
stalled in vehicle.
1. JOINTS AND CONNECTIONS
1) Remove the rear exhaust pipes and muffler.
2) Remove the heat shield cover. (If equipped)
3) Check for any looseness of yoke flange connect-
ing bolts and center bearing retaining bolts.
2. SPLINES AND BEARING LOCATIONS
1) Remove the rear exhaust pipe and muffler. (A) Propeller shaft
2) Remove the heat shield cover. (If equipped) (B) Dial gauge
3) Turn the propeller shaft by hand to see if abnor-
mal free play exists at splines. Also move yokes to 4. CENTER BEARING FREE PLAY
see if the abnormal free play exists at spiders and
bearings. 1) Remove the rear exhaust pipe and muffler.
2) Remove the heat shield cover. (If equipped)
3) While holding propeller shaft near center bearing
with your hand, move it up and down, and left and
right to check for any abnormal bearing free play.

B3M1604

DS-16
 FRONT AXLE
3. Front Axle
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Jack-up the vehicle, support it with safety
stands, and remove the front wheels.
3) Unlock the axle nut.
14
4) Remove the axle nut using a socket wrench.
CAUTION:
Be sure to loose and retighten axle nut after re-
moving wheel from vehicle. Failure to follow
this rule may damage wheel bearings.
5) Remove the stabilizer link.
G4M0215
6) Remove the disc brake caliper from the housing,
and suspend it from strut using a wire.
DS-17
DRIVE SHAFT SYSTEM
7) Remove the front drive shaft assembly from the
hub. If it is hard to remove, use STs.
ST1 926470000 AXLE SHAFT PULLER
ST2 927140000 AXLE SHAFT PULLER
PLATE
CAUTION:
Be careful not to damage oil seal lip when re-
moving front drive shaft.
When replacing front drive shaft, also replace
inner oil seal.
8) Remove the disc rotor from the hub.
If disc rotor seizes up within hub, drive disc rotor out
by installing an 8-mm bolt in screw hole on the ro-
tor.
u B4M 1670
9) Remove the cotter pin and castle nut which se-
cure tie-rod end to housing knuckle arm.
(A) Cotterpin
(B) Castle nut
(C) Tie-rod
 FRONT AXLE
DRIVE SHAFT SYSTEM

10) Using a puller, remove the tie-rod ball joint from
the knuckle arm.
11) On ABS equipped models, remove the ABS
sensor assembly and harness in advance.
12) Remove the transverse link ball joint from the
housing.
B: INSTALLATION
1) Install the transverse link ball joint to the hous-
ing.
Tightening torque:
49 N-m (5.0 kgf-m, 36 ft-lb)
2) While aligning alignment mark on camber adjust-
ing bolt head, connect the housing and strut.
CAUTION:
Use a new self-locking nut.
Tightening torque:
152 N-m (15.5 kgf-m, 112 ft-lb)
3) Install the ABS sensor on the housing (only ve-
hicle equipped with ABS).
Tightening torque:
32 N-m (3.3 kgf-m, 24 ft-lb)
4 ) Install the disc rotor on the hub.
5) Install the disc brake caliper on the housing.
Tightening torque:
78 N.m (8 kgf-m, 57.9 ft-lb)
6) Install the front drive shaft. <Ref. to DS-32, IN-
STALLATION, Front Drive Shaft.>
7) Connect the stabilizer link.
8) Connect the tie-rod end ball joint and knuckle
arm with a castle nut, and insert the cotter pin into
the tie-rod end.
Castle nut tightening torque:
Tighten to 27.0 N-m (2.75 kgf-m, 19.9 ft-lb),
and tighten further within 60" until cotter pin
hole is aligned with a slot in the nut.
CAUTION:
When connecting, do not hit cap at the bottom
of tie-rod end with hammer.

13) After scribing an alignment mark on camber ad-

justing bolt head, remove bolts which connect
housing and strut, and disconnect the housing from
the strut.

(A) Cotter pin

(B) Castle nut
(C) Tie-rod

1970
-

DS-18
 FRONT AXLE 1
DRIVE SHAFT SYSTEM

9) While depressing brake pedal, tighten the axle C: DISASSEMBLY

nut and lock it securely. 1) Using ST1, support housing and hub securely.
Tightening torque: 2) Attach ST2 to housing and drive hub out.
186 N-m (19 kgf-m, 137 ft-lb) ST1 927060000 HUB REMOVER
ST2 927080000 HUB STAND
CAUTION:
Use a new axle nut.
Always tighten axle nut before installing
wheel on vehicle. If wheel is installed and
comes in contact with ground when axle nut is
loose, wheel bearings may be damaged.
Be sure to tighten axle nut to specified
torque. Do not overtighten it as this may dam-
age wheel bearing.
10) After tightening the axle nut, lock it securely.
I

I G4M0238 1 v
11) Install the wheel and tighten the wheel nuts to
specified torque.
Tightening torque:
90 N.m (9.2 kgf-m, 66.5 ft-lb)
G4M0223
If inner bearing race remains in the hub, remove it
with a suitable tool (commercially available).
CAUTION:
Be careful not to scratch polished area of
hub.
Be sure to install inner race on the side of
outer race from which it was removed.

DS-19
 Y
FRONT AXLE
DRIVE SHAFT SYSTEM

3) Remove the disc cover from the housing. 8) Using ST and a hydraulic press, drive hub bolts
out.
ST 927080000 HUB STAND
CAUTION:
Be careful not to hammer the hub bolts. This
may deform hub.

G4M0225

4) Using a standard screwdriver, remove the outer

and inner oil seals.
CAUTION:
Do not use old oil seals.
G4M0228
5) Using flat bladed screwdriver, remove the snap
ring.
CAUTION:
Be careful not to damage housing at removal.

H4M1001

6) Using STl , support housing securely.

7) Using ST2, press inner race to drive out outer
bearing.
ST1 927400000 HOUSING STAND
ST2 927100000 BEARING PULLER
CAUTION:
Do not remove outer race unless it is faulty.
Discard outer race after removal.
Do not replace inner or outer race separately;
always replace as a unit.

DS-20
 I
FRONT AXLE
DRIVE SHAFT SYSTEM

D: ASSEMBLY 5) Using pliers, install the snap ring in its groove.

1) Attach the hub to ST securely. CAUTION:
ST 927080000 HUB STAND Make sure to install it firmly to groove.

G4M0230

2) Using a hydraulic press, press the new hub bolts 6) Using ST1 and ST2, press the outer oil seal until
into place. it contacts the bottom of housing.
CAUTION: ST1 927410000 OIL SEAL INSTALLER
Be sure to press hub bolts until their seating ST2 927400000 HOUSING STAND
surfaces contact the hub. CAUTION:
NOTE: Do not apply pressure more than 3.92 kN (0.4
Use 12 mm (0.47 in) dia. holes in HUB STAND to ton, 0.4 US ton, 0.4 Imp ton).
prevent bolts from tilting.
3) Clean the dust or foreign particles from inside
the housing.
4) Using ST1 and ST2, press a new bearing into
place.
ST1 927400000 HOUSING STAND
ST2 927100000 BEARING PULLER
CAUTION:
Always press outer race when installing bear-
ing.
Be careful not to remove the plastic lock from
inner race when installing bearing. 7) Using ST1 and ST2, press the inner oil seal until
Charge bearing with new grease when outer it contacts circlip.
race is not removed. ST1 927410000 OIL SEAL INSTALLER
Do not apply pressure more than 30 kN (3.1 ST2 927400000 HOUSING STAND
ton, 2.8 US ton, 3.1 Imp ton). CAUTION:
Specified grease: Do not apply pressure more than 3.92 kN (0.4
ton, 0.4 US ton, 0.4 Imp ton).
SHELL 6459N

G4M0234

8) Invert the ST and housing.

ST 927400000 HOUSING STAND

DS-21
 FRONT AXLE
DRIVE SHAFT SYSTEM

9) Apply the sufficient grease to oil seal lip. E: INSPECTION

Specified grease 1) Inspect the rattle of bearing, give the tires a
SHELL 6459N shake with grasping both the upper and lower sides
of the tire. And also inspect to rotate the wheel
CAUTION: smoothly.
If specified grease is not available, remove
bearing grease and apply Auto Rex A instead.
Do not mix different types of grease.
10) Install the disc cover to housing the three bolts.
Tightening torque:
18 N-m (1.8 kgf-m, 13.0 ft-lb)
11) Attach the hub to ST1 securely.
12) Clean the dust or foreign particles from the pol-
ished surface of hub.
13) Using ST2, press the bearing into hub by driv-
ing inner race.
STI 927080000 HUB STAND 2) Inspect the lean of axis direction using a dial
ST2 927120000 HUB INSTALLER gauge. Replace the hub bearing if the load range
exceed the limitation.
CAUTION:
Do not apply pressure more than 25 kN (2.5 ton, Limit:
2.3 US ton, 2.5 Imp ton). Maximum: 0.05" (0.0020in)

G4M0235

3) Inspect the removed parts for wear and damage.

If defective, replace with new ones.
CAUTION:
If bearing is faulty, replace it as the bearing
set.
Be sure to replace oil seal at every overhaul.

L (A) Replace as a set.

H4M1002C

DS-22
 REAR AXLE I
DRIVE SHAFT SYSTEM

4. Rear Axle 8) Disconnect the parking brake cable end

A: REMOVAL
1. DISC BRAKE
1) Disconnect the ground cable from battery.
2) Jack-up the vehicle, and remove the rear wheel
cap and wheels.
CAUTION:
Be sure to loosen and retighten the axle nut af-
ter removing wheel from vehicle. Failure to fol-
low this rule may damage wheel bearings.
3) Unlock the axle nut. 9) Disconnect the rear stabilizer from rear lateral
4) Remove the axle nut using a socket wrench. link.
5) Return the parking brake lever and loosen the 10) Remove the bolts which secure trailing link as-
adjusting nut. sembly to the rear housing.
CAUTION:
Discard old self-locking nut. Relpace with a
new one.

(1) Parking brake lever

(2) Lock nut S4M0109
(3) Adjusting nut
11) Remove the bolts which secure lateral assem-
6) Remove the disc brake caliper from the back bly to the rear housing.
plate, and suspend it from strut using a piece of CAUTION:
wire. Discard old self-locking nut. Relpace with a
new one.

7) Remove the disc rotor from the hub.

NOTE:
If disc rotor seizes up within hub, drive it out by in-
stalling an 8-mm bolt into bolt hole in disc rotor.

DS-23
 REAR AXLE
DRIVE SHAFT SYSTEM

12) Disengage the BJ from the housing splines, 2. DRUMBRAKE

and remove the rear drive shaft assembly.
If it is hard to remove, use STs.
STI 926470000 AXLE SHAFT PULLER
ST2 927140000 AXLE SHAFT PULLER
PLATE
CAUTION:
Be careful not to damage the oil seal lip when
removing rear drive shaft.
When rear drive shaft is to be replaced, also
replace inner oil seal with a new one.
I
1) Disconnect the ground cable from battery.
2) Jack-up the vehicle, and remove the rear wheel
cap and wheels.
CAUTION:
Be sure to loosen and retighten the axle nut af-
ter removing wheel from vehicle. Failure to fol-
low this rule may damage wheel bearings.
3) Unlock the axle nut.
4) Remove the axle nut using a socket wrench.
5) Return the parking brake lever and loosen the
adjusting nut.

N G4M0247

13) Remove the rear ABS sensor from the back

plate (only vehicle equipped with ABS).
(1) Parking brake lever
(2) Locknut
(3) Adjusting nut

6) Remove the brake drum from hub.

7) If it is difficult to remove brake drum, remove the
adjusting hole cover from the back plate, and then
turn the adjusting screw using a slot-type screw-
driver until the brake shoe separates from the
drum.

(1) ABS sensor

14) Remove the bolts which secure rear housing to

strut, and separate the two.

(1) Back plate

(2) Wheel cylinder
(3) Adjuster ASSY pawls
(4) Adjusting lever
(5) Tightening direction
(6) Push

DS-24
 REAR AXLE
DRIVE SHAFT SYSTEM

NOTE: 11) Remove the bolts which secure trailing link as-
If brake drum is difficult to remove, drive it out by in- sembly to the rear housing.
stalling an 8-mm bolt into bolt hole in brake drum. CAUTION:
I Discard old self-locking nut. Replace with a
new one.

I G4M0243 1

8) Using a flare-net wrench, disconnect the brake

hose from the wheel cylinder. S4M0109 I
CAUTION: 12) Remove the bolts which secure lateral link as-
Cover open end of wheel cylinder to prevent en- sembly to the rear housing.
try of foreign particles. CAUTION:
Discard old self-locking nut. Replace with a
new one.

9) Disconnect the parking brake cable end.

13) Disengage the BJ from the housing splines,

and remove the rear drive shaft assembly.
If it is hard to remove, use STs.
ST1 926470000 AXLE SHAFT PULLER
ST2 927140000 AXLE SHAFT PULLER
PLATE
CAUTION:
Be careful not to damage the oil seal lip when
removing rear drive shaft.
I \
When rear drive shaft is to be replaced, also
(1) Cable end replace inner oil seal with a new one.
I
10) Disconnect the rear stabilizer from the rear lat-
eral link.

I
// U
G4M0247

DS-25
I REAR AXLE
DRIVE SHAFT SYSTEM

14) Remove the rear ABS sensor from the back B: INSTALLATION
plate (only vehicle equipped with ABS).
1. DISC BRAKE
1) Connect the rear housing assembly and strut as-
sembly.
CAUTION:
Use a new self-locking nut.
Tightening torque:
196 N-m (20 kgf-m, 145 ft-16)
2) Fit the BJ (bell joint) to the rear housing splines.
CAUTION:
Be careful not to damage inner oil seal lip.
(1) ABS sensor 3) Connect the rear housing assembly to the lateral
link assembly.
15) Remove the bolts which secure rear housing to
strut, and separate the two. CAUTION:
Use a new self-locking nut.
Tightening torque:
137 N-m (14 kgf-m, 101 ft-16)

4) Connect the rear housing assembly to the trail-

ing link assembly.
CAUTION:
Use a new self-locking nut.
Tightening torque:
113 N-m (1 1.5 kgf-m, 83 ft-16)

S4M0109

5) Connect the rear stabilizer to the rear lateral link.

CAUTION:
Use a new self-locking nut.
Tightening torque:
44 N-m (4.5 kgf-m, 32.5 ft-lb)

DS-26
 REAR AXLE
DRIVE SHAFT SYSTEM

6) Connect the parking brake cable to the parking 13) Install the wheel and tighten the wheel nuts to
brake. specified torque.
7) Install the disc rotor on the rear housing assem- Tightening torque:
bly. 88 N-m (9 kgf-m, 65 ft-lb)
8) Install the disc brake caliper on the back plate.
Tightening torque:
2. DRUMBRAKE
52 N.m (5.3 kgf-m, 38.3 ft-lb) 1) Connect the rear housing assembly and strut as-
sembly.
CAUTION:
Use a new self-locking nut.
Tightening torque:
196 N-m (20 kgf-m, 745 ff-lb)
2) Fit the BJ (bell joint) to rear housing splines.
CAUTION:
Be careful not to damage inner oil seal lip.
3) Connect the rear housing assembly to the lateral
link assembly.
9) Install the rear ABS sensor and brake cable CAUTION:
bracket (only vehicle equipped with ABS). Use a new self-locking nut.
Tightening torque:
137 N.m (74 kgf-m, 101 ff-lb)

(1) ABS sensor

10) Bleed air from brake system. <Ref. to BR-44,

REPLACEMENT, Brake FIuid.>
11) Adjust the parking brake lever stroke by turning
adjuster.
12) Move the brake lever back to apply brakes.
While depressing brake pedal, tighten the axle nut
using a socket wrench. Lock the axle nut after tight-
I.
4) Connect the rear housing assembly to the trail-
ing link assembly.
CAUTION:
Use a new self-locking nut.
Tightening torque:
173 N.m (1 7.5 kgf-m, 83 ff-lb)
ening.
Tightening torque:
786 N-m (79 kgf-m, 737 ft-lb)
CAUTION:
Use a new axle nut.
Always tighten axle nut before installing
wheel on vehicle. If wheel is installed and
comes in contact with ground when axle nut is
loose, wheel bearings may be damaged.
Be sure to tighten axle nut to specified
torque. Do not overtighten it as this may dam- S4M0109
age wheel bearing.

DS-27
I REAR AXLE
DRIVE SHAFT SYSTEM

5) Connect the rear stabilizer to the rear lateral link. C: DISASSEMBLY

CAUTION: 1) Using STI and ST2, remove the hub from the
Use a new self-locking nut. rear housing.
ST 927080000 HUB STAND
Tightening torque:
ST 927420000 HUB REMOVER
44 N-m (4.5 kgf-m, 32.5 ft-lb)
6) Connect the parking brake cable to the parking
brake. I I
7) Clean the brake pipe connection. Using a flare-
nut wrench, connect the brake pipe to the wheel
cylinder.
8) Connect the rear ABS sensor to the back plate
(only vehicle equipped with ABS).

G4M02501

2) Remove the back plate from the rear housing

3) Using a standard screwdriver, remove the outer
and inner oil seals.
CAUTION:
Use new oil seals.
4) Using flat bladed screwdriver, remove the snap
ring.
(1) ABS sensor CAUTION:
Be careful not to damage housing at removal.
9) Connect the parking brake cable to the lever.
IO) Install the brake drum on the rear housing as-
sembly.
11) Bleed air from brake system. <Ref. to BR-44,
REPLACEMENT, Brake FIuid.>
12) Adjust the parking brake lever stroke by turning
adjuster.
13) Move the brake lever back to apply brakes.
While depressing brake pedal, tighten the axle nut
using a socket wrench. Lock the axle nut after tight-
0
ening. H4M1003

Tightening torque: 5 ) Using STI and ST2, remove the bearing by

186 N-m (19 kgf-m, 137 ft-lb) pressing inner race.
CAUTION: STI 927430000 HOUSING STAND
Use a new axle nut. ST2 927440000 BEARING REMOVER
Always tighten axle nut before installing CAUTION:
wheel on vehicle. If wheel is installed and Do not remove bearing unless damaged.
comes in contact with ground when axle nut is Do not re-use bearing after removal.
loose, wheel bearings may be damaged.
Be sure to tighten axle nut to specified
torque. Do not overtighten it as this may dam-
age wheel bearing.
14) Install the wheel and tighten the wheel nuts to
specified torque.
Tightening torque:
90 Nom(9.2 kgf-m, 66.5 ft-lb)
U

G4M0252

DS-28
 REAR AXLE
DRIVE SHAFT SYSTEM

6) Remove the tone wheel bolts and remove the D: ASSEMBLY

tone wheel from the hub (only vehicle equipped 1) Using ST, press the new hub bolt into place.
with ABS).
7 ) Using ST, press the hub bolt out. CAUTION:
ST 927080000 HUB STAND Ensure hub bolt closely contacts hub.
Use a 12 mm (0.47 in) hole in the ST to pre-
CAUTION: vent hub bolt from tilting during installation.
Be careful not to hammer the hub bolts. This ST 927080000 HUB STAND
may deform hub.

30
-
G4M0221
2) Remove the foreign particles (dust, rust, etc.)
from the mating surfaces of hub tone wheel, and in-
stall the tone wheel to hub (only vehicle equipped
with ABS).
CAUTION:
Ensure tone wheel closely contacts hub.
Be careful not to damage tone wheel teeth.

(1)

S4M0370P

(1) Tone wheel

DS-29
 REAR AXLE
DRIVE SHAFT SYSTEM
3) Clean the housing interior completely. Using
STI and ST2, press the bearing into the housing.
ST1 927430000 HOUSING STAND
ST2 927440000 BEARING REMOVER
CAUTION:
Always press iouter race when installing
bearing.
Be careful not to remove plastic lock from in-
ner race when installing bearing.
Charge bearing with new grease when outer
race is not removed.
Do not apply pressure more than 30 kN (3.1
ton, 2.8 US ton, 3.1 Imp ton).
I S4M0266A
4) Using plier, install the snap ring.
CAUTION:
Ensure snap ring fits in groove properly.
(1) Plier
DS-30
5) Using ST1 and ST2, press the outer oil seal unit
it comes in contact with snap ring.
STI 927430000 HOUSING STAND
ST2 927460000 OIL SEAL INSTALLER
CAUTION:
Do not apply pressure more than 3.92 kN (0.4
ton, 0.4 US ton, 0.4 Imp ton).
S4M0267E
(1) Snap ring
6) Invert both ST1 and housing.
7) Using ST2, press the inner oil seal into the hous-
ing until it touches bottom.
ST1 927430000 HOUSING STAND
ST2 927460000 OIL SEAL INSTALLER
CAUTION:
Do not apply pressure more than 3.92 kN (0.4
ton, 0.4 US ton, 0.4 ImD ton).
 REAR AXLE 1
DRIVE SHAFT SYSTEM

8) Using ST1 and ST2, press the sub seal into
place.
ST1 927430000 HOUSING STAND
ST2 927460000 OIL SEAL INSTALLER
CAUTION:
Do not apply pressure more than 3.92 kN (0.4
ton, 0.4 US ton, 0.4 Imp ton).
E: INSPECTION
1) Inspect the rattle and lean of axis direction of the
removed parts as the same procedure of Front Axle
<Ref. to DS-22, INSPECTION, Front Axle.>
The lean of axis direction
Maximum: 0.05" (0.0020in)
2) Inspect the removed parts for wear and damage.
If defective, replace with a new one.
CAUTION:
If a bearing is faulty, replace it as the bearing
set.
Be sure to replace oil seal at every overhaul.

S4M0269A

9) Apply the sufficient grease to oil seal lip.

Specified grease:
SHELL 6459N
CAUTION:
H4M1002C
If specification grease is not available, re-
move bearing grease and apply Auto Rex A in-
(A) Replace as a set.
stead.
Do not mix different types of grease.
10) Install back plate to rear housing.
Tightening torque:
52 N.m (5.3 kgf-m, 38 ft-16)
11) Using ST1 and ST2, press the baring into hub.
ST1 927080000 HUB STAND
ST2 927450000 HUB INSTALLER
CAUTION:
Do not apply pressure more than 25 kN (2.5 ton,
2.3 US ton, 2.5 Imp ton).

DS-31
 FRONT DRIVE SHAFT
DRIVE SHAFT SYSTEM

5. Front Drive Shaft 6 : INSTALLATION

1) Insert the BJ into hub splines.
A: REMOVAL
CAUTION:
1) Disconnect the ground cable from battery.
Be careful not to damage inner oil seal lip and
2) Jack-up the vehicle, support it with safety stands tone wheel.
(rigid racks), and remove the front wheel cap and
wheels. 2) Using STI and ST2, pull the drive shaft into
3) Unlock the axle nut. place.
4) Depress the brake pedal and remove the axle STI 922431000 AXLE SHAFT INSTALLER
nut using a socket wrench. ST2 927390000 ADAPTER
CAUTION: CAUTION:
Be sure to loosen and retighten axle nut after Do not hammer drive shaft when installing it.
removing wheel from vehicle. Failure to follow
this rule may damage wheel bearings.
5 ) Remove the stabilizer link from the transverse
link.
6) Disconnect the transverse link from the housing.
7) Remove the spring pin which secures transmis-
sion spindle to SFJ.
CAUTION:
Use a new spring pin.

3) Tighten the axle nut temporarily.

4) Install the SFJ on transmission spindle and drive
spring pin into place.
CAUTION:
Always use a new spring pin.

8) Remove the front drive shaft assembly. If it is

hard to remove, use STI and ST2.
STI 926470000 AXLE SHAFT PULLER
ST2 927140000 AXLE SHAFT PULLER
PLATE
CAUTION:
Be careful not to damage the oil seal lip and
tone wheel when removing front drive shaft. 5 ) Connect the transverse link to the housing.
When front drive shaft is to be replaced, also Tightening torque (self-locking nut):
replace inner oil seal. 49 N-m (5.0 kgf-m, 36 ft-lb)
CAUTION:
Use a new self-locking nut.
6) Install the stabilizer bracket.

DS-32
 a
FRONT DRIVE SHAFT
DRIVE SHAFT SYSTEM

7) While depressing brake pedal, tighten the axle C: DISASSEMBLY - /

nut to the specified torque. 1) Place alignment marks on the shaft and outer
Tightening torque: race.
186 N.m (1 9 kgf-m, 137 fi-lb)
CAUTION:
Use a new axle nut.
Always tighten axle nut before installing
wheel on vehicle. If wheel is installed and
comes in contact with ground when axle nut is
loose, wheel bearings may be damaged.
Be sure to tighten axle nut to specified
torque. Do not overtighten it as this may dam-
age wheel bearing. 04M0774
I
8) After tightening axle nut, lock it securely.
2) Remove the SFJ boot band and boot.
CAUTION:
Be careful not to damage boot.

B4M0775 1
3) Remove the circlip from SFJ outer race using
screwdriver.

04M0776

4) Remove the SFJ outer race from shaft assem-

bly.
5 ) Wipe off grease.
CAUTION:
The grease is a special grease. Do not confuse
with other greases.

DS-33
I FRONT DRIVE SHAFT
I
DRIVE SHAFT SYSTEM

6) Place alignment mark on free ring and trunnion. 1 1 ) Place the drive shaft in a vise between wooden
bIocks.
CAUTION:
Do not place drive shaft directly in the vise; use
wooden block.
12)Raise the boot band claws by means of screw-
driver and hammer

04M0777

7) Remove the free ring from trunnion.

CAUTION:
Be careful with the free ring position.
8) Place alignment mark on trunnion and shaft.
04M2220B

(A) Boot band claws

13)Cut and remove the boot.

CAUTION:
The boot must be replaced with a new one
whenever it is removed.

04M0778

9) Remove the snap ring and trunnion.

W 14)Thus, disassembly of axle is completed, but BJ

cannot be disassembled.
B4M0779

CAUTION:
Be sure to wrap shaft splines with vinyl tape to
prevent boot from scratches.
IO) Remove the SFJ boot.

DS-34
 FRONT DRIVE SHAFT
DRIVE SHAFT SYSTEM

D: ASSEMBLY 7) Install the boot projecting portion to shaft groove.

CAUTION:
Use specified grease.
,C)
EBJ side:
NTG2218 (Part No. 28093AA000)
SFJ side:
SSG6003 (Part No. 28093TAOOO)
1) Place the EBJ boot and small boot band on the
BJ side of shaft.
CAUTION:
Be sure to wrap shaft splines with vinyl tape to
N B4M 1297C

prevent boot from scratches. (A) Boot

2) Place the drive shaft in a vise. (6) Small boot band
(C) Shaft
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 EBJ.
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 the grease to the shaft.
NOTE:
The inside of the larger end of BJ boot and the boot
qroove shall be cleaned so as to be free from
irease and other substances.
5) Install the boot projecting portion to the EBJ
groove.

(A) EBJ
(6) Lorge boot band
(C) Boot

6) Set the large boot band in place.

DS-35
I FRONT DRIVE SHAFT
DRIVE SHAFT SYSTEM

8) Tighten the boot bands using ST, torque wrench 14) Align alignment marks on free ring and trunnion
and socket flex handle. and install the free ring.
ST 28099AC000 BOOT BAND PLlER CAUTION:
Be careful with the free ring position.

(A) Large boot band

(B) Boot
(C) Torque wrench
(D) Socket flex handle
(E) BJ

Tightening torque:
Large boot band
157 N-m (16.0 kgf-m, 116 ff-lb) or more
Small boot band
733 N.m (73.6 kgf-m, 98 ff-lb) or more
84M0777
9) Place the SFJ boot at the center of shaft.
10) Align alignment marks and install the trunnion 15) A g n alignment marks on shaft and outer race,
on the shaft. and install outer race.

I 04M0778 I 04MQ774

11) Install the snap ring to the shaft.
CAUTION:
Confirm that the snap ring is completely fitted
in the shaft groove.
12) Fill 100 to 110 g (3.53 to 3.88 oz) of specified
grease into the interior of SFJ outer race.
13) Apply a coat of specified grease to the free ring
and trunnion.
16) Install the circlip in the groove on the SFJ outer
race.
CAUTION:
Pull the shaft lightly and assure that the circlip
i s completely fitted in the groove.
17) Apply an even coat of the specified grease 30
to 40 g (1.06 to 1.41 oz) to the entire inner surface
of boot.
18) Install the SFJ boot taking care not to twist it.
CAUTION:
The inside of the larger end of SFJ boot and
the boot groove shall be cleaned so as to be
free from grease and other substances.
When installing SFJ boot, position outer race
of SFJ at center of its travel.

DS-36
 FRONT DRIVE SHAFT
DRIVE SHAFT SYSTEM

19) Put a band through the clip and wind twice in E: INSPECTION
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) SFJ (Shudder-less Freering tripod Joint)
20) Pinch the end of band with pliers. Hold the clip Check seizure, corrosion, damage and excessive
and tighten securely. Play.
2) Shaft
NOTE: Check excessive bending, twisting, damage and
When tightening boot, exercise care so that the air wear.
within the boot is appropriate. 3) EBJ (Bell Joint)
21) Tighten the band by using ST. Check seizure, corrosion, damage and excessive
ST 925091000 BAND TIGHTENING TOOL Play.
NOTE: 4) Boot
Tighten the band until it cannot be moved by hand. Check for wear, warping, breakage or scratches.
5) Grease
Check for discoloration or fluidity.

22) Tap on the clip with the punch provided at the

end of ST.
ST 925091000 BAND TIGHTENING TOOL
CAUTION:
Tap to an extent that the boot underneath is not
damaged.

G4M029C

23) Cut off band with an allowance of about 10 mm

(0.39 in) left from the clip and bend this allowance
over the clip.
CAUTION:
Be careful so that the end of the band is in close
contact with clip.
24) Fix up boot on the EBJ in the same manner.
NOTE:
Extend and retract the SFJ to provide equal grease
coating.

DS-37
 FRONT DRIVE SHAFT BOOTS
DRIVE SHAFT SYSTEM

6. Front Drive Shaft Boots

A: INSPECTION
Inspect the wear, warping, breakage or scratches
for boot. If faulty, repair or replace.
B: REPLACEMENT
1 ) Disconnect the ground terminal from battery.
2) Jack-up the vehicle, support it with safety stands
(rigid racks), and remove the front wheel cap and
wheels.
NOTE:
Do not remove the axle nut.
3) Remove the stabilizer link.
4) Disconnect the transverse link from the housing.
5) Remove the spring pin which secures transmis-
sion spindle to the SFJ.
CAUTION:
Use a new spring pin.

6) Remove the EBJ and SFJ boots from the drive

shaft. <Ref. to DS-33, DISASSEMBLY, Front Drive
Shaft.>
7) Install the EBJ and SFJ boots to the drive shaft.
<Ref. to DS-35, ASSEMBLY, Front Drive Shaft.>
8) Install the SFJ on transmission spindle and drive
spring pin into the place.
CAUTION:
Always use a new spring pin.

9) Connect the transverse link to the housing.

10) Install the stabilizer link.

DS-38
 REAR DRIVE SHAFT
1
DRIVE SHAFT SYSTEM

7. Rear Drive Shaft 5) Remove the axle nut and drive shaft. If it is hard
to remove, use ST1 and ST2.
A: REMOVAL ST1 926470000 AXLE SHAFT PULLER
1) Disconnect the ground cable from battery. ST2 927140000 AXLE SHAFT PULLER
2) Lift-up the vehicle, and remove the rear wheel PLATE
cap and wheels. CAUTION:
CAUTION: Be careful not to damage tone wheel when re-
Be sure to loosen and retighten axle nut after moving rear drive shaft.
removing wheel from vehicle. Failure to follow
this rule may damage wheel bearings.
3) Unlock the axle nut.
4) Remove the DOJ from rear differential using ST.
ST 28099PA100 DRIVE SHAFT REMOVER
NOTE:
The side spline shaft circlip comes out together
with the shaft.

(1) Bolt
(2) DOJ

CAUTION:
Be careful not to damage the side bearing re-
tainer. Always use bolt as shown in figure, as
supporting point for ST during removal.
ST 28099PA100 DRIVE SHAFT REMOVER

(1) Side bearing retainer

DS-39
 REAR DRIVE SHAFT
DRIVE SHAFT SYSTEM

B: INSTALLATION 6) Align the DOJ and differential splines.

1) Insert the BJ or EBJ into the rear hub splines. 7) Push the housing to insert DOJ into the differen-
tial.
CAUTION:
Be careful not to damage tone wheel. NOTE:
Make sure the DOJ is inserted properly.
2) Using ST1 and ST2, pull the drive shaft into the
place.
ST1 922431000 AXLE SHAFT INSTALLER
ST2 927390000 ADAPTER
CAUTION:
Do not hammer drive shaft when installing it.

G3M0050

B4M1690A
3) Tighten the axle nut temporarily.
4) Usina ST, install the DOJ into differential.
ST 28099PA090 SIDE OIL SEAL PROTEC-
TOR
CAUTION:
Discard old self-locking nut. Replace with a
new one.
8) While depressing brake pedal, tighten the axle
nut using a socket wrench.
Tightening torque:
235 N-m (24 kgf-m, 174 ft-lb)
CAUTION:
Use a new axle nut for rear use only.
Always tighten axle nut before installing
wheel on vehicle. If wheel is installed and
comes in contact with ground when axle nut is
loose, wheel bearings may be damaged.
Be sure to tighten axle nut to specified
torque. Do not overtighten it as this may dam-
age wheel bearing.
9) After tightening axle nut, lock it securely.

5) Insert the DOJ spline end into the bore of side oil
seal, and remove ST.
CAUTION:
Do not allow DOJ splines to damage side oil
seal.
ST 28099PA090 SIDE OIL SEAL PROTEC-
TOR

DS-40
 REAR DRIVE SHAFT
DRIVE SHAFT SYSTEM

C: DISASSEMBLY 7) Wipe off the grease and take out balls.

1) Straighten the bent claw of larger end of DOJ CAUTION:
boot. The grease is a special grease (grease for con-
2) Loosen the band by means of screwdriver or pli- stant velocity joint). Do not confuse with other
ers with care of not damaging boot. greases.
NOTE:
Disassemble exercising care not to lose balls (6
PCS).

3) Remove the boot band on the small end of DOJ

boot in the same manner.
4) Remove the larger end of DOJ boot from DOJ 27E
outer race.
5 ) Pry and remove the round circlip located at the (A) Outer race
neck of DOJ outer race with a screwdriver. (6) 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.
IO) Take out the DOJ inner race.
11) Take off the DOJ cage from shaft and remove
DOJ boot.
CAUTION:
G4M0282 I Be sure to wrap shaft splines with vinyl tape to
prevent boot from scratches.
6) Take out the DOJ outer race from shaft assem-
bly. 12) Remove the BJ or EBJ boot in the same proce-
dure as DOJ boot.
13) Thus, disassembly of axle is completed, but BJ
or EBJ is unable to be disassembled.

DS-41
 REAR DRIVE SHAFT
DRIVE SHAFT SYSTEM

D: ASSEMBLY 5) Install the cage, which was previously fitted, to

inner race fixed upon shaft.
CAUTION:
Use specified grease. NOTE:
Fit the cage with the protruded part aligned with the
BJ side (Non-turbo model): track on the inner race and then turn by a half pitch.
Molylex No. 2 (Part No. 723223010)
EBJ side (Turbo model):
NTG 2218 (Part No. 28093AA000)
DOJ side:
VU-3A702 (Yellow) (Part No. 23223GA050)
1) Install the BJ or EBJ boot in specified position,
and fill it with 60 to 70 g (2.12 to 2.47 oz) of speci-
fied grease.
2) Place the DOJ boot at the center of shaft.
B4M0228E
CAUTION:
Be sure to wrap shaft splines with vinyl tape to
(A) inner race
prevent boot from scratches.
(B) Cage
3) Insert the DOJ cage onto shaft.
NOTE: 6) Fill 80 to 90 g (2.82 to 3.17 oz) of specified
Insert the cage with the cut-out portion facing the grease into the interior of DOJ outer race.
shaft end, since the cage has an orientation. 7) Apply a coat of specified grease to the cage
pocket and six balls.
8) Insert six balls into the cage pocket.
9) Align the outer race track and ball positions and
place in the part where shaft, inner race, cage and
balls are previously installed, and then fit outer
race.

6, S4M0376B

(A) Cage
(B) Cut-out portion ~~~
-_
4) Install the DOJ inner race on shaft and fit snap
ring with pliers. B4M0227E

NOTE:
Confirm that the snap ring is completely fitted in the (A) Outer race
shaft groove. (B) Grease

I G4M0285

DS-42
 I
REAR DRIVE SHAFT
DRIVE SHAFT SYSTEM

10) Install the circlip in the groove on the DOJ outer 16) Tap on the clip with the punch provided at the
race. end of ST.
NOTE: ST 925091000 BAND TIGHTENING TOOL
Assure that the balls, cage and inner race are CAUTION:
completely fitted in the outer race of DOJ. Tap to an extent that the boot underneath is not
Exercise care not to place the matched position damaged.
of circlip in the ball groove of outer race.
Pull the shaft lightly and assure that the circlip is
completely fitted in the groove.

G4M0290

17) Cut off the band with an allowance of about 10

4 mm (0.39 in) left from the clip and bend this allow-
G4M0282
ance over the clip.
11) Apply an even coat of the specified grease [20 CAUTION:
to 30 g (0.71 to 1.06 oz)] to the entire inner surface Be careful so that the end of the band is in close
of boot. Also apply grease to shaft. contact with clip.
12) Install the DOJ boot taking care not to twist it.
18) Fix up the boot on the BJ or EBJ in the same
NOTE: manner.
The inside of the larger end of DOJ boot and the
NOTE:
boot groove shall be cleaned so as to be free from
Extend and retract the DOJ to provide equal grease
grease and other substances.
coating.
When installing DOJ boot, position outer race of
DOJ at center of its travel. E: INSPECTION
13) Put a band through the clip and wind twice in Check the removed parts for damage, wear, corro-
alignment with band groove of boot. sion etc. If faulty, repair or replace.
CAUTION: 1) DOJ (Double Offset Joint)
Use a new band. Check seizure, corrosion, damage, wear and ex-
cessive play.
14) Pinch the end of band with pliers. Hold the clip
and tighten securely. 2) Shaft
Check excessive bending, twisting, damage and
NOTE: wear.
When tightening boot, exercise care so that the air 3) BJ (Bell Joint) and EBJ (Eightball Bell Joint)
within the boot is appropriate. Check seizure, corrosion, damage and excessive
15) Tighten the band by using ST. Play.
ST 925091000 BAND TIGHTENING TOOL 4) Boot
NOTE: Check for wear, warping, breakage or scratches.
Tighten the band until it cannot be moved by hand. 5) Grease
Check for discoloration or fluidity.

G4M0289
 REAR DRIVE SHAFT BOOTS
DRIVE SHAFT SYSTEM
~ __

8. Rear Drive Shaft Boots 7) Remove the DOJ from rear differential using ST.
ST 28099PA100 DRIVE SHAFT REMOVER
A: INSPECTION NOTE:
Inspect the wear, warping, breakage or scratches The side spline shaft circlip comes out together
for boot. If faulty, repair or replace. with the shaft.
B: REPLACEMENT
1) Disconnect the ground terminal from battery.
2) Lift-up the vehicle, and remove the rear wheel
cap and wheels.
NOTE:
Axle nut need not be removed.
3) Remove the ABS sensor clamps and parking
brake cable bracket.
4) Disconnect the stabilizer link from the lateral link.
5) Remove the bolts which secure lateral link as-
sembly to the rear housing.
6) Remove the bolts which secure trailing link as- (1) Bolt
sembly to the rear housing. (2) DOJ

CAUTION:
Be careful not to damage the side bearing re-
tainer. Always use bolt as shown in figure, as
supporting point for ST during removal.
ST 28099PA100 DRIVE SHAFT REMOVER

(1) Side bearing retainer

8) Remove the DOJ and BJ or EBJ boots from the

drive shaft. <Ref. to DS-41, DISASSEMBLY, Rear
Drive Shaft.>
9) Install the DOJ and BJ or EBJ boots to the drive
shaft. <Ref. to DS-42, ASSEMBLY, Rear Drive
Shaft.>

DS-44
 REAR DRIVE SHAFT BOOTS
DRIVE SHAFT SYSTEM

10) Using ST, install the DOJ into differential.
ST 28099PA090 SIDE OIL SEAL PROTEC-
TOR
14) Connect the rear housing assembly to the trail-
ing link assembly, and tighten the self-locking nut.
15) Connect the rear housing assembly to the lat-
era1 link assembly, and tighten the self-locking nut.
16) Connect the stabilizer link to the lateral link.
17) Install the ABS sensor clamps and parking
brake cable bracket.

11) Insert the DOJ spline end into the bore of side
oil seal, and remove ST.
CAUTION:
Do not allow DOJ splines to damage side oil
seal.
ST 28099PA090 SIDE OIL SEAL PROTEC-
TOR

12) Align the DOJ and differential splines.

13) Push the housing to insert DOJ into the differ-
ential.
NOTE:
Make sure the DOJ is inserted properly.

I G3M005C

CAUTION:
Discard old self-locking nut. Replace with a
new one.

DS-45
 GENERAL DIAGNOSTIC TABLE
DRIVE SHAFT SYSTEM

9. General Diagnostic Table

A:INSPECTION
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
NOTE:
Vibration is caused by propeller shaft dur-
ing operation and is transferred to vehicle
body. Generally vibration increase in pro-
portion to vehicle speed.
2. Tapping when starting and noise
while cruising, Cawed by Propeller
-
shaft.
3. Front wheel shimmy
4. Wander or pulling
(1) Worn or damaged universal joint. Replace.
(2) Unbalanced propeller shaft due to Replace.
bend or dent,
(3)Loose installation of propeller shaft, Retighten.
(4) Worn or damaged center bearing and Replace.
damaaed center mountina
I " rubber.
(1) Worn or damaged universal joint. Replace.
(2) Worn spline of sleeve yoke. Replace.
(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.
(1) Worn or damaged hub bearing Repair or replace.
(1) Worn or damaged hub bearing Repair or replace.

DS-46
ABS

ABS
Page
1. General Description .................................................................................... 2
2. ABS Control Module and Hydraulic Control Unit (ABSCM&H/U)................7
3. ABS Sequence Control ............................................................................. 11
4. Front ABS Sensor ..................................................................................... 14
5. Rear ABS Sensor ...................................................................................... 18
6. Front Tone Wheel ..................................................................................... 21
7. Rear Tone Wheel ...................................................................................... 22
8. G Sensor ................................................................................................... 23
 GENERAL DESCRIPTION
ABS

1. General Description
A: SPECIFICATIONS
Item Standard or remarks
Front 0.3 - 0.8 mm (0.012 - 0.031 in)
ABS sensor gap
Rear 0.7 - 1.2 mm (0.028- 0.047 in)

ABS sensor resistance

I Front I 1.25k0.25 kR I
ABS sensor
I Rear I 1.Of0.2 k!2 I
RH White
Front
- LH Yellow
Marks of the harness
RH Light blue
Rear
LH Brown

ABS control module and hydraulic control unit (ABSCM&H/U) AT cc

marks MT CD

ABS-2
 GENERAL DESCRIPTION
ABS

B: COMPONENT
1. SENSOR

El
/-----Q

BROOOl

(1) G sensor (4) Rear ABS sensor LH Tightening torque: N.m (kgf-m, fi-lb)
(2) Rear ABS sensor RH (5) Front ABS sensor LH T1: 7.4 (0.75, 5.4)
(3) ABS spacer (6) Front ABS sensor RH T2: 32 (3.3,24)

ABS-3
I
GENERAL DESCRIPTION
ABS

2. ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT (ABSCM&H/U)

(1) Stud bolt (6) Front-RH outlet Tightening torque: N.m (kgf-m, ft-lb)
(2) Damper (7) Primary inlet T1: lS(1.8, 13.0)
(3) ABS control module and hydraulic (8) Rear-LH outlet T2: 29 (3.0, 21.7)
control unit (9) Rear-RH outlet T3: 32 (3.3.24)
(4) Front-LH outlet (10) Bracket
(5) Secondary inlet

ABS-4
 GENERAL DESCRIPTION
1
ABS

C: CAUTION
Wear working clothing, including a cap, protec-
tive goggles, and protective shoes during opera-
tion.
Remove contamination including dirt and corro-
sion before removal, installation or disassembly.
Keep the disassembled parts in order and pro-
tect them from dust or dirt.
Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary re-
moval, installation, disassembly, and replacement.
Be careful not to burn your hands, because each
part in the vehicle is hot after running.
Be sure to tighten fasteners including bolts and
nuts to the specified torque.
Place shop jacks or safety stands at the specified
points.
Before disconnecting electrical connectors of
sensors or units, be sure to disconnect negative
terminal from battery.

ABS-5
 GENERAL DESCRIPTION
ABS

D: PREPARATION TOOL
1. SPECIAL TOOLS

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

24082AA150 ;ARTRIDGE rroubleshootingfor electrical systems.
(New apopted tool)

02M3876
22771AA030 SELECT MONITOR Troubleshooting for electrical systems.
<IT b English: 22771AA030 (Without printer)
German: 22771AA070 (Without printer)
French: 22771AA080 (Without printer)
Spanish: 22771AA090 (Without printer)

02M3877

2. GENERAL PURPOSE TOOLS

TOOL NAME REMARKS

Circuit tester Used for measuring resistance, voltage and ampere.
Pressure gauge Used for measuring oil pressure.
Oscilloscope Used for measuring sensor.

ABS-6
I ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT (ABSCM&H/U)
ta
ABS

2. ABS Control Module and Hy- 8) Remove the ABSCM&H/U from engine compart-
ment.
draulic Control Unit (AB- CAUTION:
SCM&H/U) ABSCM&H/U cannot be disassembled. Do
not attempt to loosen the bolts and nuts.
A: REMOVAL Do not drop or bump the ABSCM&H/U.
1) Disconnect the ground terminal from battery. Do not turn the ABSCM&H/U upside down or
2) Remove the air intake duct from engine compart- place it on its side.
ment to facilitate removal of ABSCM&H/U. Be careful to prevent foreign particles from
3) Use an air gun to get rid of water around the AB- getting into the ABSCM&H/U.
SCM&H/U. Apply a coat of rust-preventive wax (Nippeco
CAUTION: LT or GB) to bracket attaching bolt after tight-
The contact will be insufficient if the terminal ening.
gets wet. Do not pull the harness when disconnecting
4) Pull off the lock of the ABSCM&H/U connector to connector.
remove it.

/- B4M1222

5) Disconnect the connector from ABSCM&H/U.

CAUTION:
Be careful not to let water or other foreign mat-
ter contact the ABSCM&H/U terminal.
6) Unlock the cable clip.
7) Disconnect the brake pipes from ABSCM&H/U.
CAUTION:
Wrap the brake pipes with vinyl bag to avoid
spilling brake fluid on vehicle body.

ABS-7
 ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT (ABSCM&H/U)
ABS

B: INSTALLATION
1) Install the ABSCM&H/U bracket.
Tightening torque:
32 N-m (3.3 kgf-m, 24 ff-16)
2) Install the ABSCM&H/U.
Mark Model
CAUTION:
Confirm that the specifications of the AB- cc AT
SCM&H/U conforms to the vehicle specifica- I CD I MT I
tions.
Tightening torque:
18 N.m (1.8 kgf-m, 13.0 ff-16)

I /- 04M1222
3) Connect the brake pipes to their correct AB-
SCM&H/U connections.
Tightening torque:
15 N.m (1.5 kgf-m, 10.8 ft-lb)
4) Using cable clip, secure the ABSCM&H/U har-
ness to bracket.
5 ) Connect the connector to the ABSCM&H/U.
CAUTION:
Be sure to remove all foreign matter from in-
side the connector before connecting.
Ensure that the ABSCM&H/U connector is se-
curely locked.
6) Install the air intake duct.
Non-turbo model:
<Ref. to IN(S0HC)-7, INSTALLATION, Air Intake
Duct.>
Turbo model:
<Ref. to IN(D0HC TURBO)-8, INSTALLATION, Air
Intake Duct.>
7) Bleed air from the brake system. <Ref. to BR-46,
Air Bleeding.>
(1) Mark
1. CHECKING THE HYDRAULIC UNIT ABS
OPERATION BY PRESSURE GAUGE
1) Lift-up the vehicle and remove wheels.
2) Disconnect the air bleeder screws from the FL
and FR caliper bodies.
3) Connect two pressure gauges to the FL and FR
caliper bodies.
CAUTION:
Pressure gauges used exclusively for brake
fluid must be used.
Do not employ the pressure gauge previously
used for transmission since the piston seal is
expanded and may lead to malfunction of the
brake.
NOTE:
Wrap a sealing tape around the pressure gauge.

I R4M 1797

ABS-8
 I
ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT (ABSCM&H/U)
ABS

2. CHECKING THE HYDRAULIC UNIT ABS

OPERATION WITH BRAKE TESTER
1) In the case of AWD AT Non-turbo vehicles, in-
stall a spare fuse with the FWD connector in the
main fuse box to simulate FWD vehicles.

Front wheel Rear wheel

3,432 kPa 3,432 kPa
Initial value (35 kgf/cm2,498 (35 kgf/cm2,498
Psi) Psi)
When 490 kPa 490 kPa
decom- (5 kgf/cm2, 71 psi) (5 kgf/cm2,71 psi) (1) Main fuse box
pressed or less or less (2) FWD connector
3,432 kPa 3,432 kPa
2) Prepare for operating the ABS sequence control.
When (35 kgf/cm2,498 (35 kgf/cm2,498
compressed Psi)
<Ref. to ABS-I 1, ABS Sequence Control.>
Psi)
or more or more 3) Set the front wheels or rear wheels on the brake
~

tester and set the select lever’s position at “neu-

8) Remove the pressure gauges from FL and FR t ral”.
caliper bodies.
9 ) Remove the air bleeder screws from the RL and
RR caliper bodies.
10) Connect the air bleeder screws to the FL and
FR caliper bodies.
11) Connect two pressure gauges to the RL and
RR caliper bodies.
12) Bleed air from the pressure gauges and the FL
and FR caliper bodies.
13) Perform the ABS sequence control.
<Ref. to ABS-I 1, ABS Sequence Control.>
14) When the hydraulic unit begins to work, at first
the RR side performs decompression, holding, and
compression, and then the RL side performs de-
compression, holding, and compression.
15) Read the values indicated on the pressure
gauges and check if they meet the standard value.
16) After checking, remove the pressure gauges
from caliper bodies.
17) Connect the air bleeder screws to RL and RR
caliper bodies.
18) Bleed air from the brake line.

(1) Brake tester

4) Operate the brake tester.

5) Perform ABS sequence control.
<Ref. to ABS-1 1, ABS Sequence Control.>

ABS-9
 ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT (ABSCM&H/U)
ABS

6) Hydraulic unit begins to work; and check the fol-

lowing working sequence.
(1) The FL wheel performs decompression,
holding, and compression in sequence, and
subsequently the FR wheel repeats the cycle.
(2) The RR wheel performs decompression,
holding, and compression in sequence, and
subsequently the RL wheel repeats the cycle.
7) Read the values indicated on the brake tester
and check if the fluctuation of values, when decom-
pressed and compressed, meet the standard val-
ues.
Front wheel Rear wheel
981 N 981 N
Initial value
(100 kgf, 221 Ib)

1 I I
(100 kgf, 221 Ib)

I Empressed

When
(50 ~ ~ 0 l y O l b ) 5
or less
981 N
(0:;1yO
or less
981 N
Ib)

(100 kgf, 221 Ib) (100 kgf, 221 Ib)

compressed
or more or more

8 ) After checking, also check if any irregular brake

pedal tightness is felt.

ABS-1 0
 ABS SEQUENCE CONTROL m
ABS

3. ABS Sequence Control 2. ABS SEQUENCE CONTROL WITH SE-

A: OPERATION
1) Under the ABS sequence control, after the hy-
draulic unit solenoid valve is driven, the operation
of the hydraulic unit can be checked by means of
the brake tester or pressure gauge.
2) ABS sequence control can be started by diagno-
sis connector or select monitor.
1. ABS SEQUENCE CONTROL WITH DIAG-
NOSIS CONNECTOR
1) Connect the diagnosis terminals to terminals No.
3 and No. 6 of the diagnosis connector beside driv-
er’s seat heater unit.
& (1) When using the brake tester, depress the
BR0094
(1) Diagnosis connector
(2) Diagnosis terminals
’ (3) 3 terminal
(4) 6 terminal
2) Set the speed of all wheels at 4 km/h (2 MPH) or
less.
3) Turn the ignition switch OFF.
4) Within 0.5 seconds after the ABS warning light
goes out, depress the brake pedal and hold it im-
mediately after the ignition switch is turned to ON.
CAUTION:
Do not depress the clutch pedal.
NOTE:
When the ignition switch is set to on, the brake
pedal must not be depressed.
Engine must not operate.
5 ) After completion of ABS sequence control, turn
the ignition switch OFF.
LECT MONITOR
NOTE:
In the event of any trouble, the sequence control
may not be operative. In such a case, activate the
sequence control, referring to “ABS SEQUENCE
CONTROL WITH DIAGNOSIS CONNECTOR’’.
<Ref. to ABS-11, ABS SEQUENCE CONTROL
WITH DIAGNOSIS CONNECTOR, ABS Sequence
Control.>
When the diagnosis terminal is connected to the
diagnosis connector, the sequence control will not
operate.
1) Connect the select monitor to data link connector
under the driver’s seat instrument panel lower cov-
er.
2) Turn the ignition switch ON.
3) Turn the select monitor switch ON.
4) Put the select monitor to “BRAKE CONTROL”
mode.
5 ) When “Function check sequence’’ is selected,
‘ABS sequence control’ will start.
6) The message ’Press Brake Pedal Firmly’ is dis-
played as follows:
brake pedal with braking force of 981 N (100 kgf,
221 Ib).
(2) When using the pressure gauge, depress
the brake pedal so as to make the pressure
gauge indicate 3,432 kPa (35 kg/cm2, 498 psi).
CAUTION:
Do not depress the clutch pedal.
7) When the message “Press YES’’ is displayed,
press the YES key.
8) Operation points will be displayed on the select
monitor.

ABS-1 1
 ABS SEQUENCE CONTROL
ABS

3. CONDITIONS FOR ABS SEQUENCE CONTROL

4 km/h Unit: second

- 10 km/h (6 MPH) or less

Speed of all wheels

Terminal No.3 and No.6

Operational LOW I I I
guide line of ON
sequence
control
Ignition key switch
OFF J 1.5 _IA j
I

j 1.5 1.4
w-v
i 1.0 i 1.4 Ljl
-1-
0.6
I
I
I
ABS warning light I
I

I ' I 1 I I 1 I
HIGH
Stop light switch
LOW
I
;
Withinm j I
I
!
I
1
!
1
1
!
I
I
!
I , I
I 1 I
AT ABS signal I1 1
I 1I
I I 1 I I 1 I I

I 1 I I
I I
I 1 I
I 1 I
II 1
1 I

OFF ! I 1 I

I 1 I
FL inlet valve ON j I1 1
1
I
OFF
Operational FR outlet valve ON j I
I
1
1
I
I
OFF' 1
I
I 1 I
.I 1. I
pattern of ON I I
I
1
1
I 1 I I I
I
I 1 I
FR inlet valve
sequence
control
I
I
I 1
1
I
I
1
1
I

I I 1
I
I I
I
I
I

RR outlet valve ON
OFF
j I
I
1
1
I
I
l
1
l
1
I
I
I
1I .
; 1 1 I 1 I
I
I 1
,
I I

RR inlet valve ON I I
I
1
1
I
I
1
1
I
I
I
I

I , Point A ~

I*
I 1
I
I
I
1
1
I
I
I
1
I
I
I
1
I
1
1
1
1
1
I
I
I
I
I
I
I
. .
I
I
I
I
I
I
I
1
1
1
1
1
1
1
I
I
I
I
I
I
I
I
I
I
I
I
I
I
n
I

Operational Pressure of master cylinder !

pressure of Pressure of FL wheel cylinder !
Pressure of FR wheel cvlinder !
sequence Pressure of RR wheel c h d e r l !
control IPressure of RL wheel cilinderl j / II
I
I
,
I
I .I
.I ,
I
I
I
. I
W
L
I I I
I
1
1
I
I
1
1
I
I
I
I
1
,
I
I i I B4M1001A
NOTE:
When the select monitor is used, control operation starts at point A. The patterns from IGN key ON to the
point A show that operation is started by diagnosis connector.
HIGH means high voltage.
LOW means low voltage.

ABS-I 2
 ABS SEQUENCE CONTROL
ABS
~~ ~

4. CONDITIONS FOR COMPLETION OF

ABS SEQUENCE CONTROL
When the following conditions develop, the ABS
sequence control stops and ABS operation is re-
turned to the normal control mode.
1) When the speed of at least one wheel reaches
10 km/h (6 MPH).
2) When terminal No. 3 or No. 6 are separated from
diagnosis terminals. (When the select monitor is
not used.)
3) When the brake pedal is released during se-
quence control and the braking lamp switch is set
to OFF.
4) When the brake pedal is depressed after the ig-
nition key is turned to ON, and before ABS warning
light goes out. (When the select monitor is not
used.)
5 ) When the brake pedal is not depressed after the
ignition key is turned to ON, and within 0.5 seconds
after ABS warning light goes out. (When the select
monitor is not used.)
6) After completion of the sequence control.
7) When malfunction is detected. (When the select
monitor is used.)

ABS-1 3
 FRONT ABS SENSOR
ABS

4. Front ABS Sensor
A: REMOVAL
1) Disconnect the ground terminal from battery.
2) Jack-up the vehicle, support it with rigid racks,
and remove the wheel.
3) Disconnect the front ABS sensor connector lo-
cated next to the front strut mounting house in en-
gine compartment.
4) Remove the bolts which secure sensor harness
to strut.
6) Remove the bolts which secure front ABS sen-
sor to housing, and remove the front ABS sensor.
CAUTION:
Be careful not to damage the pole piece locat-
ed at tip of the sensor and teeth faces during re-
moval.
Do not pull the sensor harness during remov-
ai.

B4M2209

5 ) Remove the bolts which secure sensor harness

to body.

(1) To front ABS sensor connector

(2) Bracket

ABS-14
 FRONT ABS SENSOR 1
ABS

B: INSTALLATION 3) Place a thickness gauge between the ABS sen-

sor's and tone wheel's tooth face. After standard
1) Temporarily install the front ABS sensor on
clearance is obtained over the entire perimeter,
housing.
tighten the ABS sensor on housing to specified
CAUTION: torque.
Be careful not to strike the ABS sensor's pole
piece and tone wheel's teeth against adjacent ABS sensor standard clearance:
metal parts during installation. 0.3 - 0.8 mm (0.012 -
0.031 in)
Tightening torque:
32 N-m (3.3 kgf-m, 24 ft-16)

1
84M220E

2) Install the front ABS sensor on strut and wheel

apron bracket.
Tightening torque: CAUTION:
32 N-m (3.3 kgf-m, 24 ft-16) Check the marks on the harness to make sure
that no distortion exists.
RH: White
LH: Yellow
NOTE:
If the clearance is outside specifications, readjust.
4) After confirmation of the ABS sensor clearance,
connect the connector to ABS sensor.
5) Install the wheel.
6) Connect the battery ground terminal to battery.
1728C
I

(1) To front ABS sensor connector

(2) Bracket

ABS-15
 FRONT ABS SENSOR
ABS

C: INSPECTION 2) Measure the distance “B” between the surface

where front axle housing meets the ABS sensor,
1. ABS SENSOR and the tone wheel.
1) Check the pole piece of the ABS sensor for for- NOTE:
eign particles or damage. If necessary, clean the Measure so that the gauge touches the tone wheel
pole piece or replace the ABS sensor. teeth top.
2) Measure the ABS sensor resistance.

B4M0248
(1) Axle housing
Terminal No. Standard (2) Tone wheel
1 and2 1.25f0.25 kQ
3) Find the gap between the ABS sensor pole face
and the surface of the tone wheel teeth by putting
the measured values in the formula below and cal-
culating.
ABS sensor clearance = B - A
ABS sensor standard clearance:
0.3 - 0.8 mm (0.012 - 0.031 in)
NOTE:
If the clearance is outside specifications, readjust.

A
A

B4M2482A

ABS-I 6
 1
FRONT ABS SENSOR
ABS

3. OUTPUT VOLTAGE D: ADJUSTMENT

Adjust the gap using spacer (Part No. 26755A000).
Output voltage can be checked by the following
method. Install a resistor and condenser, then ro-
tate the wheel about 2.75 km/h (2 MPH) or equiva-
lent.
NOTE:
Regarding terminal No., please refer to item 1. ABS
SENSOR.

+60 mV

-60

Standard output voltage:

0.12 - 1 v
(When it is 20 Hz) 1
Oscilloscope

_-
_-
LL --
--
r

ABS-1 7
 REAR ABS SENSOR
ABS

5. Rear ABS Sensor B: INSTALLATION

A: REMOVAL
1) Disconnect the ground terminal from battery.
2) Jack-up the vehicle, suppofl it with rigid racks,
and remove the wheel.
3) Remove the rear seat and disconnect the rear
ABS sensor connector.
4) Remove the rear sensor harness bracket from
rear trailing link and bracket.
5) Remove the rear ABS sensor from back plate.
1) Temporarily install the rear ABS sensor on back
plate.
CAUTION:
Be careful not to strike the ABS sensor's pole
piece and tone wheel's teeth against adjacent
metal parts during installation.

(1) Rear ABS sensor

link.
(1) Rear ABS sensor
Tightening torque:
32 N-m (3.3 kgf-m, 24 ff-lb)

(1) Rear sensor harness

(2) Trailing link

ABS-I 8
 REAR ABS SENSOR
ia
ABS

3) Place a thickness gauge between the ABS sen- C: INSPECTION

sor’s and tone wheel’s tooth face. After standard
clearance is obtained over the entire perimeter, 1. ABS SENSOR
tighten the ABS sensor on rear arm to specified 1) Check the pole piece of the ABS sensor for for-
torque. eign particles or damage. If necessary, clean the
ABS sensor standard clearance: pole piece or replace the ABS sensor.
0.7- f.2mm(0.028-00.047in) 2) Measure the ABS sensor resistance.
Tightening torque:
32 N.m (3.3 kgf-m, 24 ff-lb) I
CAUTION:
Check the marks on the harness to make sure
that no distortion exists.
RH: White
LH: Yellow
NOTE:
If the clearance is outside specifications, readjust.
4) After confirmation of the ABS sensor clearance,
connect the connector to ABS sensor. Terminal No. Standard
5) Connect the battery ground terminal to battery.
~~~~ ~

CAUTION:
If resistance is outside the standard value, re-
place the ABS sensor with a new one.
Check the marks on the harness to make sure
that no distortion exists.
RH: Light blue
LH: Brown
NOTE:
Check the ABS sensor cable for discontinuity. If
necessary, replace with a new one.

ABS-I 9
 REAR ABS SENSOR

2. SENSORGAP 3. OUTPUT VOLTAGE

Clearances (sensor gaps) should be measured one Output voltage can be checked by the following
by one to ensure the tone wheel and speed sensor method. Install a resistor and condenser, then ro-
are installed correctly. tate the wheel about 2.75 km/h (2 MPH) or equiva-
NOTE: lent.
If clearance is narrow, adjust by using the spacer NOTE:
(Part No. 26755AA000). Regarding terminal No., please refer to item 1. ABS
If clearance is wide, check the outputted voltage SENSOR.
then replace the ABS sensor or tone wheel if the
outputted voltage is outside the specification. +60 mV

ABS sensor clearance:

0.7 -7.2 mm (0.028 - 0.047 in) -60 mV

Tone wheel 1 Standard output voltage:

0.12 - 1 v
--E=
(When it is 20 Hz)
Oscilloscope

%nsor gap BR0002 To terminal

To terminal

H4M1141P

D: ADJUSTMENT
Adjust the gap using spacer (Part No.
26755AA000).

ABS-20
 FRONT TONE WHEEL
PI
ABS

6. Front Tone Wheel

A: REMOVAL
Refer to Front Drive Shaft, because the front tone
wheel is integrated with front drive shaft.
<Ref. to DS-32, REMOVAL, Front Drive Shaft.>
B: INSTALLATION
Refer to Front Drive Shaft, because the front tone
wheel is integrated with front drive shaft.
<Ref. to DS-32, INSTALLATION, Front Drive
Shaft.>
C: INSPECTION
Visually check the tone wheels teeth (44 pieces) for
cracks or dents. If necessary, replace the tone
wheel with a new one.
NOTE:
Replace the BJ assembly with a new one as a sin-
gle unit if there is any defect found on the tone
wheel, since it is unitized with the BJ assembly of
drive shaft.

ABS-21
 REAR TONE WHEEL
ABS

7. Rear Tone Wheel

A: REMOVAL
Refer to Rear Drive Shaft, because the rear tone
wheel is integrated with hub.
<Ref. to DS-23, REMOVAL, Rear Axle.>
B: INSTALLATION
Refer to Rear Drive Shaft, because the rear tone
wheel is integrated with hub.
<Ref. to DS-26, INSTALLATION, Rear Axle.>
C: INSPECTION
Visually check the tone wheels teeth (44 pieces) for
cracks or dents. If necessary, replace the tone
wheel with a new one.

ABS-22
 1
G SENSOR
ABS

8. GSensor B: INSTALLATION
1) Install in the reverse order of removal.
A: REMOVAL CAUTION:
1) Disconnect the ground terminal from battery. Do not drop or bump the G sensor.
Tightening torque (G sensor):
32 N.m (3.3 kgf-m, 24 ft-lb)

2) Remove the console cover.

<Ref. to El-41, Console Box.>
3) Disconnect the connector from G sensor.
4) Remove the G sensor from body.
CAUTION:
Do not drop or bump the G sensor.

ABS-23
 G SENSOR
ABS

C: INSPECTION
Step Check Yes No
CHECK SUBARU SELECT MONITOR. Do you have the SUBARU 30 to step 5. Go to step 2.
SELECT MONITOR?
I CHECK G SENSOR. Is the voltage 2.3k0.2 V when 30 to step 3. Replace G sensor.
1)Turn the ignition switch to OFF. G sensor is horizontal?
2)Remove the G sensor from vehicle.
3)Connect the connector to G sensor.
4)Turn the ignition switch to ON.
5)Measure the voltage between G sensor con-
nector terminals.
Connector & terminal:
(8292) NO.2 (+) - NO. 3 (-)
I CHECK G SENSOR. Is the voltage 3.9k0.2 V when
Measure the voltage between G sensor con- G sensor is inclined forwards
nector terminals. to go"?
Connector & terminal:
(8292) NO.2 (+) - NO. 3 (-)
I CHECK G SENSOR.
Measure the voltage between G sensor con-
nector terminals.
G sensor is inclined backwards
to go"?
nd/
Is the voltage 0.7f0.2 V when 3 sensor is nor- Replace G sensor.

Connector & terminal:

(8292) NO.2 (+) - NO. 3 (-)
I CHECK G SENSOR. Is the indicated reading 30 to step 6. Replace G sensor.
1)Turn the ignition switch to OFF. 2.3f0.2 V when the vehicle is
2)Connect the select monitor connector to data in horizontal position?
link connector.
3)Turn the 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.
I CHECK G SENSOR. Is the indicated reading
1)Remove the console box. 3.9f0.2 V when G sensor is
2)Remove the G sensor from vehicle. (Do not inclined forwards to go"?
disconnect connector.)
3)Read the select monitor display.
CHECK G SENSOR. Is the indicated reading 3 sensor is nor- Replace G sensor.
Read the select monitor display. 0.7k0.2 V when G sensor is nal.
inclined backwards to go"?

ABS-24
ABS (DIAGNOSTICS)

ABS
Page
1. Basic Diagnostic Procedure ........................................................................ 2
2. Check List for Interview............................................................................... 6
3. General Description .................................................................................... 9
4. Electrical Components Location................................................................ 12
5. Control Module I/O Signal ......................................................................... 14
6. Subaru Select Monitor............................................................................... 18
7. Read Diagnostic Trouble Code (DTC) ...................................................... 20
8. Inspection Mode ........................................................................................ 21
9. Clear Memory Mode.................................................................................. 22
10. ABS Warning Light Illumination Pattern .................................................... 23
11. List of Diagnostics Trouble Code (DTC) ................................................... 24
12. Diagnostics Chart with Diagnosis Connector ............................................ 29
13. Diagnostics Chart with Subaru Select Monitor .......................................... 96
14. General Diagnostics Table ...................................................................... 183
I BASIC DIAGNOSTIC PROCEDURE
ABS (DIAGNOSTICS)

1. Basic Diagnostic Procedure

A: PROCEDURE
1. WITHOUT SUBARU SELECT MONITOR
CAUTION:
Remove foreign matter (dust, water, etc.) from the ABSCM&H/U connector during removal and instal-
lation.
NOTE:
To check harness for broken wires or short circuits, shake it while holding it or the connector.
When the ABS warning light illuminates, read and record the diagnostic trouble code (DTC) indicated by
ABS warning light.

Step Check Yes No

I CHECK PRE-INSPECTION. Is unit that might influence the Go to step 2. Repair or replace
1)Ask the customer when and how the trouble ABS problem normal? each unit.
occurred using interview checklist. <Ref. to
ABS-6, Check List for Interview.>
2)Before performing diagnosis, inspect the unit
which might influence the ABS problem. <Ref.
to ABS-9, INSPECTION, General Descrip-
tion.>
! CHECK INDICATION OF DIAGNOSTIC Is the diagnostic trouble code Go to step 3. Inspect using diag
TROUBLE CODE (DTC). nostic chart for
Calling up diagnostic trouble code (DTC). ABS warning light
<Ref. to ABS-20, Read Diagnostic Trouble failure.cRef. to
Code (DTC).> ABS-29, Diagnos-
tics Chart with
Diagnosis Con-
nector.>
NOTE:
Call up diagnostic
trouble code (DTC]
again after inspect.
ing ABS warnins
light. <Ref. to ABS.
20, Read Diagnos
tic Trouble Code
(DTC).>
I CHECK DIAGNOSTIC TROUBLE CODE Is only the start code issued? Go to step 4. Go to step 5.
(DTC).
NOTE:
Record all diagnostic trouble codes (DTC).
I PERFORM THE GENERAL DIAGNOSTICS. Is only the start code issued? IComplete the Go to step 5.
1)Inspect using “General Diagnostics Table”. diagnosis.
<Ref. to ABS-I 83, General DiagnosticsTable.>
2)Perform the clear memory mode. <Ref. to
ABS-22, WITHOUT SUBARU SELECT MONI-
TOR, OPERATION, Clear Memory Mode.>
3)Perform the inspection mode. <Ref. to ABS-
21, Inspection Mode.>
Calling up the diagnostic trouble code (DTC).
<Ref. to ABS-20, Read Diagnostic Trouble
Code (DTC).>

ABS-2
 m
ii
BASIC DIAGNOSTIC PROCEDURE
ABS (DIAGNOSTICS)

Step Check Yes No

) PERFORM THE DIAGNOSIS. Is only the start code issued? 2omplete the Inspect using
1)lnspect using “Diagnostics Chart with Diag- iiagnosis. “DiagnosticsChart
nostic Connectof.<Ref. to ABS-29, Diagnos- with Diagnostic
tics Chart with Diagnosis Connector.> Connectof. <Ref.
NOTE: to ABS-29, Diag-
For diagnostic trouble code (DTC) list, refer tc nostics Chart with
“List of DiagnosticsTrouble Code (DTC)”.<Ref. Diagnosis Con-
to ABS-24, WITHOUT SUBARU SELECT nector.>
MONITOR, LIST, List of Diagnostics Trouble
Code (DTC).>
2)Repair the trouble cause.
3)Perform the clear memory mode. <Ref. to
ABS-22, WITHOUT SUBARU SELECT MONI-
TOR, OPERATION, Clear Memory Mode.>
I
4)Perform the inspection mode. <Ref. to ABS-
21, Inspection Mode.>
5)Calling up the diagnostic trouble code (DTC).
I
<Ref. to ABS-20, Read Diagnostic Trouble
Code (DTC).>

ABS-3
 BASIC DIAGNOSTIC PROCEDURE
ABS (DIAGNOSTICS)

2. WITH SUBARU SELECT MONITOR

CAUTION:
Remove foreign matter (dust, water, etc.) from the ABSCM&H/U connector during removal and instal-
lation.
NOTE:
To check harness for broken wires or short circuits, shake it while holding it or the connector.
Check the list for interview. <Ref. to ABS-26, WITH SUBARU SELECT MONITOR, LIST, List of Diagnos-
tics Trouble Code (DTC).>

Step Check Yes No

CHECK PRE-INSPECTION. Is unit that might influence the o
; to step 2. lepair or replace
1)Ask the customer when and how the trouble ABS problem normal? !ach unit.
occurred using interview checklist. <Ref. to
ABS-6, Check List for Interview.>
2)Before performing diagnosis, inspect the unit
which might influence the ABS problem. <Ref.
to ABS-9, INSPECTION, General Descrip-
tion.>
CHECK INDICATION OF TROUBLE CODE Is the corresponding trouble 30 to step 3. ;o to step 4.
DISPLAY. encoding?
1)Turn the ignition switch to OFF.
2)Connect the SUBARU SELECT MONITOR
to data link connector.
3)Turn the ignition switch to ON and SUBARU
SELECT MONITOR to ON.
NOTE:
If the communication function of the selec
monitor cannot be executed normally, check
the communication circuit. <Ref. to ABS-96
COMMUNICATION FOR INITIALIZING IM.
POSSIBLE, Diagnostics Chart with Subaru Se,
lect Monitor.>
4)Read the diagnostic trouble code (DTC).
<Ref. to ABS-19, READ CURRENT DATA,
OPERATION, Subaru Select Monitor.>
5)Record all diagnostic trouble codes (DTC)
and frame data.
PERFORM THE GENERAL DIAGNOSTICS. IS no diagnostic trouble code 2omplete the ;o to step 4.
1)lnspect using “General Diagnostics Table”. :DTC) designated and ABS liagnosis.
<Ref. to ABS-183, General DiagnosticsTable.> Narning light goes out after
2)Perform the clear memory mode. <Ref. to :urning on?
ABS-19, CLEAR MEMORY MODE, OPERA-
TION, Subaru Select Monitor.>
3)Perform the inspection mode. <Ref. to ABS-
21, Inspection Mode.>
4)Calling up the diagnostic trouble code (DTC).
<Ref. to ABS-I 8, READ DIAGNOSTIC TROU-
BLE CODE (DTC), OPERATION, Subaru
Select Monitor.>

ABS-4
 1
BASIC DIAGNOSTIC PROCEDURE
ABS (DIAGNOSTICS)

Step Check Yes No

I PERFORM THE DIAGNOSIS. Is no diagnostic trouble code Complete the Inspect using
1)lnspect using “Diagnostics Chart with Sub- (DTC) designated and does diagnosis. “DiagnosticsChart
aru Select Monitor”.<Ref. to ABS-96, Diagnos- ABS warning light go out after with Subaru Select
tics Chart with Subaru Select Monitor.> turning on? Monitor”. <Ref. to
NOTE: ABS-96, Diagnos-
tics Chart with
Subaru Select
Monitor.>

ABS-5
 CHECK LIST FOR INTERVIEW
ABS (DIAGNOSTICS)

2. Check List for Interview

A: CHECK
Check the following items about the vehicle's state.
1. STATE OF ABS WARNING LIGHT
ABS warning light 0 Always
comes on. CI Sometimes
U Only once
CI Does not come on
When / how long does it come on?:
Ignition key position CI LOCK
CI ACC
CI ON (before starting engine)
CI START
CI On after starting (Engine is running)
0 On after starting (Engine is stop)
Timing CI Immediately after ignition is ON.
Q Immediately after ignition starts.
CI When advancing km/h to km/b
MPHto MPF
0 While traveling at a constant speed km/h I MPF
Q When decelerating km/h to km/b
MPHto MPF

Steering time : sec

Q When turning to left Steering angle : deg
1 Steering time : sec

Parts name :
Operating condition :

ABS-6
 CHECK LIST FOR INTERVIEW
ABS (DIAGNOSTICS)

2. SYMPTOMS
4BS operating condi-
tion c1 Operates only when abruptly applying brakes.

*How to steD on brake pedal

Vehicle speed :
t km/h
MPH

a) Operating time : sec

What kind of noise? D Knock

D Gong gong
D Bong
D Buzz
D Gong gong buzz
D Others :

D Stick
D Press down once with a clunk
c1 Press and released
D Others :
Behavior of vehicle a) Directional stability cannot be obtained or steering arm refuses to work when applying brakes :
D Yes/ D No
When : I D Vehicle turns to right

When : D Vehicle turns to right

c1 Vehicle turns to left
CI Spins
D Others :

What : 0 Braking distance is long

D Brakes lock or drag
D Pedal stroke is long
c1 Pedal sticks
D Others :

What : c1 Fails to accelerate

D Engine stalls
D Others :

Where
What kind :
f) Occurrence of abnormal noise : P Yes / D No
Where
What kind :
a) Occurrence of other Dhenomena : D Yes / D No
What kind :

ABS-7
 CHECK LIST FOR INTERVIEW
ABS (DIAGNOSTICS)

3. CONDITIONS UNDER WHICH TROUBLE OCCURS

:nvironment a) Weather 3 Fine
Ll Cloudy
CI Rainy
U Snowy
U Various/Others :
b) Ambient temperature OF ("C)
c) Road F u r b a n area
0 Suburbs
U Highway
U General road
U Ascending slope
U Descending slope
U Paved road
U Gravel road
U Muddy road
U Sandy place
U Others :
d) Road surface U Dry
CI Wet
U New-fallen snow
U Compressed snow
U Frozen slope
U Others :
2ondition a) Brakes Deceleration : g
U Continuous / U Intermittent
b) Accelerator Acceleration : 9
D Continuous / U Intermittent
c) Vehicle speed km/h I MPH
U Advancing
U Accelerating
U Reducing speed
CI Low speed
CI Turning
U 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. : 0 Yes / U No
g) Chain is passed around tires. : U Yes / U No
h) T tire is used. : U Yes / Q No
i) Condition of suspension alignment :
j) Loading state :
k) Repair parts are used. : U Yes / Q No
What :
I) Others :

ABS-8
 GENERAL DESCRIPTION
3. General Description
A: CAUTION
1. SUPPLEMENTAL RESTRAINT SYSTEM
“AIR BAG”
The airbag system wiring harness is routed near
the ABS sensor, ABS control module and hydraulic
control unit.
CAUTION:
All Airbag system wiring harness and con-
nectors are colored yellow. Do not use electri-
cal test equipment on these circuit.
Be careful not to damage the Airbag system
wiring harness when servicing the ABS sensor,
ABS control module and hydraulic control unit.
a
ABS (DIAGNOSTICS)
B: INSPECTION
Before performing diagnostics, check the following
items which might affect ABS problems:
1. BATTERY
Measure the battery voltage and specific gravity of
electrolyte.
Standard voltage: 12 V, or more
Specific gravity: Above 1.260
2. BRAKE FLUID
1) Check the brake fluid level.
2) Check for brake fluid leakage.
3. HYDRAULIC UNIT
Check the hydraulic unit.
With brake tester <Ref. to ABS-9, CHECKING
THE HYDRAULIC UNIT ABS OPERATION WITH
BRAKE TESTER, INSPECTION, ABS Control
Module and Hydraulic Control Unit (ABSCM&H/
U).>
Without brake tester <Ref. to ABS-8, CHECK-
ING THE HYDRAULIC UNIT ABS OPERATION
BY PRESSURE GAUGE, INSPECTION, ABS
Control Module and Hydraulic Control Unit (AB-
SCM&H/U).>
4. BRAKEDRAG
Check for brake drag.
5. BRAKE PAD AND ROTOR
Check the brake pad and rotor.
Front <Ref. to BR-17, INSPECTION, Front
Brake Pad.> and <Ref. to BR-18, INSPECTION,
Front Disc Rotor.>
Rear <Ref. to BR-24, INSPECTION, Rear
Brake Pad.> and <Ref. to BR-26, INSPECTION,
Rear Disc Rotor.> or <Ref. to BR-31, INSPEC-
TION, Rear Drum Brake Shoe.> and <Ref. to BR-
32, INSPECTION, Rear Drum Brake Drum.>
6. TIRE
Check the tire specifications, tire wear and air pres-
sure. <Ref. to WT-2, SPECIFICATIONS, General
Description.>
 GENERAL DESCRIPTION
ABS (DIAGNOSTICS)

C: PREPARATION TOOL
1. SPECIAL TOOLS

ILLUSTRATION I TOOL NUMBER DESCRIPTION REMARKS

24082AA150 CARTRIDGE Troubleshooting for electrical systems.
(Newly adopted tool)

B2M3876
22771AA030 SELECT MONITOR Troubleshooting for electrical systems.
KIT 1 English: 22771AA030 (Without printer)

1 German: 22771AA070 (Without printer)

1 French: 22771AA080 (Without printer)

1 Spanish: 22771AA090 (Without printer)

B2M3877

2. GENERAL PURPOSE TOOLS

I TOOL NAME I REMARKS I

Circuit tester 1 Used for measuring resistance, voltage and ampere.
Oscilloscope I Used for measuring sensor.

ABS-I 0
GENERAL DESCRIPTION
ABS (DIAGNOSTICS)

ABS-I 1
 ELECTRICAL COMPONENTS LOCATION
ABS (DIAGNOSTICS)

4. Electrical Components Location

A: LOCATION

(1) ABS control module and hydraulic (5) Data link connector (for Subaru (8) ABS sensor
control unit (ABSCM&H/U) select monitor) (9) Wheel cylinder
(2) Proportioning valve (6) Transmission control module (only (10) G sensor
(3) Diagnosis connector AT vehicle) (1 1) Stop light switch
(4) ABS warning light (7) Tone wheel (12) Master cylinder

ABS-12
 ELECTRICAL COMPONENTS LOCATION
ABS IDIAGNOSTICS)

(4 BR0079
64M1226B

\I - I
BR0056

REAR
(7)

ABS-I 3
 CONTROL MODULE I/O SIGNAL
ABS (DIAGNOSTICS)

5. Control Module I/O Signal

A: ELECTRICAL SPECIFICATION

ABS control module and

hydraulic control unit connector
I

Connector switch

B4M1220A
NOTE:
The terminal numbers in the ABS control module and hydraulic control unit connector are as shown in the
figure.
When the connector is removed from the ABSCM&H/U, the connector switch closes the circuit between
terminal No. 22 and No. 23. The ABS warning light illuminates.

ABS-14
 CONTROL MODULE I/O SIGNAL
a
ABS (DIAGNOSTICS)

Terminal No. InputlOutput signal

Contents
(+)-(-) Measured value and measuring conditions
Front left wheel 9-1 0
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.)
I Rear rightwheel 14-1 5
Valve relay power supply 24-23 10-15V
Motor relay power supply 25-23 10-15V
power supply 30-28 4.75 - 5.25 V
G sensor*2 ground 28 -
output 6-28 2.3f0.2 V when the vehicle is in horizontal position.
Less than 1.5 V when the stop light is OFF and, 10 - 15 V
Stop light switch*l 2-23
. liaht
when the stoD * is ON.
Less than 1.5 V during 1.5 seconds when ignition switch is ON,
ABS warning light*2 22-23
and 10 - 15 V after 1.5 seconds.
AT ABS signal*2 Less than 1.5 V when the ABS control still operates and more
31-23
(AT model only) than 5.5 V when ABS does not operate.
Less than 1.5 V when the ABS control still operates and more
ABS operation signal monitor*2 3-23
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 the ignition switch is ON.
tor*2 Terminal No. 6 4-23 10 - 15 V when the ignition switch is ON.
Power supply*l 1-23 10 - 15 V when the ignition switch is ON.
Grounding line 23 -
Grounding line 26 -

ABS-I 5
 CONTROL MODULE I/O SIGNAL
ABS (DIAGNOSTICS)
B: SCHEMATIC
ABS control module and hydraulic
control unit (ABSCM&H/U)
ABS control module area
Valve relay
Motor relay
Motor
Front left inlet solenoid valve
Front left outlet solenoid valve
Front right inlet solenoid valve
BR0108
(9) Front right outlet solenoid valve (17) ABS warning light
(10 ) Rear left inlet solenoid valve (18) Stop light switch
(11) Rear left outlet solenoid valve (19) Stop light
(12) Rear right inlet solenoid valve (20) G sensor
(13) Rear right outlet solenoid valve (21) Front left ABS sensor
(14) Transmissioncontrol module (only (22) Front right ABS sensor
AT model) (23) Rear left ABS sensor
(15 ) Diagnosis connector (24) Rear right ABS sensor
(16) Data link connector
ABS-I 6
 CONTROL MODULE I/O SIGNAL ABS (DIAGNOSTICS)

C: WAVEFORM
ABS sensor

[VI
Terminal NO.
9 - 10 Standard output
11 - 1 2 voltage at 20 Hz:
7 - 8 0.12 - 1 v
14 - 15

B4M2526A

ABS-I 7
 SUBARU SELECT MONITOR
ABS (DIAGNOSTICS)
6. Subaru Select Monitor
A: OPERATION
1. READ DIAGNOSTIC TROUBLE CODE
WC)
1) Prepare the Subaru Select Monitor kit.
2) Connect the diagnosis cable to Subaru Select
Monitor.
3) Insert the cartridge into Subaru Select Monitor.
<Ref. to ABS-IO, SPECIAL TOOLS, PREPARA-
TION TOOL, General Description.>
S2M0286
4) Connect the Subaru Select Monitor to data link
connector.
(1) Data link connector is located in the lower
portion of the instrument panel (on the driver’s
side).
I
(2) Connect the diagnosis cable to data link
connector.
ABS-18
5) Turn the ignition switch to ON (engine OFF) and
Subaru Select Monitor switch to ON.
” S2M0288D
(1) Power switch
6) On the ((Main Menu)) display screen, select the
{Each System Check} and press the [YES] key.
7) On the ((System Selection Menu)) display
screen, select the {Brake Control System} and
press the [YES] key.
8) Press the [YES] key after displayed the informa-
tion of engine type.
9) On the ((ABS Diagnosis))display screen, select
the {Diagnostic Code(s) Display} and press the
[YES] key.
10) On the ((Diagnostic Code@) Display)) display
screen, select the {Current Diagnostic Code(s)} or
{History Diagnostic Code(s)} and press the [YES]
key.
NOTE:
For detailed operation procedure, refer to the
SUBARU SELECT MONITOR OPERATION MAN-
UAL.
For detailed concerning diagnostic trouble codes
(DTC), refer to the LIST OF DIAGNOSTICSTROU-
BLE CODE (DTC). <Ref. to ABS-24, List of Diag-
nostics Trouble Code (DTC).>
 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
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. It
G sensor output Signal V
appears on the select monitor display in volts.
ON or OFF
Valve Relay Signal Valve Relay Signal

I e I a v Signal 1 Motor Relay Signal I ON or OFF I

I ABS Signal to TCM 1 ABS operation signal from ABS control module to TCM
I 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. ON or OFF
ON or OFF
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
I I I 1
NOTE:
For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL.
3. CLEAR MEMORY MODE
1) On the ((Main Menu. display screen, select the {2. Each System Check} and press the ((YES))key.
2) On the ((SystemSelect Menu))display screen, select {Brake System} and press the ((YES))key.
3) Press the ((YES))key after displayed the information of engine type.
4) On the (<BrakeControl Diagnosis,) display screen, select the {Clear Memory} and press the ((YES), key.
5 ) When the “Done” and “turn ignition switch O F F are shown on the display screen, turn the Subaru Select
Monitor and ignition switch to OFF.
NOTE:
For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL.

ABS-1 9
 READ DIAGNOSTIC TROUBLE CODE (DTC)
ABS (DIAGNOSTICS)

7. Read Diagnostic Trouble 2) Turn the ignition switch OFF.

3) Connect the diagnosis connector terminal 6 to
Code (DTC) diagnosis terminal.
A: OPERATION 4) Turn the ignition switch ON.
5) ABS warning light is set in the diagnostic mode
1. WITHOUT SUBARU SELECT MONITOR and blinks to identify diagnostic trouble code
(DTC).
1) Take out the diagnosis connector from side of
driver's seat heater unit. 6) After the start code (1 1) is shown, the diagnostic
trouble code (DTC) will be shown in order of the last
information first.
These repeat for a maximum of 3 minutes.
NOTE:
When there are no diagnostic trouble code
(DTC) in memory, only the start code (1 1) is shown.
When on-board diagnosis of the ABS control
module detects a problem, the information (up to a
maximum of three) will be stored in the EEP ROM
as a diagnostic trouble code (DTC). When there
BRO110 are more than three, the most recent three will be
stored. (Stored codes will stay in memory until they
(1) Diagnosis connector are cleared.)
(2) Diagnosis terminals
(3) 3 terminal
(4) 6 terminal

Example of DTC indication

DTC: 21

^.. 1 1 2 1 1 1 2 1

k-! 0.3 sec 0.3 sec \L 0.3 sec

DTC: 21 Start code DTC: 21

I DTC: 22,31
1 1 2 2 3 1 1 1

Start code DTC: 22 DTC: 31 Start code

BR0081

2. WITH SUBARU SELECT MONITOR

Refer to SUBARU SELECT MONITOR for information about how to obtain and understand the diagnostic
trouble code (DTC). <Ref. to ABS-18, Subaru Select Monitor.>

ABS-20
 INSPECTION MODE I
ABS (DIAGNOSTICS)

8. Inspection Mode
A: OPERATION
Reproduce the condition under which the problem
has occurred as much as possible.
Drive the vehicle at a speed more than 40 km/h (25
MPH) for at least one minute.

ABS-21
 CLEAR MEMORY MODE
ABS (DIAGNOSTICS)

9. Clear Memory Mode

A: OPERATION
1. WITHOUT SUBARU SELECT MONITOR
1) After calling up a diagnostic trouble code (DTC),
disconnect the diagnosis connector terminal 6 from
diagnosis terminal.

(1) Diagnosis connector

(2) Diagnosis terminals
(3) 3 terminal
(4) 6 terminal
2) Repeat 3 times within approx. 12 seconds; connecting and disconnecting terminal 6 and diagnosis termi-
nal for at least 0.2 seconds each time.

Diagnostic trouble code (DTC) indicatione mode

-- a
Memory erase mode

GND(Low level) GND open (High level)

Terminal 8

0.2 sec 0.2 sec or more

or more

12 sec or less

BR0082

NOTE:
After diagnostics is completed, make sure to clear memory. Make sure only start code (1 1) is shown after
memory is cleared.
2. WITH SUBARU SELECT MONITOR
Refer to SUBARU SELECT MONITOR for information about how to clear the diagnostic trouble code (DTC).
<Ref. to ABS-18, Subaru Select Monitor.>

ABS-22
 ABS WARNING LIGHT ILLUMINATION PATTERN
ABS (DIAGNOSTICS)

1O.ABS Warning Light Illumination Pattern

A: INSPECTION

START

Ignition key switch

OFF '-I

Goes out. Goes out.

ABS warning light
1.5 s

~ 4 ~ 0 7A8 1

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 cir-
cuit. <Ref. to ABS-29, Diagnostics Chart with Diagnosis Connector.>
NOTE:
Even though the ABS warning light does not go out 1.5 seconds after it illuminates, the ABS system operates
normally when the warning light goes out while driving at approximately 12 km/h (7 MPH). However, the Anti-
lock brakes do not work while the ABS warning light is illuminated.

ABS-23
 LIST OF DIAGNOSTICS TROUBLE CODE (DTC)
ABS (DIAGNOSTICS)

11.List of Diagnostics Trouble Code (DTC)

A: LIST
1. WITHOUT SUBARU SELECT MONITOR
3TC No Contents of diagnosis Index No.
Start code
11 DTC is shown after start code. -
Only start code is shown in normal condition.
<Ref. to ABS-40, DTC 21 ABNORMAL ABS SENSOR (OPEN CIR-
21 Front right ABS sensor CUIT OR INPUT VOLTAGE TOO HIGH) (FRONT RH), Diagnostics
Chart with Diagnosis Connector.>
<Ref. to ABS-40, DTC 23 ABNORMAL ABS SENSOR (OPEN CIR-
23 Front left ABS sensor CUIT OR INPUT VOLTAGE TOO HIGH) (FRONT LH), Diagnostics
Abnormal ABS sensor Chart with Diagnosis Connector.>
(Open circuit or input
voltage too high) <Ref. to ABS-40, DTC 25 ABNORMAL ABS SENSOR (OPEN CIR-
25 Rear right ABS sensor CUIT OR INPUT VOLTAGE TOO HIGH) (REAR RH), Diagnostics
Chart with Diagnosis Connector.>
<Ref. to ABS-41, DTC 27 ABNORMAL ABS SENSOR (OPEN CIR-
27 Rear left ABS sensor CUIT OR INPUT VOLTAGE TOO HIGH) (REAR LH), Diagnostics
Chart with Diaanosis Connector.>
s

<Ref. to ABS-46, DTC 22 ABNORMAL ABS SENSOR (FRONT RH),

22 Front right ABS sensor
Diagnostics Chart with Diagnosis Connector.>

~
24 Front left ABS sensor I <Ref. to ABS-46, DTC 24 ABNORMAL ABS SENSOR (FRONT LH),
Diaanostics
u Chart with Diaanosis Connector.>
I

Abnormal ABS sensor <Ref to ABS-46, DTC 26 ABNORMAL ABS SENSOR (REAR RH),
26 Rear r'ght ABS
(Abnormal ABS sen- Diaanostics Chart with Diaanosis Connector.>
sor signal) <Ref. to ABS-47, DTC 28 ABNORMAL ABS SENSOR (REAR LH),
28 Rear left ABS sensor
Diagnostics Chart with Diagnosis Connector.>
<Ref. to ABS-53, DTC 29 ABNORMAL ABS SENSOR SIGNAL
29 Any one of four (ANY ONE OF FOUR), Diagnostics Chart with Diagnosis Connec-
tor.>
<Ref. to ABS-57, DTC 31 ABNORMAL INLET SOLENOID VALVE
31 Front right inlet valve ClRCUIT(S) IN ABSCM&H/U (FRONT RH), Diagnostics Chart with
Diagnosis Connector.>
<Ref. to ABS-61, DTC 32 ABNORMAL OUTLET SOLENOID VALVE
32 Front right outlet valve CIRCUIT(S) IN ABSCM&H/U (FRONT RH), Diagnostics Chart with
Diagnosis Connector.>
<Ref. to ABS-57, DTC 33 ABNORMAL INLET SOLENOID VALVE
33 Front left inlet valve CIRCUIT(S) IN ABSCM&H/U (FRONT LH), Diagnostics Chart with
Diagnosis Connector.>
1 <Ref. to ABS-61, DTC 34 ABNORMAL OUTLET SOLENOID VALVE
34 Abnormal solenoid Front left outlet valve CIRCUIT(S) IN ABSCM&H/U (FRONT LH), Diagnostics Chart with
valve circuit(s) in ABS Diagnosis Connector.>
control module and <Ref. to ABS-57, DTC 35 ABNORMAL INLET SOLENOID VALVE
35 hydraulic unit Rear right inlet valve CIRCUIT(S) IN ABSCM&H/U (REAR RH), Diagnostics Chart with
Diagnosis Connector.>
<Ref. to ABS-61, DTC 36 ABNORMAL OUTLET SOLENOID VALVE
36 Rear right outlet valve CIRCUIT(S) IN ABSCM&H/U (REAR RH), Diagnostics Chart with
Diagnosis Connector.>
<Ref. to ABS-57, DTC 37 ABNORMAL INLET SOLENOID VALVE
37 Rear left inlet valve CIRCUIT(S) IN ABSCM&H/U (REAR LH), Diagnostics Chart with
Diagnosis Connector.>
<Ref. to ABS-61, DTC 38 ABNORMAL OUTLET SOLENOID VALVE
38 Rear left outlet valve ClRCUIT(S) IN ABSCM&H/U (REAR LH), Diagnostics Chart with
Diagnosis Connector.>

ABS-24
 LIST OF DIAGNOSTICS TROUBLE CODE (DTC)
ABS (DIAGNOSTICS)

DTC No. Contents of diagnosis Index No.

<Ref. to ABS-66, DTC 41 ABNORMAL ABS CONTROL MODULE,
41 Abnormal ABS control module
Diagnostics Chart with Diagnosis Connector.>
<Ref. to ABS-69, DTC 42 SOURCE VOLTAGE IS ABNORMAL.,
42 Source voltage is abnormal.
Diagnostics Chart with Diagnosis Connector.>
<Ref. to ABS-74, DTC 44 A COMBINATION OF AT CONTROL
44 A combination of AT control abnormal
ABNORMAL, Diagnostics Chart with Diagnosis Connector.>
<Ref. to ABS-77, DTC 51 ABNORMAL VALVE RELAY, Diagnostics
51 Abnormal valve relay
Chart with Diagnosis Connector.>
<Ref. to ABS-81, DTC 52 ABNORMAL MOTOR AND/OR MOTOR
52 Abnormal motor and/or motor relay
RELAY, Diagnostics Chart with Diagnosis Connector.>
<Ref. to ABS-86, DTC 54 ABNORMAL STOP LIGHT SWITCH,
54 Abnormal stop light switch
Diagnostics Chart with Diagnosis Connector.>
<Ref. to ABS-89, DTC 56 ABNORMAL G SENSOR OUTPUT VOLT-
56 Abnormal G sensor output voltage
AGE. Diaanostics Chart with Diaanosis Connector.>

ABS-25
 LIST OF DIAGNOSTICS TROUBLE CODE (DTC)
ABS (DIAGNOSTICS)

2. WITH SUBARU SELECT MONITOR

DTC
Display screen Contents of diagnosis Index No.
No.
- Communication for ini- Select monitor commu- <Ref. to ABS-96, COMMUNICATION FOR INITIALIZING IMPOSSI-
tializing impossible nication failure BLE, Diagnostics Chart with Subaru Select Monitor.>

- I No trouble code
Although no trouble
code appears on the
select monitor display,
the ABS warning light
remains on.
<Ref. to ABS-101, NO TROUBLE CODE, Diagnostics Chart with
Subaru Select Monitor.>

Open or short circuit in Open or short circuit in <Ref. to ABS-104, DTC 21 OPEN OR SHORT CIRCUIT IN FRONT
21 front right ABS sensor front right ABS sensor RIGHT ABS SENSOR CIRCUIT, Diagnostics Chart with Subaru
circuit circuit Select Monitor.>
Front right ABS sensor Front right ABS sensor <Ref. to ABS-110, DTC 22 FRONT RIGHT ABNORMAL ABS SEN-
22
abnormal signal abnormal signal SOR SIGNAL, Diagnostics Chart with Subaru Select Monitor.>
Open or short circuit in Open or short circuit in <Ref. to ABS-104, DTC 23 OPEN OR SHORT CIRCUIT IN FRONT
23 front left ABS sensor front left ABS sensor LEFT ABS SENSOR CIRCUIT, DiagnosticsChart with Subaru Select
circuit circuit Monitor.>
Front left ABS sensor Front left ABS sensor <Ref. to ABS-110, DTC 24 FRONT LEFT ABNORMAL ABS SEN-
24
abnormal signal abnormal signal SOR SIGNAL, Diagnostics Chart with Subaru Select Monitor.>
Open or short circuit in Open or short circuit in <Ref. to ABS-104, DTC 25 OPEN OR SHORT CIRCUIT IN REAR
25 rear right ABS sensor rear right ABS sensor RIGHT ABS SENSOR CIRCUIT, Diagnostics Chart with Subaru
circuit circuit Select Monitor.>
Rear right ABS sensor Rear right ABS sensor <Ref. to ABS-1 10, DTC 26 REAR RIGHT ABNORMAL ABS SEN-
26
abnormal signal abnormal signal SOR SIGNAL, Diagnostics Chart with Subaru Select Monitor.>
Open or short circuit in Open or short circuit in <Ref. to ABS-105, DTC 27 OPEN OR SHORT CIRCUIT IN REAR
27 rear left ABS sensor rear left ABS sensor LEFT ABS SENSOR CIRCUIT, DiagnosticsChart with Subaru Select
circuit circuit Monitor.>
Rear left ABS sensor Rear left ABS sensor <Ref. to ABS-1 11, DTC 28 REAR LEFT ABNORMAL ABS SENSOR
28
abnormal signal abnormal signal SIGNAL, Diagnostics Chart with Subaru Select Monitor.>
Abnormal ABS sensor Abnormal ABS sensor <Ref. to ABS-117, DTC 29 ABNORMAL ABS SENSOR SIGNAL ON
29 signal on any one of signal on any one of ANY ONE OF FOUR SENSOR, Diagnostics Chart with Subaru
four sensor four Select Monitor.>
Front right inlet valve Front right inlet valve <Ref. to ABS-121, DTC 31 FRONT RIGHT INLET VALVE MAL-
31
malfunction malfunction FUNCTION, Diagnostics Chart with Subaru Select Monitor.>
Front right outlet valve Front right outlet valve <Ref. to ABS-125, DTC 32 FRONT RIGHT OUTLET VALVE MAL-
32
malfunction malfunction FUNCTION, Diagnostics Chart with Subaru Select Monitor.> '

Front left inlet valve Front left inlet valve <Ref. to ABS-121, DTC 33 FRONT LEFT INLET VALVE MALFUNC-
33
malfunction malfunction TION, Diagnostics Chart with Subaru Select Monitor.>
Front left outlet valve Front left outlet valve <Ref. to ABS-125, DTC 34 FRONT LEFT OUTLET VALVE MAL-
34
malfunction malfunction FUNCTION, Diagnostics Chart with Subaru Select Monitor.>
Rear right inlet valve Rear right inlet valve <Ref. to ABS-121, DTC 35 REAR RIGHT INLET VALVE MALFUNC-
35
malfunction malfunction TION, Diagnostics Chart with Subaru Select Monitor.>
Rear right outlet valve Rear right outlet valve <Ref. to ABS-125, DTC 36 REAR RIGHT OUTLET VALVE MAL-
36
malfunction malfunction FUNCTION, Diagnostics Chart with Subaru Select Monitor.>
Rear left inlet valve Rear left inlet valve <Ref. to ABS-121, DTC 37 REAR LEFT INLET VALVE MALFUNC-
37
malfunction malfunction TION, Diagnostics Chart with Subaru Select Monitor.>
Rear left outlet valve Rear left outlet valve <Ref. to ABS-125, DTC 38 REAR LEFT OUTLET VALVE MALFUNC-
38
malfunction malfunction TION, Diagnostics Chart with Subaru Select Monitor.>

1
1
i 1I A D C A--4"-l --A..l-
MPO l.UIIlIUI IIIUUUIG

malfunction
I ABS controlmodule I Cnel. LO H nD m3 - I dl0, DTC 41 ABS CONTROL MODULE MALFUNC-
and hydraulic control
unit malfunction
I .n-S I- A 4-

TION, Diagnostic:s Chart with Subaru Select Monitor.>

Power supply voltage Power supply voltage <Ref. to ABS-132, DTC 42 POWER SUPPLY VOLTAGE TOO LOW,
42
too low too low Diagnostics Chart with Subaru Select Monitor.>
Power supply voltage Power supply voltage <Ref. to ABS-134, DTC 42 POWER SUPPLY VOLTAGE TOO HIGH,
42
too high too high Diagnostics Chart with Subaru Select Monitor.>

ABS-26
 LIST OF DIAGNOSTICS TROUBLE CODE (DTC)
a
ABS (DIAGNOSTICS)

' L'
Display screen Contents of diagnosis Index No.
No.
ABS-AT control (Non ABS-AT control (Non <Ref. to ABS-138, DTC 44 ABS-AT CONTROL (NON CON-
44
Controlled) Controlled) TROLLED), Diagnostics Chart with Subaru Select Monitor.>
ABS-AT control (Con- ABS-AT control (Con- <Ref. to ABS-I 40, DTC 44 ABS-AT CONTROL (CONTROLLED),
44
trolled) trolled) Diagnostics Chart with Subaru Select Monitor.>
<Ref. to ABS-143, DTC 51 VALVE RELAY MALFUNCTION, Diag-
51 Valve relay malfunction Valve relay malfunction
I
nostics Chart with Subaru Select Monitor,>
<Ref. to ABS-I 47, DTC 51 VALVE RELAY ON FAILURE, Diagnos-
51 Valve relay ON failure Valve relay ON failure
tics Chart with Subaru Select Monitor.>
Open circuit in motor Open circuit in motor <Ref. to ABS-151, DTC 52 OPEN CIRCUIT IN MOTOR RELAY CIR-
52
relay circuit relay circuit CUIT, Diagnostics Chart with Subaru Select Monitor.>
<Ref. to ABS-I 55, DTC 52 MOTOR RELAY ON FAILURE, Diagnos-
52 Motor relay ON failure Motor relay ON failure
tics Chart with Subaru Select Monitor.r
<Ref. to ABS-159, DTC 52 MOTOR MALFUNCTION, Diagnostics
52 Motor malfunction Motor malfunction
Chart with Subaru Select Monitor.>
Stop light switch signal Stop light switch signal <Ref. to ABS-162, DTC 54 STOP LIGHT SWITCH SIGNAL CIRCUIT
54
circuit malfunction circuit malfunction MALFUNCTION, Diagnostics Chart with Subaru Select Monitor.>
Open or short circuit in Open or short circuit in <Ref. to ABS-165, DTC 56 OPEN OR SHORT CIRCUIT IN G SEN-
56
G sensor circuit G sensor circuit SOR CIRCUIT, Diagnostics Chart with Subaru Select Monitor.>
Battery short in G sen- Battery short in G sen- <Ref. to ABS-169, DTC 56 BATTERY SHORT IN G SENSOR CIR-
56
sor circuit sor circuit CUIT, Diagnostics Chart with Subaru Select Monitor.>
Abnormal G sensor Abnormal G sensor <Ref. to ABS-175, DTC 56 ABNORMAL G SENSOR HIGH M OUT-
56
high output high p output PUT, Diagnostics Chart with Subaru Select Monitor.>
Detection of G sensor Detection of G sensor <Ref. to ABS-179, DTC 56 DETECTION OF G SENSOR STICK,
56
stick stick Diagnostics Chart with Subaru Select Monitor.>

ABS-27
I LIST OF DIAGNOSTICS TROUBLE CODE (DTC)
ABS (DIAGNOSTICS)

ABS-28
 I
DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR
ABS (DIAGNOSTICS)

12.Diagnostics Chart with Diagnosis Connector

A: ABS WARNING LIGHT DOES NOT COME ON.
DIAGNOSIS:
ABS warning light circuit is open or shorted.
TROUBLE SYMPTOM:
When the ignition switch is turned ON (engine OFF), ABS warning light does not come on.

ABS-29
 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR
ABS (DIAGNOSTICS)

WIRING DIAGRAM:

BATTERY
SBF-3 SBF-1
3 c
t

1
m
RELAY HOLDER
BROO83

ABS-30
 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR
ABS IDIAGNOSTICS)

Step Check Yes No

I CHECK IF OTHER WARNING LIGHTS TURN )o other warning lights turn io to step 2. 3epair the combi-
ON. In? iation meter.
Turn the ignition switch to ON (engine OFF). cRef. to IDI-11,
Zombination
Weter Assembly.>
2 CHECK ABS WARNING LIGHT BULB. s the ABS warning light bulb i o to step 3. Replace the ABS
1)Turn the ignition switch to OFF. IK? Narning light bulb.
2)Remove the combination meter. <Ref. to IDI-11,
3)Remove the ABS warning light bulb from Zombination
combination meter. Weter Assembly.>
3 CHECK BATTERY SHORT OF ABS WARN- s the voltage less than 3 V? ;o to step 4. Repair the warning
ING LIGHT HARNESS. light harness.
1)Disconnectthe connector (B200) from con-
nector (F74).
2)Measure the voltage between connector
(8200) and chassis ground.
Connector & terminal
(6200) No. 19 (+) - Chassis ground (-):
S CHECK BATTERY SHORT OF ABS WARN- s the voltage less than 3 V? i o to step 5. Repairthe warning
ING LIGHT HARNESS. light harness.
1)Turn the ignition switch to ON.
2)Measure the voltage between connector
(8200) and chassis ground.
Connector & terminal
(B200) No. 19 (+) - Chassis ground (-):
5 CHECK WIRING HARNESS. s the voltage between 10 and ;o to step 6. Repair the wiring
1)Turn the ignition switch to OFF. 5 V? harness.
2)lnstall the ABS warning light bulb from com-
bination meter.
3)lnstall the combination meter.
4)Turn the ignition switch to ON.
5)Measure the voltage between connector
(B200) and chassis ground.
Connector & terminal
(8200) No. 19 (+) - Chassis ground (-):
6 CHECK BATTERY SHORT OF ABS WARN- s the voltage less than 3 V? ;o to step 7. Repair the wiring
ING LIGHT HARNESS. harness.
1)Turn the ignition switch to OFF.
2)Measure the voltage between connector
(F74) and chassis ground.
Connector & terminal
(F74) No. 19 (+) - Chassis ground (-):
7 CHECK BATTERY SHORT OF ABS WARN- s the voltage less than 3 V? ;o to step 8. Repair the wiring
ING LIGHT HARNESS. harness.
1)Turn the ignition switch to ON.
2)Measure the voltage between connector
(F74) and chassis ground.
Connector & terminal
(F74) No. 19 (+) - Chassis ground (-):
8 CHECK GROUND CIRCUIT OF ABSCM&HIU s the resistance less than 0.5 ;o to step 9. Repair the
Measure the resistance between ABSCM&HlU 2? ABSCM&HlU
and chassis ground. ground harness.
Connector & terminal
(F49) NO. 23 - GND:
9 CHECK WIRING HARNESS. s the resistance less than 0.5 20 to step 10. Repair the har-
Measure the resistance between connector n? nesslconnector.
(F74) and chassis ground.
Connector & terminal
(F74) No. 19 (+) - Chassis ground (-):

ABS-31
 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR
ABS (DIAGNOSTICS)

Step Check Yes No

10 CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in con- Repair the con- Replace the
Turn the ignition switch to OFF. nectors between combination nector. ABSCM&H/U.
meter and ABSCM&H/U? <Ref. to ABS-7,
ABS Control Mod-

I
ule and Hydraulic
Control Unit
(ABSCM&H/U).>

ABS-32
 ii
DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR
ABS (DIAGNOSTICS)

B: ABS WARNING LIGHT DOES NOT GO OFF.

DIAGNOSIS:
ABS warning light circuit is open or shorted.
TROUBLE SYMPTOM:
When starting the engine and while the ABS warning light is kept ON.

ABS-33
 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR
ABS (DIAGNOSTICS)

WIRING DIAGRAM:

BATTERY
SBF-3 SBF-1
C

m
RELAY HOLDER
BR0083

ABS-34
 1
DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR
ABS (DIAGNOSTICS)

Step Check Yes No

I CHECK INSTALLATION OF ABSCM&H/U ;the ABSCM&H/U connector io to step 2. nsert ABSCM&H/
CONNECTOR. iserted into ABSCM until the J connector into
Turn the ignition switch to OFF. lamp locks onto it? 4BSCM&H/U until
he clamp locks
into it.
! CHECK DIAGNOSIS TERMINAL. ;the resistance less than 0.5 io to step 3. 3epalr the diagno-
Measure the resistance between diagnosis ter- I? ;is terminal har-
minals (B81) and chassis ground. less.
Terminals
Diagnosis terminal (A) - Chassis
ground:
Diagnosis terminal (B) - Chassis
ground:
3 CHECK DIAGNOSIS LINE. s the resistance less than 0.5 YO to step 4. qepair harness
1)Turn the ignition switch to OFF. 2? :onnector
2)Connect the diagnosis terminal (881) to Detween
diagnosis connector (B82) No. 6. \BSCM&H/U and
3)Disconnect the connector from ABSCM& jiagnosis connec-
H/U. tor.
4)Measure the resistance between
ABSCM&H/U connector and chassis ground.
Connector & terminal
(F49) No. 4 - Chassis ground:
1 CHECK GENERATOR. s the voltage between 10 and 50 to step 5. Repair the genera
1)Start the engine. 5 V? tor. <Ref. to SC-
2)ldle the engine. 13. Generator.>
3)Measure the voltage between generator and
chassis ground.
Terminal
Generator B terminal (+) - Chassis
ground (-):
5 CHECK BAlTERY TERMINAL. s there poor contact at battery 3epair the battery Go to step 6.
Turn the ignition switch to OFF. erminal? erminal.
6 CHECK POWER SUPPLY OF ABSCM. s the voltage between 10 and ;o to step 7. Repair the
1)Disconnectthe connector from ABSCM& I5 V? ABSCM&H/U
H/U. power supply cir-
2)Start the engine. cuit.
3)ldle the engine.
4)Measure the voltage between ABSCM&H/U
connector and chassis ground.
Connector & terminal
(F49) No. 1 (+) - Chassis ground (-):
7 CHECK WIRING HARNESS. loes the ABS warning light i o to step 8. Repair the front
1)Disconnectthe connector (F74) from con- ,emain off? wiring harness.
nector (8200).
2)Turn the ignition switch to ON.
8 CHECK PROJECTION AT ABSCM&H/U. 9re the projection broken? i o to step 9. Replace the
1)Turn the 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).>

ABS-35
 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR
ABS (DIAGNOSTICS)

Step Check Yes No

I CHECK ABSCM&H/U. Is the resistance more than 1 Go to step 10. Replace the
Measure the resistance between ABSCM&H/U MR? ABSCM&H/U.
terminals. <Ref. to ABS-7,
Terminal ABS Control Mod-
NO.22 - NO. 23: ule and Hydraulic
Control Unit
(ABSCM&H/U).>
0 CHECK WIRING HARNESS. Is the resistance less than 0.5 Go to step 11. Repair the har-
Measure the resistance between connector Q? ness.
(F74) and chassis ground.
Connector & terminal
-
(F74) No. 20 Chassis ground: I
1 CHECK WIRING HARNESS. Is the resistance more than 1 Go to step 12. I Repair the har-
1)Connect the connector to ABSCM&H/U. MR? ness.
2)Measure the resistance between connector
(F74) and chassis ground.
Connector & terminal
(F74)No. 20 - Chassis ground:
2 CHECK POOR CONTACT IN ABSCM&H/U Is there poor contact in Repair the con- Replace the
CONNECTOR. ABSCM&H/U connector? nector. ABSCM&H/U.
<Ref. to ABS-7,
ABS Control Mod-
ule and Hydraulic
Control Unit
(ABSCM&H/U).>

ABS-36
 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR
ABS (DIAGNOSTICS)

C: DIAGNOSTIC TROUBLE CODE (DTC) DOES NOT APPEAR.

DIAGNOSIS:
Diagnosis circuit is open.
TROUBLE SYMPTOM:
The ABS warning light turns on or off normally but the start code cannot be read out in the diagnostic mode.

ABS-37
 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR
ABS (DIAGNOSTICS)

WIRING DIAGRAM:

BATTERY

DIAGNOSIS

m
RELAY HOLDER
BR0083

ABS-38
 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR
ABS (DIAGNOSTICS)

!-
Step Check
1 CHECK DIAGNOSIS TERMINAL. Is the resistance less than 0.5 So to step 2. Repair the diagno-
1)Turn the ignition switch to OFF. n? sis terminal har-
2)Measure the resistance between diagnosis ness.
terminals (881) and chassis ground.
Terminals
Diagnosis terminal (A) - Chassis
ground:
Diagnosis terminal (B) - Chassis
ground:
2 CHECK DIAGNOSIS LINE. Is the resistance less than 0.5
1)Turn the ignition switch to OFF. Q? connector
2)Connect the diagnosis terminal (B81) to between
diagnosis connector (B82) No. 6. ABSCM&H/U and
3)Disconnect the connector from ABSCM& diagnosis connec-
HIU. tor.
4)Measure the resistance between
ABSCM&H/U connector and chassis ground.
Connector & terminal
i
(F49) No. 4 - Chassis ground:
3 CHECK POOR CONTACT IN ABSCM&H/U Is there poor contact in Repair the con- Replace the
CONNECTOR. ABSCM&H/U connector? nector. ABSCM&H/U.
<Ref. to ABS-7,
ABS Control Mod-
ule and Hydraulic
Control Unit
(ABSCM&H/U).>

ABS-39
 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR
1
ABS (DIAGNOSTICS)

D: DTC21
ABNORMAL ABS SENSOR (OPEN CIRCUIT OR INPUT VOLTAGE TOO
HIGH) (FRONT RH)
NOTE:
For the diagnostic procedure, refer to DTC 27. <Ref. to ABS-41, DTC 27 ABNORMAL ABS SENSOR (OPEN
CIRCUIT OR INPUT VOLTAGE TOO HIGH) (REAR LH), Diagnostics Chart with Diagnosis Connector.>

E: DTC23
ABNORMAL ABS SENSOR (OPEN CIRCUIT OR INPUT VOLTAGE TOO
HIGH) (FRONT LH)
NOTE:
For the diagnostic procedure, refer to DTC 27. <Ref. to ABS-41, DTC 27 ABNORMAL ABS SENSOR (OPEN
CIRCUIT OR INPUT VOLTAGE TOO HIGH) (REAR LH), Diagnostics Chart with Diagnosis Connector.>

F: DTC25
ABNORMAL ABS SENSOR (OPEN CIRCUIT OR INPUT VOLTAGE TOO
HIGH) (REAR RH)
NOTE:
For the diagnostic procedure, refer to DTC 27. <Ref. to ABS-41, DTC 27 ABNORMAL ABS SENSOR (OPEN
CIRCUIT OR INPUT VOLTAGE TOO HIGH) (REAR LH), Diagnostics Chart with Diagnosis Connector.>

ABS-40
 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR
fa
ABS (DIAGNOSTICS)
_ _ _ _ ~

G: DTC27
ABNORMAL ABS SENSOR (OPEN CIRCUIT OR INPUT VOLTAGE TOO
HIGH) (REAR LH)
DIAGNOSIS:
Faulty ABS sensor (Broken wire, input voltage too high)
Faulty harness connector
TROUBLE SYMPTOM:
ABS does not operate.

ABS41
 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR
ABS (DIAGNOSTICS)

WIRING DIAGRAM:

@ ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT

1.
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ABS REAR REAR
SENSOR LH SENSOR RH ABS ABS
SENSOR LH SENSOR RH

BR0084

ABS-42
 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR Is
ABS (DIAGNOSTICS)

Step Check Yes No

CHECK ABS SENSOR. s the resistance between 1 20 to step 2. 3eplace the ABS
1)Turn the ignition switch to OFF. ind 1.5 kR? sensor. Front:
2)Disconnect the connector from ABS sensor. :Ref. to ABS-I 4,
3)Measure the resistance of ABS sensor con- 7ont ABS Sen-
nector terminals. ;or.> Rear: <Ref.
Terminal :o ABS-18, Rear
Front RH No. 1 - No. 2: 4BS Sensor.>
-
Front LH No. 1 No. 2:
Rear RH No. 1 -No. 2:
-
Rear LH No. 1 No. 2:
CHECK BATTERY SHORT OF ABS SEN- s the voltage less than 1 V? 20 to step 3. 3eplace the ABS
SOR. sensor. Front:
1)Disconnect the connector from ABSCM& :Ref. to ABS-14,
H/U. 3ont ABS Sen-
2)Measure the voltage between ABS sensor :or.> Rear: <Ref.
and chassis ground. :o ABS-18, Rear
Terminal 4BS Sensor.>
Front RH No. 1 (+) - Chassis ground (-):
Front LH No. 1 (+) - Chassis ground (-):
Rear RH No. 2 (+) - Chassis ground (-):
Rear LH No. 2 (+) - Chassis ground (-):
I CHECK BATTERY SHORT OF ABS SEN- s the voltage less than 1 V? 30 to step 4. Replace the ABS
SOR. sensor. Front:
1)Turn the ignition switch to ON. <Ref. to ABS-14,
2)Measure the voltage between ABS sensor Front ABS Sen-
and chassis ground. :or.> Rear: <Ref.
Terminal to ABS-I 8, Rear
Front RH No. 1 (+) - Chassis ground (-): ABS Sensor.>
Front LH No. 1 (+) - Chassis ground (-):
Rear RH No. 2 (+) - Chassis ground (-):
Rear LH No, 2 (+) - Chassis ground (-):
I CHECK HARNESS/CONNECTOR BETWEEN Is the resistance between 1 20 to step 5. Repair harness/
ABSCM&H/U AND ABS SENSOR. and 1.5 kR? connector
1)Turnthe ignition switch to OFF. between
2)Connect the connector to ABS sensor. ABSCM&H/U and
3)Measure the resistance between ABS sensor.
ABSCM&H/U connector terminals.
Connector & terminal
DTC 21 / (F49) NO. 11 - NO. 12:
DTC 23 / (F49) NO. 9 - NO. 10:
DTC 25 / (F49) NO. 14 - NO. 15:
DTC 27 / (F49) NO. 7 - NO. 8:
b CHECK BAlTERY SHORT OF HARNESS. Is the voltage less than 1 V? 30 to step 6. Repair harness
Measure the voltage between ABSCM&H/U between
connector and chassis ground. ABSCM&H/U and
Connector i? terminal ABS sensor.
-
DTC 21 / (F49) No. 11 (+) Chassis
ground (-):
-
DTC 23 / (F49) No. 9 (+) Chassis
ground (-):
DTC 25 / (F49) No. 14 (+) - Chassis
ground (-):
DTC 2 7 / (F49) No. 7 (+) - Chassis
ground 6):

ABS-43
 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR
ABS (DIAGNOSTICS)

Step Check Yes No

i CHECK BAlTERY SHORT OF HARNESS. s the voltage less than 1 V? ;o to step 7. Repair harness
1)Turn the ignition switch to ON. between
2)Measure the voltage between ABSCM&H/U ABSCM&H/U and
connector and chassis ground. ABS sensor.
Connector & terminal
DTC 21 /(F49) No. 11 (+) - Chassis
ground (-):
DTC 23 / (F49) No. 9 (+) - Chassis
ground (-):
DTC 25 / (F49) No. 14 (+) - Chassis
ground (-):
DTC 27/ (F49) No. 7 (+) - Chassis
ground (-):
r CHECK INSTALLATION OF ABS SENSOR. Are the ABS sensor installation 20 to step 8. Tighten the ABS
Turn the ignition switch to OFF. Iolts tightened securely? sensor installation
Tightening torque: bolts securely.
32 N.m (3.3 kgf-m, 24 ft-lb)
$ CHECK ABS SENSOR GAP. s the gap within the specifica- 20 to step 9. Adjust the gap.
Measure the tone wheel to ABS sensor piece ions? NOTE:
gap over entire perimeter of the wheel. Adjust the gap u s
Front wheel ing spacers (Par
0.3 - 0.8 mm (0.012 - 0.031 in) No. 26755AA000)
Rear wheel If spacers canno
0.7 - 1.2 mm (0.028 - 0.047 in) correct the gap, re.
place worn sensoi
or worn tone
wheel.
b CHECK TONE WHEEL RUNOUT. s the runout less than 0.05 20 to step 10. Replace the tone
Measure the tone wheel runout. nm (0.0020 in)? wheel. Front:
<Ref. to ABS-21,
Front Tone
Wheel.> Rear:
<Ref. to ABS-22,
Rear Tone
Wheel.>
10 CHECK GROUND SHORT OF ABS SENSOR. s the resistance more than 1 20 to step 11. Replace the ABS
1)Turnthe ignition switch to ON. dR? sensor and
2)Measure the resistance between ABS sen- ABSCM&H/U.
sor and chassis ground. Front: <Ref. to
Terminal ABS-14, Front
Front RH No. 1 - Chassis ground: ABS Sensor.>
Front LH No. 1 - Chassis ground: Rear: <Ref. to
Rear RH No. 1 - Chassis ground: ABS-18, Rear
Rear LH No. 1 - Chassis ground: ABS Sensor.>
and <Ref. to
ABS-7, ABS Con-
trol Module and
Hydraulic Control
Unit (ABSCM&H/
U).>

ABS-44
 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR m
ABS (DIAGNOSTICS)

Step Check No
11 CHECK GROUND SHORT OF HARNESS. Repair harness
1)Turnthe ignition switch to OFF: between
2)Connect the connector to ABS sensor. ABSCM&H/U and
3)Measure the resistance between ABS sensor.
ABSCM&H/U connector terminal and chassis Replace
ground. ABSCM&H/U.
Connector & terminal <Ref. to ABS-7,
DTC 21 / (F49) No. 11 - Chassis ground: ABS Control Mod-
DTC 23 / (F49) No. 9- Chassis ground: ule and Hydraulic
DTC 25 / (F49) No. 14 - Chassis ground: Control Unit
-
DTC 27/(F49) No. 7 Chassis ground: (ABSCM&H/U).>
12 CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in con- Repair the con- Go to step 13.
nectors between ABSCM&H/U nector.
and ABS sensor?
13 CHECK ABSCM&H/U. Is the same diagnostic trouble Replace the Go to step 14.
1)Connect all connectors. :ode as in the current diagno- ABSCM&H/U.
2)Erase the memory. sis still being output? <Ref. to ABS-7,
3)Perform the inspection mode. ABS Control Mod-
4)Read out the diagnostic trouble code. ule and Hydraulic
Control Unit
(ABSCM&H/U).>
14 CHECK ANY OTHER DIAGNOSTIC TROU- Are other diagnostic trouble Proceed with the A temporary poor
BLE CODES APPEARANCE. codes being output? diagnosis corre- contact.
sponding to the NOTE:
diagnostic trouble Check harnes:
code. and connector:
between AB,
SCM&H/U anc
ABS sensor.

ABS-45
I la
DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR
ABS (DIAGNOSTICS)

H: DTC22
ABNORMAL ABS SENSOR (FRONT RH)
NOTE:
For the diagnostic procedure, refer to DTC 28. <Ref. to ABS-47, DTC 28 ABNORMAL ABS SENSOR (REAR
LH), Diagnostics Chart with Diagnosis Connector.>

I: DTC24
ABNORMAL ABS SENSOR (FRONT LH)
NOTE:
For the diagnostic procedure, refer to DTC 28. <Ref. to ABS-47, DTC 28 ABNORMAL ABS SENSOR (REAR
LH), Diagnostics Chart with Diagnosis Connector.>

J: DTC26
ABNORMAL ABS SENSOR (REAR RH)
NOTE:
For the diagnostic procedure, refer to DTC 28. <Ref. to ABS-47, DTC 28 ABNORMAL ABS SENSOR (REAR
LH), Diagnostics Chart with Diagnosis Connector.>

ABS-46
 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR
ia
ABS (DIAGNOSTICS)

K: DTC28
ABNORMAL ABS SENSOR (REAR LH)
DIAGNOSIS:
Faulty ABS sensor signal (noise, irregular signal, etc.)
Faulty harnesskonnector
TROUBLE SYMPTOM:
ABS does not operate.

ABS-47
 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR
ABS (DIAGNOSTICS)

WIRING DIAGRAM:

ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT

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FRONT FRONT
ABS ABS REAR REAR
SENSOR LH SENSOR RH ABS ABS
SENSOR LH SENSOR RH

BR0084

ABS-48
 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR
m
ABS (DIAGNOSTICS)

Step Check Yes No

CHECK INSTALLATION OF ABS SENSOR. Are the ABS sensor installation 30 to step 2. 7ghten the ABS
Turn the ignition switch to OFF. bolts tightened securely? iensor installation
Tightening torque: lolts securely.
32 N.m (3.3 kgf-m, 24 ft-lb)
I CHECK ABS SENSOR GAP. Is the gap within the specifica- 30 to step 3. idjust the gap.
Measure the tone wheel to ABS sensor piece tions? JOTE:
gap over entire perimeter of the wheel. idjust the gap us
Front wheel 'lg spacer (Par
0.3 - 0.8 mm (0.012 - 0.031 in) do. 26755AA000)
f spacers canno
:orrect the gap, re
)lace worn senso
)r worn tonc
vheel.
I PREPARE OSCILLOSCOPE. Is an oscilloscope available? 30 to step 4. io to step 5.
I CHECK ABS SENSOR SIGNAL. Is the oscilloscope pattern 30 to step 8. 20 to step 7.
1)Raise all four wheels off ground. smooth, as shown in the fig-
2)Turn the ignition switch OFF. ure?
3)Connect the oscilloscope to the connector.
4)Turn the ignition switch ON.
5)Rotate the wheels and measure voltage at
specified frequency. <Ref. to ABS-17, WAVE-
FORM, Control Module I/O Signal.>
NOTE:
When this inspection is completed, the ABS
control module sometimes stores the DTC 29.
Connector & terminal
DTC 22 /
(F95) NO. 1 (+) - NO. 2 (-):
DTC 24 /
(F94) NO. 1 (+) - NO. 2 (-):
DTC26/
(699) NO. 9 (+) - NO. 10 (-):
DTC28/
(699) NO. 4 (+) - NO. 5 (-):
CHECK CONTAMINATION OF ABS SENSOR Is the ABS sensor piece or the rhoroughly io to step 6.
OR TONE WHEEL. tone wheel contaminated by 'emove dirt or
Remove the disc rotor or drum from hub in dirt or other foreign matter? ither foreign mat-
accordance with diagnostic trouble code. er.
i CHECK DAMAGE OF ABS SENSOR OR Are there broken or damaged 3eplace the ABS 30 to step 7.
TONE WHEEL. in the ABS sensor piece or the sensor or tone
tone wheel? Nheel. Front: <Ref.
:o ABS-14, Front
4BS Sensor.>
3ear: <Ref. to
46s-18, Rear
4BS Sensor.> and
Front: <Ref. to
46s-21, Front
Tone Wheel.>
?ear: <Ref. to
465-22, Rear
Tone Wheel.>

ABS-49
 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR
ABS (DIAGNOSTICS)
~ ~ _ _ _ ~ ~~

Step Check Yes No

I CHECK TONE WHEEL RUNOUT. s the runout less than 0.05 So to step 8. Replace the tone
Measure the tone wheel runout. nm (0.0020 in)? wheel. Front:
<Ref. to ABS-21,
Front Tone
Wheel.> Rear:
<Ref. to ABS-22,
Rear Tone
Wheel.>
1 CHECK RESISTANCE OF ABS SENSOR. s the resistance between 1 So to step 9. Replace the ABS
1)Turn the ignition switch OFF. ind 1.5 kR? sensor. Front:
2)Disconnect the connector from ABS sensor. <Ref. to ABS-14,
3)Measure the resistance between ABS sen- Front ABS Sen-
sor connector terminals. sor.> Rear: <Ref.
Terminal to ABS-18, Rear
Front RH No. 1 - No. 2: ABS Sensor.>
Front LH No. 1 -No. 2:
-
Rear RH No. 1 No. 2:
-
Rear LH No. 1 No. 2:
CHECK GROUND SHORT OF ABS SENSOR. s the resistance more than 1 So to step 10. Replace the ABS
Measure the resistance between ABS sensor dR? sensor. Front:
and chassis ground. <Ref. to ABS-14,
Terminal Front ABS Sen-
-
Front RH No. 1 Chassis ground: sor.> Rear: <Ref.
Front LH No. 1 - Chassis ground: to ABS-18, Rear
Rear RH No. 1 - Chassis ground: ABS Sensor.>
-
Rear LH No. 1 Chassis ground:
IO CHECK HARNESWCONNECTOR BETWEEN s the resistance between 1 So to step 11. Repair harness1
ABSCM&HIU AND ABS SENSOR. md 1.5 kR? connector
1)Connect the connector to ABS sensor. between
2)Disconnect the connector from ABSCM& ABSCM&H/U and
H/U. ABS sensor.
3)Measure the resistance at ABSCM&HIU
connector terminals.
Connector & terminal
-
DTC 22 / (F49) NO. 11 NO. 12:
DTC 24 / (F49) NO. 9 - NO. 10:
-
DTC 26 /(F49) NO. 14 NO. 15:
-
DTC 28 / (F49) NO. 7 NO. 8:
I1 CHECK GROUND SHORT OF HARNESS. s the resistance more than 1 i o to step 12. Repair harness/
Measure the resistance between ABSCM&H/U dQ? connector
connector and chassis ground. between
Connector & terminal ABSCM&H/U and
-
DTC 22 / (F49) No. 11 Chassis ground: ABS sensor.
DTC 24 / (F49) No. 9 - Chassis ground:
-
DTC 26 / (F49) No. 14 Chassis ground:
-
DTC 28 / (F49) No. 7 Chassis ground:
12 CHECK GROUND CIRCUIT OF ABSCM&H/U. s the resistance less than 0.5 So to step 13. Repair the
Measure the resistance between ABSCM&H/U 2? ABSCM&H/U
and chassis ground. ground harness.
Connector & terminal
(F49) NO. 23 - GND:
13 CHECK POOR CONTACT IN CONNECTORS. s there poor contact in con- lepair the con- Go to step 14.
lectors between ABSCM&H/L lector.
md ABS sensor?
14 CHECK SOURCES OF SIGNAL NOISE. s the car telephone or the So to step 15. Properly install the
vireless transmitter properly car telephone or
nstalled? the wireless trans-
mitter.

ABS-50
 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR a
ABS (DIAGNOSTICS)

Step Check Yes No

5 CHECK SOURCES OF SIGNAL NOISE. Are noise sources (such as an nstall the noise ;o to step 16.
antenna) installed near the sources apart from
sensor harness? he sensor har-
less.
6 CHECK SHIELD CIRCUIT. Is the resistance less than 0.5 30 to step 17. 3epair the shield
1)Connect all connectors. Q? iarness.
2)Measure the resistance between shield con-
nector and chassis ground.
Connector & terminal
-
DTC 26 / (6200) No. 1 1 Chassis
ground:
DTC 28 / (6200) No. 3 - Chassis ground
NOTE:
For the DTC 22 and 24:
Go to step 17.
I7 CHECK ABSCM&H/U. Is the same diagnostic trouble 3eplace the 20 to step 18.
1)Connect all connectors. code as in the current diagno- 4BSCM&H/U.
2)Erase the memory. sis still being output? :Ref. to ABS-7,
3)Perform the inspection mode. 4BS Control Mod-
4)Read out the diagnostic trouble code. Jle and Hydraulic
Zontrol Unit
:ABSCM&H/U).>
18 CHECK ANY OTHER DIAGNOSTIC TROU- Are other diagnostic trouble Proceed with the 4 temporary noise
BLE CODES APPEARANCE. codes being output? jiagnosis corre- nterference.
sponding to the
%agnostictrouble
:ode.
I

ABS-51
DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR

ABS-52
 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR
ABS (DIAGNOSTICS)
~~

L: DTC29
ABNORMAL ABS SENSOR SIGNAL (ANY ONE OF FOUR)
DIAGNOSIS:
Faulty ABS sensor signal (noise, irregular signal, etc.)
Faulty tone wheel
Wheels turning freely for a long time
TROUBLE SYMPTOM:
ABS does not operate.

ABS-53
 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR
ABS (DIAGNOSTICS)

WIRING DIAGRAM:

@ ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT

IC
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FRONT FRONT
ABS ABS REAR REAR
SENSOR LH SENSOR RH ABS ABS
SENSOR LH SENSOR RH

BR0084

ABS-54
 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR
ABS (DIAGNOSTICS)

Step Check Yes No

CHECK IF THE WHEELS HAVE TURNED :heck if the wheels have been lThe ABS is nor- /Go to step 2.
FREELY FOR A LONG TIME. urned freely for more than one mal. Erase the
ninute, such as when the vehi- diagnostic trouble
:le is jacked-up, under full-lock code.
:ornering or when tire is not in NOTE:
:ontact with road surface. When the wheels
turn freely for a
long time, such as
when the vehicle is
towed or jacked-
up, or when steer-
ing wheel is contin-
uously turned all
the way, this trou-
ble code may
sometimes occur.
! CHECK TIRE SPECIFICATIONS. 4re the tire specifications cor- Go to step 3. Replace the tire.
Turn the ignition switch to OFF. ect?
1 CHECK WEAR OF TIRE. s the tire worn excessively? Replace the tire. Go to step 4.
I CHECK TIRE PRESSURE. s the tire pressure correct? Go to step 5. Adjust the tire
pressure.
CHECK INSTALLATION OF ABS SENSOR. 4re the ABS sensor installation Go to step 6. Tighten the ABS
Tightening torque: iolts tightened securely? sensor installation
32 N.m (3.3 kgf-m, 24 ft-lb) bolts securely.
i CHECK ABS SENSOR GAP. s the gap within the specifica- Go to step 7. Adjust the gap.
Measure the tone wheel to ABS sensor piece ions? NOTE:
gap over entire perimeter of the wheel. Adjust the gap us,
Specifications ing spacer (Part
Front wheel No. 26755AAOOO).
0.3 - 0.8 mm (0.012 - 0.031 in) If spacers cannot
Rear wheel correct the gap, re-
0.7 - 1.2 mm (0.028 - 0.047 in) place worn sensor
or worn tone
wheel.
PREPARE OSCILLOSCOPE. s an oscilloscope available? Go to step 8. Go to step 9.
I CHECK ABS SENSOR SIGNAL. s the oscilloscope pattern Go to ster, 12. Go to step 9.
1)Raise all four wheels off ground. imooth, as shown in figure?
2)Turn the ignition switch OFF.
3)Connect the oscilloscope to the connector.
4)Turn the ignition switch ON.
5)Rotate the wheels and measure voltage at
specified frequency. <Ref. to ABS-17, WAVE-
FORM, Control Module I/O Signal.>
NOTE:
When this inspection is completed, the AB
SCM&H/U sometimes stores the DTC 29.
Connector & terminal
Front RH
(F95) NO. 1 (+) - NO. 2 (-):
Front LH
(F94) NO. 1 (+) - NO.2 (-):
Rear RH
(B99) NO. 9 (+) - NO. 10 (-):
Rear LH
(B99) NO. 4 (+) - NO. 5 (-):

ABS55
~
DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR
ABS (DIAGNOSTICS)

Step Check Yes No

3 CHECK CONTAMINATION OF ABS SENSOR s the ABS sensor piece or the Thoroughly 30 to step 10.
OR TONE WHEEL. one wheel contaminated by remove dirt or
Remove the disc rotor from hub. lirt or other foreign matter? other foreign mat-
ter.
IO CHECK DAMAGE OF ABS SENSOR OR 4re there broken or damaged Replace the ABS 30 to step 11.
TONE WHEEL. eeth in the ABS sensor piece sensor or tone
)r the tone wheel? wheel. Front: <Ref.
to ABS-14, Front
ABS Sensor.>
Rear: <Ref. to
ABS-18, Rear
ABS Sensor.>
and Front: <Ref.
to ABS-21, Front
Tone Wheel.>
Rear: <Ref. to
ABS-22, Rear
Tone Wheel.>
I1 CHECK TONE WHEEL RUNOUT. s the runout less than 0.05 Go to step 12. 3eplace the tone
Measure the tone wheel runout. nm (0.0020 in)? Nheel. Front:
:Ref. to ABS-21,
3ont Tone
Nhee1.z Rear:
:Ref. to ABS-22,
3ear Tone
Nheeb
12 CHECK ABSCM&H/U . s the same diagnostic trouble Replace the 30 to step 13.
1)Turn the ignition switch to OFF. ;ode as in the current diagno- ABSCM&H/U.
2)Connect all connectors. ;is still being output? <Ref. to ABS-7,
3)Erase the memory. ABS Control Mod-
4)Perform the inspection mode. ule and Hydraulic
5)Read out the diagnostic trouble code. Sontrol Unit
[ABSCM&H/U).>
13 CHECK ANY OTHER DIAGNOSTIC TROU- 4re other diagnostic trouble Proceed with the 4 temporary poor
BLE CODES APPEARANCE. ;odes being output? diagnosis corre- :ontact.
sponding to the
diagnostic trouble
:ode.

ABS-56
 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR I
ABS (DIAGNOSTICS)
~~

M: DTC31
ABNORMAL INLET SOLENOID VALVE CIRCUIT(S) IN ABSCM&H/U (FRONT
RH)
NOTE:
For the diagnostic procedure, refer to DTC 37. <Ref. to ABS-57, DTC 37 ABNORMAL INLET SOLENOID
VALVE CIRCUIT(S) IN ABSCM&H/U (REAR LH), Diagnostics Chart with Diagnosis Connector.>

N: DTC33
ABNORMAL INLET SOLENOID VALVE CIRCUIT(S) IN ABSCM&H/U (FRONT
LH)
NOTE:
For the diagnostic procedure, refer to DTC 37. <Ref. to ABS-57, DTC 37 ABNORMAL INLET SOLENOID
VALVE CIRCUIT(S) IN ABSCM&H/U (REAR LH), Diagnostics Chart with Diagnosis Connector.>

0: DTC35
ABNORMAL INLET SOLENOID VALVE ClRCUIT(S) IN ABSCM&H/U (REAR
RH)
NOTE:
For the diagnostic procedure, refer to DTC 37. <Ref. to ABS-57, DTC 37 ABNORMAL INLET SOLENOID
VALVE CIRCUIT(S) IN ABSCM&H/U (REAR LH), Diagnostics Chart with Diagnosis Connector.>

P: DTC37
ABNORMAL INLET SOLENOID VALVE ClRCUIT(S) IN ABSCM&H/U (REAR
LH)
DIAGNOSIS:
Faulty harness/connector
Faulty inlet solenoid valve in ABSCM&H/U
TROUBLE SYMPTOM:
ABS does not operate.

ABS-57
 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR
ABS (DIAGNOSTICS)

WIRING DIAGRAM:

BATTERY
n

RELAY
HOLDER

ABS
RELAY

@ ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT

BR0005

ABS-58
 9
DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR
ABS (DIAGNOSTICS)
~

Step Check Yes No

I CHECK INPUT VOLTAGE OF RELAY HOLD- s the voltage more than 10 V? Go to step 2. Repair open circuit
ER. in harness
1)Turn the ignition switch to OFF. between battery
2)Remove the fuse. m d Relay holder
3)Measure the voltage between ABS relay Zonnector.
connector and chassis ground.
Connector & terminal
(8225) No. 5 (+) - Chassis ground (-):
2 CHECK RELAY HOLDER. Is the fuse blown out? IReplace the fuse. Go to step 3.
3 CHECK INPUT VOLTAGE OF ABS RELAY. Is the voltage more than 10 V? Go to step 4. Repair open circuit
1)lnstall the fuse. in harness
2)Remove the ABS relay. between battery
3)Turn the ignition switch to ON. and Relay holder
4)Measure the voltage between ABS relay connector.
connector and chassis ground.
Connector & terminal

k
(8264) No. 2 (+) - Chassis ground (-):
4 CHECK INPUT VOLTAGE OF ABS RELAY. IS the voltage more than 10 V? Go to step 5. Repair harness
Measure the voltage between ABS relay con- connector
nector and chassis ground. between battery,
Connector & terminal ignition switch and
(8264) No. 1 (+) - Chassis ground (-): ABS relay.
5 CHECK GROUND CIRCUIT OF ABS RELAY. Is the resistance less than 5 Go to step 6. Repair open circuit
1)Turn the ignition switch to OFF. n? between ABS
2)Measure the resistance between ABS relay relay and chassis
connector and chassis ground. ground.
Connector & terminal
(8264) No. 3 (+) - Chassis ground:
6 CHECK the ABS RELAY. Is the resistance less than 10 Go to step 7. Replace the ABS
1)Connect the battery to ABS relay terminal n? relay.
No. 1 and 3.
2)Measure the resistance between ABS relay
terminals.
7 CHECK INPUT VOLTAGE OF ABSCM&H/U. Repair harness
1)Disconnectthe connector from ABSCM& 15 V? connector
H/U. between ABS
2)Run the engine at idle. relay and
3)Measure the voltage between ABSCM&H/U ABSCM&H/U.

7-j-
connector and chassis ground.
Connector & terminal
(F49) No. 1 (+) - Chassis ground (-):
0 CHECK GROUND CIRCUIT OF ABSCM&H/U. Is the resistance less than 0.5 Go to step 9. Repair the
1)Turn the ignition switch to OFF. ABSCM&H/U
2)Measure the resistance between ground harness.
ABSCM&H/U connector and chassis ground.
Connector & terminal
-
(F49) No. 23 Chassis ground:
9 CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in con- Repair the con- Go to step 10.
nectors between generator, nector.
battery and ABSCM&H/U?
10 CHECK ABSCM&H/U. Is the same diagnositc trouble Replace the Go to step 11.
1)Connect all connectors. code as in the current diagno- ABSCM&H/U.
2)Erase the memory. sis still being output? <Ref. to ABS-7,
3)Perform the inspection mode. ABS Control Mod-
4)Read out the diagnostic trouble code. ule and Hydraulic
Control Unit
(ABSCM&H/U).>

ABS-59
 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR
ABS (DIAGNOSTICS)

Step Check
11 CHECK ANY OTHER DIAGNOSTIC TROU- Are other diagnostic trouble
BLE CODES APPEARANCE. codes being output?
sponding to the
diagnostic trouble
code.

ABS-60
 a
DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR
ABS (DIAGNOSTICS)

Q: DTC32
ABNORMAL OUTLET SOLENOID VALVE CIRCUIT(S) IN ABSCM&H/U
(FRONT RH)
NOTE:
For the diagnostic procedure, refer to DTC 38. <Ref. to ABS-61, DTC 38 ABNORMAL OUTLET SOLENOID
VALVE CIRCUIT(S) IN ABSCM&H/U (REAR LH), Diagnostics Chart with Diagnosis Connector.>

R: DTC34
ABNORMAL OUTLET SOLENOID VALVE CIRCUIT(S) IN ABSCM&H/U
(FRONT LH)
NOTE:
For the diagnostic procedure, refer to DTC 38. <Ref. to ABS-61, DTC 38 ABNORMAL OUTLET SOLENOID
VALVE CIRCUIT(S) IN ABSCM&H/U (REAR LH), Diagnostics Chart with Diagnosis Connector.>

S: DTC36
ABNORMAL OUTLET SOLENOID VALVE CIRCUIT(S) IN ABSCM&H/U
(REAR RH)
NOTE:
For the diagnostic procedure, refer to DTC 38. <Ref. to ABS-61, DTC 38 ABNORMAL OUTLET SOLENOID
VALVE CIRCUIT(S) IN ABSCM&H/U (REAR LH), Diagnostics Chart with Diagnosis Connector.>

T: DTC38
ABNORMAL OUTLET SOLENOID VALVE CIRCUIT(S) IN ABSCM&H/U
(REAR LH)
DIAGNOSIS:
Faulty harnesdconnector
Faulty outlet solenoid valve in ABSCM&H/U
TROUBLE SYMPTOM:
ABS does not operate.

ABS-61
 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR
ABS (DIAGNOSTICS)

WIRING DIAGRAM:

BATTERY

RELAY
HOLDER

ABS
RELAY

I @ ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT

I
I

ABS-62
 m
DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR
ABS (DIAGNOSTICS)
~~

Step Check Yes No

I CHECK INPUT VOLTAGE OF RELAY HOLD- j the voltage more than 10 V? Go to step 2. 3epair open circuit
ER. n harness
1)Turn the ignition switch to OFF. 2etween battery
2)Remove the fuse. 2nd Relay holder
3)Measure the voltage between ABS relay :onnector.
connector and chassis ground.
Connector & terminal
(8225) No. 5 (+) - Chassis ground (-):
2 CHECK RELAY HOLDER. s the fuse blown out? Replace the fuse. 30 to step 3.
3 CHECK INPUT VOLTAGE OF ABS RELAY. s the voltage more than 10 V? Go to step 4. Repair open circuit
1)lnstall the fuse. n harness
2)Remove the ABS relay. Detween battery
3)Turn the ignition switch to ON. 2nd Relay holder
4)Measure the voltage between ABS relay :onnector.
connector and chassis ground.
Connector & terminal
(8264) No. 2 (+) - Chassis ground (-):
1 CHECK INPUT VOLTAGE OF ABS RELAY. s the voltage more than 10 V? Go to step 5. Repair harness
Measure the voltage between ABS relay con- :onnector
nector and chassis ground. Detween battery,
Connector & terminal ignition switch and
(8264) No. 1 (+) - Chassis ground (-): ABS relay.
5 CHECK GROUND CIRCUIT OF ABS RELAY, s the resistance less than 5 Go to step 6. Repair open circuit
1)Turnthe ignition switch to OFF. 2? between ABS
2)Measure the resistance between ABS relay relay and chassis
connector and chassis ground. ground.
Connector & terminal
(8264) No. 3 (+)- Chassis ground:
6 . CHECK ABS RELAY. s the resistance less than 10 Go to step 7. Replace the ABS
1)Connect the battery to ABS relay terminal L? relay.
No. 1 and 3.
2)Measure the resistance between ABS relay
terminals.
7 CHECK INPUT VOLTAGE OF ABSCM&H/U. s the voltage between 10 and Go to step 8. Repair harness
1)Disconnectthe connector from ABSCM& 15 V? connector
H/U. between battery,
2)Run the engine at idle. ignition switch and
3)Measure the voltage between ABSCM&H/U ABSCM&H/U.
connector and chassis ground.
Connector & terminal
(F49) No. 1 (+) - Chassis ground (-):
B CHECK GROUND CIRCUIT OF ABSCM&H/U s the resistance less than 0.5 Go to step 9. Repair the
1)Turn the ignition switch to OFF. l? ABSCM&H/U
2)Measure the resistance between ground harness.
ABSCM&H/U connector and chassis ground.
Connector & terminal
(F49) No. 23 - Chassis ground:
9 CHECK POOR CONTACT IN CONNECTORS s there poor contact in con- Repair the con- Go to step 10.
lectors between generator, nector.
Iattery and ABSCM&H/U?
10 CHECK ABSCM&HN. s the same diagnostic trouble Replace the Go to step 11.
1)Connect all connectors. :ode as in the current diagno- ABSCM&H/U.
2)Erase the memory. ;is still being output? <Ref. to ABS-7,
3)Perform the inspection mode. ABS Control Mod-
4)Read out the diagnostic trouble code. ule and Hydraulic
Control Unit
(ABSCM&H/U).>

ABS-63
 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR
ABS (DIAGNOSTICS)

Step Check Yes No

11 CHECK ANY OTHER DIAGNOSTIC TROU- Are other diagnostic trouble Proceed with the A temporary poor
BLE CODES APPEARANCE. codes being output? diagnosis corre- contact.
sponding to the
diagnostic trouble
code.

ABS-64
DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR
ABS (DIAGNOSTICS)

ABS-65
 a
DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR
ABS (DIAGNOSTICS)

U: DTC41
ABNORMAL ABS CONTROL MODULE
DIAGNOSIS:
Faulty ABSCM&H/U.
TROUBLE SYMPTOM:
ABS does not operate.
WIRING DIAGRAM:

-
-

B4M145i

ABS-66
 3
DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR
ABS (DIAGNOSTICS)

7
Step Check Yes
I CHECK GROUND CIRCUIT OF ABSCM&H/U. s the resistance less than 0.5 Go to step 2. 3epair the
1)Turn the ignition switch to OFF. 2? 4BSCM&H/U
I
2)Disconnect the connector from ABSCM& jround harness.
H/U.
I
3)Measure the resistance between
ABSCM&H/U and chassis ground.

---
Connector & terminal
(F49)No. 23 - Chassis ground:
! CHECK POOR CONTACT IN CONNECTORS. s there poor contact in con- Repair the con- 30 to step 3.
lectors between battery, igni- nector.
ion switch and ABSCM&H/U? I
i CHECK SOURCES OF SIGNAL NOISE. s the car telephone or the Go to step 4. >roperlyinstall the
vireless transmitter properly :ar telephone or
nstalled? he wireless trans-
nitter.
I CHECK SOURCES OF SIGNAL NOISE. 4re noise sources (such as an Install the noise 30 to step 5.
mtenna) installed near the sources apart from
;ensor harness? the sensor har-
ness.
I CHECK ABSCM&H/U. s the same diagnostic trouble Replace the 30 to step 6.
1)Connect all connectors. :ode as in the current diagno- ABSCM&H/U.
2) Erase the memory. ;is still being output? <Ref. to ABS-7,
3)Perform the inspection mode. ABS Control Mod-
4)Read out the diagnostic trouble code. ule and Hydraulic
Control Unit
(ABSCM&H/U).>
5 CHECK ANY OTHER DIAGNOSTICTROU- 4re other diagnostic trouble Proceed with the
BLE CODES APPEARANCE. :odes being output? diagnosis corre- :ontact.
sponding to the
diagnostic trouble
code.

ABS-67
 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR
ABS (DIAGNOSTICS)

ABS-68
 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR
ABS (DIAGNOSTICS)

V: DTC42
SOURCE VOLTAGE IS ABNORMAL
DIAGNOSIS:
Power source voltage of the ABSCM&H/U is low or high.
TROUBLE SYMPTOM:
ABS does not operate.

ABS-69
 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR
ABS (DIAGNOSTICS)

WIRING DIAGRAM:

RELAY
HOLDER

ABS
RELAY

@ ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT

516171819

BR0085

ABS-70
 a
DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR
ABS (DIAGNOSTICS)

Step Check Yes No

CHECKGENERATOR. s the voltage between 10 and 30 to step 2. qepair the genera-
1)Start the engine. 7 V? :or. <Ref. to SC-
2)ldling after warm-up. 13, Generator.>
3)Measure the voltage between generator B
terminal and chassis ground.
Terminal
Generator 8 terminal - Chassis ground:
CHECK BATTERY TERMINAL. ire the positive and negative 30 to step 3. Tighten the clamp
Turn the ignition switch to OFF. battery terminals tightly 2f terminal.
ilamped?
CHECK INPUT VOLTAGE OF RELAY HOLD- s the voltage more than 10 V? 30 to step 4. Repair open circuit
ER. n harness
1)Turn the ignition switch to OFF. 3etween battery
2)Remove the fuse. and Relay holder
3)Measure the voltage between ABS relay :onnector.
connector and chassis ground.
Connector & terminal
(8225) No. 5 (+) - Chassis ground (-):
CHECK RELAY HOLDER. s the fuse blown out? 3eplace the fuse. Go to step 5.
CHECK INPUT VOLTAGE OF ABS RELAY. s the voltage more than 10 V? 30 to step 6. Repair open circuit
1)lnstall the fuse. in harness
2)Remove the ABS relay. between battery
3)Turn the ignition switch to ON. and Relay holder
4)Measure the voltage between ABS relay connector.
connector and chassis ground.
Connector & terminal
(8264) No. 2 (+) - Chassis ground (-):
CHECK INPUT VOLTAGE OF ABS RELAY. s the voltage more than 10 V? 30 to step 7. Repair harness
Measure the voltage between ABS relay con- connector
nector and chassis ground. between battery,
Connector & terminal ignition switch and
(8264) No. 1 (+) - Chassis ground (-): ABS relay.
CHECK GROUND CIRCUIT OF ABS RELAY. s the resistance less than 5 30 to step 8. Repair open circuit
1)Turnthe ignition switch to OFF. 2? between ABS
2)Measure the resistance between ABS relay relay and chassis
connector and chassis ground. ground.
Connector & terminal
(8264) No. 3 (+) - Chassis ground:
CHECK ABS RELAY. s the resistance less than 10 30 to step 9. Replace the ABS
1)Connect the battery to ABS relay terminal a? relay.
No. 1 and 3.
2)Measure the resistance between ABS relay
terminals.
CHECK INPUT VOLTAGE OF ABSCM&H/U. s the voltage between 10 and So to step 10. Repair harness
1)Disconnectthe connector from ABSCM& I7 V? connector
H/U. between battery,
2)Run the engine at idle. ignition switch and
3)Measure the voltage between ABSCM&H/U ABSCM&H/U.
connector and chassis grou.nd.
Connector & terminal
(F49) No. 1 (+) - Chassis ground (-):
1 CHECK GROUND CIRCUIT OF ABSCM&H/U. s the resistance less than 0.5 Go to step 11. Repair the
1)Turnthe ignition switch to OFF. 3? ABSCM&H/U
2)Measure the resistance between ground harness.
ABSCM&H/U connector and chassis ground.
Connector & terminal
(F49) No. 23 - Chassis ground:

ABS-71
I
DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR
ABS (DIAGNOSTICS)

Step Check Yes No

1 CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in con- Repair the con- Go to step 12.
nectors between generator, nector.
battery and ABSCM&H/U?
2 CHECK ABSCM&H/U. Is the same diagnostic trouble Replace the Go to step 13.
1)Connect all connectors. code as in the current diagno- ABSCM&H/U.
2)Erase the memory. sis still being output? <Ref. to ABS-7,
3)Perform the inspection mode. ABS Control Mod-
4)Read out the diagnostic trouble code. ule and Hydraulic
Control Unit
(ABSCM&H/U).>
3 CHECK ANY OTHER DIAGNOSTIC TROW Are other diagnostic trouble Proceed with the A temporary poor
BLE CODES APPEARANCE. codes being output? diagnosis corre- contact.
sponding to the
diagnostic trouble
code.

ABS-72
DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR
ABS (DIAGNOSTICS)

ABS-73
 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR
ABS (DIAGNOSTICS)

W: DTC44
A COMBINATION OF AT CONTROL ABNORMAL
DIAGNOSIS:
Combination of AT control faults
TROUBLE SYMPTOM:
ABS does not operate.
WIRING DIAGRAM:

I @ ABS CONTROL MODULE AND

HYDRAULIC CONTROL UNIT
I
1 1

: TURBO ENGINE MODEL

I
I 6: 655
A : 8
TCM

BR0086

ABS-74
 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR ii
ABS (DIAGNOSTICS)

Step Check Yes No

1 CHECK SPECIFICATIONS OF THE AB- Is an ABSCM&H/U for AT 3eplace the Go to step 2.
SCM&H/U. model installed on a MT 4BSCM&H/U.
Check specifications of the mark to the nodel? :Ref. to ABS-7,
ABSCM&H/U. 9BS Control Mod-
CC: AT de and Hydraulic
CD: MT 2ontrol Unit
:ABSCM&H/U).>
2 CHECK GROUND SHORT OF HARNESS. Is the resistance more than 1 30 to step 3. Repair harness
1)Turn the ignition switch to OFF. MQ? between TCM and
2)Disconnect two connectors from TCM. ABSCM&H/U.
3)Disconnect the connector from ABSCM&
H/U.
4)Measure the resistance between
ABSCM&H/U connector and chassis ground.
Connector & terminal
(F49) No. 3 - Chassis ground:
3 CHECK BATTERY SHORT OF HARNESS. Is the voltage less than 1 V? 30 to step 4. Repair harness
Measure the voltage between ABSCM&H/U between TCM and
connector and chassis ground. ABSCM&H/U.
Connector & terminal
(F49) No. 3 (+)- Chassis ground (-):
4 CHECK BATTERY SHORT OF HARNESS. Is the voltage less than 1 V? 30 to step 5. Repair harness
1)Turnthe ignition switch to ON. between TCM and
2)Measure the voltage between ABSCM&H/U ABSCM&H/U.
connector and chassis ground.
Connector & terminal
(F49) No, 3 (+) - Chassis ground (-):
5 CHECK TCM. Is the voltage between 10 and Go to step 7. Go to step 6.
1)Turn the ignition switch to OFF. 15 V?
2)Connect all connectors to TCM.
3)Turn the ignition switch to ON.
4)Measure the voltage between TCM connec-
tor terminal and chassis ground.
Connector & terminal
NON-TURBO MODEL
(B54) No. 19 (+) - Chassis ground (-):
TURBO MODEL
(B55) No. 21 (+) - Chassis ground (-):
6 CHECK AT. Is the AT functioning normally? Replace the TCM. Repair the AT.
7 CHECK OPEN CIRCUIT OF HARNESS. Is the voltage between 10 and Go to step 8. Repair harness/
Measure the voltage between ABSCM&H/U 15 V? connector
connector and chassis ground. between TCM and
Connector & terminal ABSCM&H/U.
-
(F49) No. 3 (+) Chassis ground (-):
(F49) No. 31 (+) - Chassis ground (-):
8 CHECK POOR CONTACT IN CONNECTORS Is there poor contact in con- Repair the con- Go to step 9.
nectors between TCM and nector.
ABSCM&H/U?
9 CHECK ABSCM&H/U. Is the same diagnostic trouble Replace the Go to step 10.
1)Turn the ignition switch to OFF. code as in the current diagno- ABSCM&H/U.
2)Connect all connectors. sis still being output? <Ref. to ABS-7,
3)Erase the memory. ABS Control Mod-
4)Perform the inspection mode. ule and Hydraulic
5)Read out the diagnostic trouble code. Control Unit
(ABSCM&H/U).r

ABS-75
 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR
ABS (DIAGNOSTICS)

Step No
10 CHECK ANY OTHER DIAGNOSTIC TROU- A temporary poor
BLE CODES APPEARANCE. codes being output? diagnosis corre- contact.
sponding to the
diagnostic trouble
code.

ABS-76
 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR
ABS (DIAGNOSTICS)

X: DTC51
ABNORMAL VALVE RELAY
DIAGNOSIS:
Faulty valve relay
TROUBLE SYMPTOM:
ABS does not operate.

ABS-??
 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR
ABS (DIAGNOSTICS)

WIRING DIAGRAM:

RELAY

I 11
I
1-1
r
I
m
N

$
I

ABS CONTROL MODULE AND

HYDRAULIC CONTROL UNIT 'I
a
I

3
a

<A - I f
RELAY MOTOR RELAY

B
m

BR0087

ABS-78
 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR
m
ABS (DIAGNOSTICS)
~~~ ~

Step Check Yes No

CHECK INPUT VOLTAGE OF RELAY HOLD- s the voltage more than 10 V? 30 to step 2. Repair open circuit
ER. in harness
1)Turn the ignition switch to OFF. between battery
2)Remove the fuse. and relay holder
3)Measure the voltage between ABS relay Connector.
connector and chassis ground.
Connector & terminal
-
(6225) No. 5 (+) Chassis ground (-):
! CHECK RELAY HOLDER. s the fuse blown out? 3eplace fuse. Go to step 3.
I CHECK INPUT VOLTAGE OF ABS RELAY. s the voltage more than 10 V? 30 to step 4. Repair open circuit
1)lnstall the fuse. in harness
2)Remove the ABS relay. between battery
3)Turn the ignition switch to ON. and relay holder
4)Measure the voltage between ABS relay connector.
connector and chassis ground.
Connector & terminal
(6264) No. 2 (+) - Chassis ground (-):
I CHECK INPUT VOLTAGE OF ABS RELAY. s the voltage more than 10 V? 30 to step 5. Repair harness
Measure the voltage between ABS relay con- connector
nector and chassis ground. between battery,
Connector & terminal ignition switch and
(6264) No. 1 (+)- Chassis ground (-): ABS relay.
CHECK GROUND CIRCUIT OF ABS RELAY. s the resistance less than 5 30 to step 6. Repair open circuit
1)Turn the ignition switch to OFF. 2? between ABS
2)Measure the resistance between ABS relay relay and chassis
connector and chassis ground. ground.
Connector & terminal
(6264) No. 3 (+) - Chassis ground:
i CHECK ABS RELAY. s the resistance less than 10 30 to step 7 . Replace the ABS
1)Connect the battery to ABS relay terminal 2? relay.
No. 1 and 3.
2)Measure the resistance between ABS relay
terminals.
? CHECK INPUT VOLTAGE OF ABSCM&HIU. s the voltage between 10 and 30 to step 8. Repair harness
1)Turn the ignition switch to OFF. I5 V? connector
2)Disconnect the connector from ABSCM& between battery,
H/U. ABS relay and
3)Run the engine at idle. ABSCM&H/U.
4)Measure the voltage between ABSCM&H/U
connector and chassis ground.
Connector & terminal
(F49) No. 1 (+) - Chassis ground (-):
(F49) No. 24 (+) - Chassis ground (-):
5 CHECK GROUND CIRCUIT OF ABSCM&H/U. s the resistance less than 0.5 Go to step 9. Repair the
1)Turn the ignition switch to OFF. ;2? ABSCM&H/U
2)Measure the resistance between ground harness.
ABSCM&H/U connector and chassis ground.
Connector & terminal
(F49) No. 23 - Chassis ground:
3 CHECK VALVE RELAY IN ABSCM&H/U. s the resistance more than 1 Go to step 10. Replace the
Measure the resistance between ABSCM&H/U VlQ? ABSCM&H/U.
and terminals. <Ref. to ABS-7,
Terminals ABS Control Mod-
NO.23 (+) - NO. 24 (-): ule and Hydraulic
Control Unit
(ABSCM&H/U).>
IO CHECK POOR CONTACT IN CONNECTORS. s there poor contact in con- Repair the con- Go to step 11.
lectors between generator, nector.
iattery and ABSCM&H/U?

ABS-79
 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR
ABS (DIAGNOSTICS)
~ ~~ ~

Step Check Yes No

I1 CHECK ABSCM&H/U. Is the same diagnostic trouble Replace the IGo to step 12.
1)Connect all connectors. code as in the current diagno- ABSCM&H/U.
2)Erase the memory. sis still being output? <Ref. to ABS-7,
3)Perform the inspection mode. ABS Control Mod-
4)Read out the diagnostic trouble code. ule and Hydraulic
Control Unit
(ABSCM&H/U).>
12 CHECK ANY OTHER DIAGNOSTIC TROU- Are other diagnostic trouble Proceed with the A temporary poor
BLE CODES APPEARANCE. codes being output? diagnosis corre- contact.
sponding to the
diagnostic trouble
code.

ABS-80
 I
DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR
ABS (DIAGNOSTICS)
~~ ~

Y: DTC 52
ABNORMAL MOTOR AND/OR MOTOR RELAY
DIAGNOSIS:
Faulty motor
Faulty motor relay
Faulty harness connector
TROUBLE SYMPTOM:
ABS does not operate.

ABS-81
 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR
ABS (DIAGNOSTICS)
~ - I

WIRING DIAGRAM:

BATTERY

ZJ
ABS RELAY 6 2 2 5

r 1

VALVE RELAY

BR0088

ABS-82
 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR II
ABS (DIAGNOSTICS)

Step Check Yes No

CHECK INPUT VOLTAGE OF ABSCM&H/U. the voltage between 10 and ;o to step 2. Repair harness/
1)Turn the ignition switch to OFF. 5 V? connector
2)Disconnect the connector from ABSCM& between battery
HIU. and ABSCM&H/U
3)Turn the ignition switch to ON. and check fuse
4)Measure the voltage between ABSCM&H/U SBF-holder.
connector and chassis ground.
Connector & terminal
(F49) No. 25 (+) - Chassis ground (-):
CHECK GROUND CIRCUIT OF MOTOR. ;the resistance less than 0.5 30 to step 3. Repair the
1)Turn the ignition switch to OFF. !? ABSCM&H/U
2)Measure the resistance between ground harness.
ABSCM&H/U connector and chassis ground.
Connector & terminal
(F49) No. 26 - Chassis ground:
CHECK INPUT VOLTAGE OF RELAY HOLD, ;the voltage more than 10 V? 30 to step 4.
ER. in harness
1)Turn the ignition switch to OFF. between battery
2)Remove the fuse. and Relay holder
3)Measure the voltage between ABS relay connector.
connector and chassis ground.
Connector & terminal
(8225) No. 5 (+) - Chassis ground (-):
CHECKRELAYHOLDER. s the fuse blown out? Replace the fuse. Go to step 5.
CHECK INPUT VOLTAGE OF ABS RELAY. j the voltage more than 10 V? Go to step 6. Repair open circui
1)lnstall the fuse. in harness
2)Remove the ABS relay. between battery
3)Turn the ignition switch to ON. and Relay holder
4)Measure the voltage between ABS relay connector.
connector and chassis ground.
Connector & terminal
(8264) No. 2 (+) - Chassis ground (-):
CHECK INPUT VOLTAGE OF ABS RELAY. ;the voltage more than 10 V? 30 to step 7 . Repair harness
Measure the voltage between ABS relay con- connector
nector and chassis ground. between battery,
Connector & terminal ignition switch and
(8264) No. 1 (+) - Chassis ground (-): ABS relay.
CHECK GROUND CIRCUIT OF ABS RELAY j the resistance less than 5 So to step 8. Repair open circuP
1)Turn the ignition switch to OFF. 2? between ABS
2)Measure the resistance between ABS relay relay and chassis
connector and chassis ground. ground.
Connector & terminal
(8264) No. 3 (+) - Chassis ground:
CHECK ABS RELAY. s the resistance less than 10 Go to step 9. Replace the ABS
1)Connect the battery to ABS relay terminal 2? relay.
No. 1 and 3.
2)Measure the resistance between ABS relay
terminals.
CHECK INPUT VOLTAGE OF ABSCM&H/U. s the voltage between 10 and Go to step 10.
1)Run the engine at idle. I5 V? connector
2)Measure the voltage between ABSCM&H/U between battery,
connector and chassis ground. ignition switch an(
Connector & terminal ABSCM&H/U.
(F49) No. 1 (+) - Chassis ground (-):

ABS-83
 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR
ABS (DIAGNOSTICS)

Step Check Yes No

IO CHECK GROUND CIRCUIT OF ABSCM&H/U. Is the resistance less than 0.5 ;o to step 11. 3epair the
1)Turn the ignition switch to OFF. n? 4BSCM&H/U
2)Measure the resistance between jround harness.
ABSCM&H/U connector and chassis ground.
Connector & terminal
(F49)No. 23 - Chassis ground:
I1 CHECK MOTOR OPERATION. Can motor revolution noise 30 to step 12. 3eplace the
Operate the sequence control. <Ref. to ABS- (buzz) be heard when carrying 4BSCM&H/U.
11, ABS Sequence Control.> out the sequence control? :Ref. to ABS-7,
NOTE: ABS Control Mod-
Use the diagnosis connector to operate the se- de and Hydraulic
quence control. >ontrol Unit
ABSCM&H/U).>
12 CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in con- lepair the con- 30 to step 13.
Turn the ignition switch to OFF. nector between generator, bat- lector.
tery and ABSCM&H/U?
13 CHECK ABSCM&H/U. Is the same diagnostic trouble leplace the 30 to step 14.
1)Connect all connectors. code as in the current diagno- \BSCM&H/U.
2)Erase the memory. sis still being output? :Ref. to ABS-7,
3)Perform the inspection mode. 4BS Control Mod-
4)Read out the diagnostic trouble code. ile and Hydraulic
:ontrol Unit
ABSCM&H/U).>
14 CHECK ANY OTHER DIAGNOSTIC TROU- Are other diagnostic trouble 'roceed with the 4 temporary poor
BLE CODES APPEARANCE. :odes being output? liagnosis corre- :ontact.
iponding to the
liagnostic trouble
:ode.

ABS-84
DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR
ABS (DIAGNOSTICS)

ABS-85
 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR
ABS (DIAGNOSTICSI

2: DTC54
ABNORMAL STOP LIGHT SWITCH
DIAGNOSIS:
Faulty stop light switch
TROUBLE SYMPTOM:
ABS does not operate.
WIRING DIAGRAM:

BATTERY
n

STOP LIGHl
SWITCH

1
11 m
I N

m
: WITHOUT CRUISE
CONTROL
: WITH CRUISE
CONTROL
ABS CONTROL MODULE AND
HYDRAULIC CONTROL UNIT

__
I 24 I 25 I
~ ~

2 7 1 2 8 1 2 9 1 3 0 1 3 1 1 23 26

BR0089

ABS-86
 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR M
ABS (DIAGNOSTICS)

Step Check Yes No

I CHECK STOP LIGHTS COME ON. Do the stop lights come on? Go to step 2. Repair the stop
Depress the brake pedal. lights circuit.
! CHECK OPEN CIRCUIT IN HARNESS. Is the voltage between 10 and Go to step 3. Repair harness
1)Turn the ignition switch to OFF. 15 V? between stop light
2)Disconnect the connector from ABSCM& switch and
H/U. ABSCM&H/U.
3)Depress the brake pedal.
4)Measure the voltage between ABSCM&H/U
connector and chassis ground.
Connector & terminal
(F49) No. 2 (+) - Chassis ground (-):
3 CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in con-
nector between stop light nector.
switch and ABSCM&H/U?
1 CHECK ABSCM&WU. Is the same diagnostic trouble Replace the Go to step 5.
1)Connect all connectors. code as in the current diagno- ABSCM&H/U.
2)Erase the memory. sis still being output? <Ref. to ABS-7,
3)Perform the inspection mode. ABS Control Mod-
4)Read out the diagnostic trouble code. ule and Hydraulic
Control Unit
(ABSCM&H/U).>
5 CHECK ANY OTHER DIAGNOSTIC TROU- Are other diagnostic trouble Proceed with the A temporary poor
BLE CODES APPEARANCE. codes being output? diagnosis corre- contact.
sponding to the
diagnostic trouble
code.

ABS-87
 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR
ABS (DIAGNOSTICS)

ABS-88
 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR
a
ABS (DIAGNOSTICS)

AA:DTC 56
ABNORMAL G SENSOR OUTPUT VOLTAGE
DIAGNOSIS:
Faulty G sensor output voltage
TROUBLE SYMPTOM:
ABS does not operate.

ABS-89
 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR
ABS (DIAGNOSTICS)

WIRING DIAGRAM:

SHIELD JOINT
CONNECTOR

7 -
$E 8200

L
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
I I
t :

,@
1
ABS
G SENSOR

BR0090

ABS-90
 9
DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR
ABS (DIAGNOSTICS)

Step Check Yes No

CHECK ALL FOUR WHEELS FOR FREE iave the wheels been turned -he ABS is nor- 20 to step 2.
TURNING. reely such as when the vehicle nal. Erase the
s lifted up, or operated on a liagnostic trouble
,oiling road? :ode.
CHECK SPECIFICATIONS OF ABSCM&H/U. Ioes the vehicle specification 3eplace the 30 to step 3.
Check specifications of the mark to the 2nd the ABSCM&H/U specifi- 4BSCM&H/U.
ABSCM&H/U. :ation match? :Ref. to ABS-7,
CC: AT 4BS Control Mod-
CD: MT ile and Hydraulic
2ontrol Unit
ABSCM&H/U).>
2AUTION:
3e sure to turn ig-
iition switch to
3FF when remov-
ng ABSCM&H/U.
CHECK INPUT VOLTAGE OF G SENSOR. IS the voltage between 4.75 30 to step 4. Repair harness/
1)Turn the ignition switch to OFF. and 5.25 V? :onnector
2)Remove the console box. Detween G senso
3)Disconnect the G sensor from body. (Do not and ABSCM&H/U
disconnect the connector.)
4)Turn the ignition switch to ON.
5)Measure the voltage between G sensor con-
nector terminals.
Connector & terminal
(6292) NO. 1 (+) - NO. 3 (-):
CHECK OPEN CIRCUIT IN G SENSOR OUT, Is the resistance between 4.3 30 to step 5. Repair harness/
PUT HARNESS AND GROUND HARNESS. and 4.9 kR? connector
1)Turnthe ignition switch to OFF. between G senso
2)Disconnect the connector from ABSCM& and ABSCM&H/U
H/U.
3)Measure the resistance between
ABSCM&H/U connector terminals.
Connector & terminal
-
(F49) NO. 6 NO.28:
CHECK GROUND SHORT IN G SENSOR Is the resistance more than 1 Go to step 6. Repair harness
OUTPUT HARNESS. MR? between G sensor
1)Disconnectthe connector from G sensor. and ABSCM&H/U.
2)Measure the resistance between
ABSCM&H/U connector and chassis ground.
Connector & terminal
(F49) No. 6 - Chassis ground:
CHECK BATTERY SHORT OF HARNESS. Is the voltage less than 1 V? Go to step 7. Repair harness
Measure the voltage between ABSCM&H/U between G sensor
connector and chassis ground. and ABSCM&H/U.
Connector & terminal
(F49) No. 6 (+) - Chassis ground (-):
CHECK BATTERY SHORT OF HARNESS. Is the voltage less than 1 V? Go to step 8. Repair harness
1)Turn the ignition switch to ON. between G sensor
2)Measure the voltage between ABSCM&H/U and ABSCM&H/U.
connector and chassis ground.
Connector & terminal
-
(F49) No. 6 (+) Chassis ground (-):

ABS-91
I
DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR
ABS (DIAGNOSTICS)

Step Check Yes No

I CHECK GROUND SHORT OF HARNESS. Is the resistance more than 1 30 to step 9. Repair harness
Measure the resistance between ABSCM&H/U MR? between G sensor
connector and chassis ground. and ABSCM&H/U.
Connector & terminal Replace the
(F49) No. 28 - Chassis ground: ABSCM&H/U.
<Ref. to ABS-7,
ABS Control Mod-
ule and Hydraulic
Control Unit
(ABSCM&H/U).>
I CHECK G SENSOR. Is the voltage between 2.1 and 30 to step 10. Replace the G
1)Turn the ignition switch to OFF. 2.4 V when G sensor is hori- sensor. <Ref. to
2)Remove the G sensor from vehicle. zontal? ABS-23, G Sen-
3)Connect the connector to G sensor. sor.>
4)Connect the connector to ABSCM&H/U.
5)Turn the ignition switch to ON.
6)Measure the voltage between G sensor con-
nector terminals.
Connector & terminal
(B292) NO. 2 (+) - NO. 3 (-):
0 CHECK G SENSOR. Is the voltage between 3.7 and o
; to step 11. Replace the G
Measure the voltage between G sensor con- 4.1 V when G sensor is sensor. <Ref. to
nector terminals. inclined forwards to go"? ABS-23, G Sen-
Connector & terminal sor.>
(B292) NO. 2 (+) - NO. 3 (-):
1 CHECK G SENSOR. Is the voltage between 0.5and o
; to step 12. Replace the G
Measure the voltage between G sensor con- 0.9 V'when G sensor is sensor. <Ref. to
nector terminals. inclined backwards to 90°? ABS-23, G Sen-
Connector & terminal sor.>
(8292) NO. 2 (+) - NO. 3 (-):
2 CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in con- 3epair connector. Go to step 13.
nector between ABSCM&H/U
and G sensor?
3 CHECK ABSC M&H/U. Is the same diagnostic trouble 3eplace the Go to step 14.
1)Connect all connectors. code as in the current diagno- 4BSCM&H/U.
2)Erase the memory. sis still being output? :Ref. to ABS-7,
3)Perform the inspection mode. 4BS Control Mod-
4)Read out the diagnostic trouble code. ile and Hydraulic
:ontrol Unit
ABSCM&H/U).>
4 CHECK ANY OTHER DIAGNOSTIC TROU- Are other diagnostic trouble 'roceed with the A temporary poor
BLE CODES APPEARANCE. codes being output? liagnosis corre- contact.
iponding to the
liagnostic trouble
:ode.

ABS-92
 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR
ABS (DIAGNOSTICS)

AB :SELECT MONIT0R AE:ANALOG DATA ARE DIS-

Applicable cartridge of select monitor: <Ref. to PLAYED.
ABS-10, SPECIAL TOOLS, PREPARATION
TOOL, General Description.> DisDlav screen I Contents to be monitored 1
Wheel speed detected by the Front Right
NOTE: FR wheel speed ABS sensor is displayed in km/h or mile/
For basic handling of the select monitor, refer to its h.
Operation Manual. Wheel speed detected by the Front Left
FL wheel speed ABS sensor is displayed in km/h or mile/
AC:DIAGNOSTIC TROUBLE CODES h.
(DTC) ARE DISPLAYED. Wheel speed detected by the Rear Right
A maximum of 3 diagnostic trouble codes (DTC) RR wheel speed ABS sensor is displayed in km/h or mile/
are displayed in order of occurrence. h.
If a particular diagnostic trouble code (DTC) is Wheel speed detected by the Rear Left
not properly stored in memory (due to a drop in AB- RL wheel speed ABS sensor is displayed in km/h or mile/
SCM&H/U power supply, etc.) when a problem oc- h. -
curs, the diagnostic trouble code (DTC), followed Stop light switch monitor voltage is dis-
Stop light switch
by a question mark appears on the select mon-
‘I?”, played.
itor display. This shows it may be an unreliable Refers to vehicle acceleration detecting
Output
reading. voltage
by the analog G sensor. It appears on
the select monitor display in volts.

AF:ON/OFF DATA ARE DISPLAYED.

21 Front Right ABS Sensor Circuit
Display screen Contents to be monitored
Open or Shorted Battery Stop light switch Stop light switch signal
(*a*)/? Valve relav siqnal Valve relay siqnal
u
Motor relay signal I Motor relay signal I
t t 1
ABS signal to TCM
ABS operation signal from ABS con-
trol module to TCM
ABS warning light
I
S4M0076A ABS warning light
Valve relay monitor Valve relay operation monitor signal
*a* refers to the troubles in order of occurrence
Motor relav monitor Motor relay operation monitor signal
(Latest, Old, Older and Reference).
DisDlav screen I Contents to be monitored
CCM signal
ABS operation signal from ABS con-
trol module to TCM I
The most recent diagnostic trouble code
Latest (DTC) appears on the select monitor dis- AG:ABS SEQUENCE CONTROL
The second most recent diagnostic trou-
ble code (DTC) appears on the select
1 I Contents to be monitored I IndexNo.

monitor display.
The third most recent diagnostic trouble sequence
Older code (DTC) appears on the select moni- control

Reference diagnostic trouble code (DTC) appears

AD:CLEAR MEMORY
Display screen Contents to be monitored
Function of clearing diagnostic trouble
Clear memory?
code (DTC) and freeze frame data.

ABS-93
 DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR
ABS (DIAGNOSTICS)

AH:FREEZE FRAME DATA

NOTE:
Data stored at the time of trouble occurrence is
shown on display.
Each time trouble occurs, the latest information
is stored in the freeze frame data in memory.
Freeze frame data will be memorized maximum
to three.
If freeze frame data is not properly stored in
memory (due to a drop in ABSCM power supply,
etc.), a diagnostic trouble code (DTC), preceded by
a question mark "?", appears on the select monitor
display. This shows it may be an unreliable read-
ing.
Display screen Contents to be monitored
Wheel speed detected by the Front Right
FR wheel speed ABS sensor is displayed in km/h or mile/
h.
Wheel speed detected by the Front Left

Wheel speed detected by the Rear Right

Wheel speed detected by the Rear Left

RL wheel speed ABS sensor is displayed in km/h or mile/
Ih.
ABSCM power
voltage IPower (in volts) supplied to ABSCM&H/U
appears on the select monitor display.
Refers to vehicle acceleration detected
G sensor output
by the analog G sensor. It appears on
voltage
the select monitor disDlav in volts.
Motor relay mon-
itor
IMotor relay operation monitor signal
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 'peration
sianal
I ABS operation signal

ABS-94
\
DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR
I ABS (DIAGNOSTICS)

ABS-95
 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICS)

13.Diagnostics Chart with Subaru Select Monitor

A: COMMUNICATION FOR INITIALIZING IMPOSSIBLE
DIAGNOSIS:
Faulty harness connector
TROUBLE SYMPTOM:
ABS warning light remains on.
WIRING DIAGRAM:

P B

DATA LINK
CONNECTOR

RELAY
HOLDER

ABS
RELAY

+ @ ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT I

m
BR0091

ABS-96
 3

DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR

ABS (DIAGNOSTICS)

Step Check Yes No

CHECK IGNITION SWITCH. Is the ignition switch ON? 30 to step 2. Turn the ignition
switch to ON, and
select ABS mode
using the select
monitor.
CHECK BATTERY. Is the voltage more than 11 V? 30 to step 3. Charge or replace
1)Turn the ignition switch to OFF. bettery.
2)Measure the battery voltage.
CHECK BAlTERY TERMINAL. Is there poor contact at battery Repair or tighten Go to step 4.
terminal? the battery termi-
181.
CHECK COMMUNICATION OF SELECT Are the name and year of the So to step 10. Go to step 5.
MONITOR. system displayed on the select
1)Turnthe ignition switch to OFF. monitor?
2)Using the select monitor, check whether
communication to other system (such as
engine, TCM, etc.) can be executed normally.
CHECK COMMUNICATION OF SELECT Are the name and year of the Go to step 10. Go to step 6.
MONITOR. system displayed on the select
1)Turn the ignition switch to OFF. monitor?
€‘)Disconnect the ABSCM&H/U connector.
3)Check whether communication to other sys-
tems (such as TCM, engine etc.) can be exe-
cuted normally.
CHECK COMMUNICATION OF SELECT Are the name and year of the Inspect the ECM. Go to step 7 .
MONITOR. system displayed on the select
1)Turnthe ignition switch to OFF. monitor?
2)Connect the ABSCM&H/U connector.
3)Disconnect the ECM connector.
4)Check whether communication to other sys-
tems (such as TCM, engine etc.) can be exe-
cuted normally.
CHECK COMMUNICATION OF SELECT Are the name and year of the Inspect the TCM. Go to step 8.
MONITOR. system displayed on the select
1)Turn the ignition switch to OFF. monitor?
2)Connect the ECM connector.
3)Disconnect the TCM connector.
4)Check whether communication to other sys-
tems (such as engine etc.) can be executed
normally.
, CHECK COMMUNICATION OF SELECT Are the name and year of the Inspect the cruise Go to step 9.
MONITOR. system displayed on the select control module.
1)Turnthe ignition switch to OFF. monitor?
2)Connect the TCM connector.
3)Disconnect the cruise control module con-
nector.
4)Check whether communication to other sys-
tems (such as engine, TCM etc.) can be exe-
cuted normally.
NOTE:
If the vehicle is not equipped with cruise control
- Go to ster, 9.

ABS-97
 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICS)

Step Check Yes No

3 CHECK HARNESS CONNECTOR BETWEEN s the resistance less than 1 30 to step 10. 3epair harness
EACH CONTROL MODULE AND DATA LINK 2? and connector
CONNECTOR. letween each con,
1)Turnthe ignition switch to OFF. :rol module and
2)Disconnect the TCM, ECM, ABSCM&H/U, lata link connec-
and, cruise control module connectors. :or.
3)Measure the resistance between
ABSCM&H/U connector and chassis ground.
Connector & terminal
(840) No. 5 - Chassis ground:
(B40) No. 4 - Chassis ground:
IO CHECK OUTPUT SIGNAL FOR ABSCM&H/ s the voltage more than 1 V? 3epair harness 20 to step 11.
U. and connector
1)Turn the ignition switch to ON. letween each con
2)Measure the voltage between ABSCM&H/U rol module and
and chassis ground. jata link connec-
Connector & terminal or.
(840) No. 5 (+) - Chassis ground (-):
(840) No. 4 (+) - Chassis ground (-):
I1 CHECK HARNESWCONNECTOR BETWEEN s the resistance less than 0.5 3epair harness 30 to step 12.
ABSCM&H/U AND DATA LINK CONNEC- 2? ind connector
TOR. letween
Measure the resistance between ABSCM&H/U iBSCM&H/U and
connector and data link connector. jata link connec-
Connector & terminal or.
-
(F49) NO. 20 (840) NO. 5:
(F49) NO. 5 - (840) NO. 4:
12 CHECK INSTALLATION OF ABSCM&HN s the ABSCM&H/U connector 20 to step 13. nsert ABSCM&H/
CONNECTOR. iserted into ABSCM&H/U until J connector into
Turn the ignition switch to OFF. he clamp locks onto it? 4BSCM&H/U.
13 CHECK INPUT VOLTAGE OF RELAY HOLD- s the voltage more than 10 V? 20 to step 14. 3epair open circuit
ER. n harness
1)Turn the ignition switch to OFF. letween battery
2)Remove the fuse. and Relay holder
3)Measure the voltage between ABS relay :onnector.
connector and chassis ground.
Connector & terminal
(8225) No. 5 (+) - Chassis ground (-):
14 CHECK RELAY HOLDER. s the fuse blown out? 3eplace the fuse. 20 to step 15.
15 CHECK INPUT VOLTAGE OF ABS RELAY. s the voltage more than 10 V? 20 to step 16. 3epair open circuit
1)lnstall the fuse. n harness
2)Remove the ABS relay. letween battery
3)Turn the ignition switch to ON. md Relay holder
4)Measure the voltage between ABS relay :onnector.
connector and chassis ground.
Connector & terminal
(8264) No. 2 (+) - Chassis ground (-):
16 CHECK INPUT VOLTAGE OF ABS RELAY. s the voltage more than 10 V? 20 to step 17. 3epair harness
Measure the voltage between ABS relay con- :onnector
nector and chassis ground. letween battery,
Connector & terminal gnition switch and
(8264) No. 1 (+) - Chassis ground (-): 4BS relay.
17 CHECK GROUND CIRCUIT OF ABS RELAY. s the resistance less 5 R? 20 to step 18. 3epair open circuit
1)Turn the ignition switch to OFF. letween ABS
2)Measure the resistance between ABS relay 'elay and chassis
connector and chassis ground. ground.
Connector & terminal
(8264) No. 3 (+) - Chassis ground:

ABS-98
 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICS)

Step Check Yes No

8 CHECK ABS RELAY. Is the resistance less than 10 Go to step 19. Replace the ABS
1)Connect the battery to ABS relay terminal Q? relay.
No. 1 and 3.
2)Measure the resistance between ABS relay
terminals.
9 CHECK POWER SUPPLY CIRCUIT. Is the voltage more than 10 V? Go to step 20. Repair open circuit
1)Turnthe ignition switch to ON (engine OFF). in harness
2)Measure the ignition power supply voltage between
ABSCM&H/U and
battery.

!O CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 Go to step 21. Repair open circuit
ABSCM&H/U AND CHASSIS GROUND. Q? in harness
1)Turn the ignition switch to OFF. between
2)Disconnect the connector from ABSCM&H/U ABSCM&H/U and
and transmission. inhibitor side con-
3)Measure the resistance of harness between nector, and poor
ABSCM&H/U and chassis ground. contact in cou-
Connector & terminal pling connector.
(F49) No. 23- Chassis ground:
!1 CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in control Repair the con- Replace the
module power supply, ground nector. ABSCM&H/U.
line and data link connector? <Ref. to ABS-7,
ABS Control Mod-
ule and Hydraulic
Control Unit
(ABSCM&H/U).>

ABS-99
 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICS)

ABS-I 00
I I

DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR

ABS (DIAGNOSTICS)

B: NO TROUBLE CODE
DIAGNOSIS:
ABS warning light circuit is shorted.
TROUBLE SYMPTOM:
ABS warning light remains on.
NO TROUBLE CODE displayed on the select monitor.
NOTE:
When the ABS warning light is OFF and “NO TROUBLE CODE” is displayed on the select monitor, the sys-
tem is in normal condition.

ABS-I 01
 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICS)

WIRING DIAGRAM:

BATTERY
SBF-3 SBF-1
3 c
U

IGNITION
SWITCH

?
z

RELAY HOLDER
BR0083

ABS-1 02
 m

DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR

ABS IDIAGNOSTICS)

Step Check Yes No

1 CHECK WIRING HARNESS. Does the ABS warning light Go to step 2. Repair the front
1)Turn the ignition switch to OFF. remain off? wiring harness.
2)Disconnect the connector (F74) from con-
nector (8200).
3)Turn the ignition switch to ON.
2 CHECK PROJECTIONAT ABSCM&H/U. Are the projection broken? Go to step 3. Replace the
1)Turn the ignition switch to OFF. ABSCM&H/U.
2)Disconnect the connector from ABSCM& <Ref. to ABS-7,
H/U. ABS Control Mod-

,
3)Check for broken projection at the ule and Hydraulic
ABSCM&H/U terminal. Control Unit
(ABSCM&H/U).>
3 CHECK ABSCM&H/U. Replace the
Measure the resistance between ABSCM&H/U MR? ABSCM&H/U.
terminals. <Ref. to ABS-7,
Terminals ABS Control Mod-
NO. 22 - NO. 23: ule and Hydraulic
Control Unit
(ABSCM&H/U).>
1 CHECK WIRING HARNESS. Is the resistance less than 0.5 Go to step 5. Repair the har-
Measure the resistance between connector R? ness.
(F74) and chassis ground.
Connector & terminal
(F74) No. 19 - Chassis ground:
5 CHECK WIRING HARNESS. Is the resistance more than 1 Go to step 6. Repair the har-
1)Connect the connector to ABSCM&H/U. ness.
2)Measure the resistance between connector
(F74) and chassis ground.
I
Connector & terminal
-
(F74) No. 19 Chassis ground:
5 CHECK POOR CONTACT IN ABSCM&H/U Is there poor contact in Repair the con- Replace the
CONNECTOR. ABSCM&H/U connector? nector. ABSCM&H/U.
<Ref. to ABS-7,
ABS Control Mod-
ule and Hydraulic
Control Unit
(ABSCM&H/U).>

ABS-103
 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICS)

C: DTC21
OPEN OR SHORT CIRCUIT IN FRONT RIGHT ABS SENSOR CIRCUIT
NOTE:
For the diagnostic procedure, refer to DTC 27. <Ref. to ABS-I 05, DTC 27 OPEN OR SHORT CIRCUIT IN
REAR LEFT ABS SENSOR CIRCUIT, Diagnostics Chart with Subaru Select Monitor.>

D: DTC23
OPEN OR SHORT CIRCUIT IN FRONT LEFT ABS SENSOR CIRCUIT
NOTE:
For the diagnostic procedure, refer to DTC 27. <Ref. to ABS-I 05, DTC 27 OPEN OR SHORT CIRCUIT IN
REAR LEFT ABS SENSOR CIRCUIT, Diagnostics Chart with Subaru Select Monitor.>

E: DTC25
OPEN OR SHORT CIRCUIT IN REAR RIGHT ABS SENSOR CIRCUIT
NOTE:
For the diagnostic procedure, refer to DTC 27. <Ref. to ABS-105, DTC 27 OPEN OR SHORT CIRCUIT IN
REAR LEFT ABS SENSOR CIRCUIT, Diagnostics Chart with Subaru Select Monitor.>

ABS-I 04
 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICS)

F: DTC27
OPEN OR SHORT CIRCUIT IN REAR LEFT ABS SENSOR CIRCUIT
DIAGNOSIS:
Faulty ABS sensor (Broken wire, input voltage too high)
Faulty harness connector
TROUBLE SYMPTOM:
ABS does not operate.

ABS-I 05
 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICS)

WIRING DIAGRAM:

ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT I

I I

1.
I
I
I
I
1.
I I
I I 1.
I I
I I I I
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.
I I I I
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I I I I I I I I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I @
I I
I I I I I I SHIELD JOINT
I I
I I I CONNECTOR
I I

1
I I ,'
I I
I I
I I
I I
I I
I I
I

e
I
I I
I I I I

F
I I I I
I I I I
I I I I
I I I I
I I I I
I I I I
I I I I 1.
I I I I I I I I
I I I I I I I I
I I I I I I I I
I I I I I I I I
I I
5
-i
I I
I I I I
I I I I
I I I I
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I I I I
I I I I
I I I I
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I I I I
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I I I I I I
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. .
I I I I I I
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5 I
5 I
5 I

@ @
I I I
7 r' r'
1
FRONT FRONT
ABS ABS REAR REAR
SENSOR LH SENSOR RH ABS ABS
SENSOR LH SENSOR RH

BROOM

ABS-I 06
 3

DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR

ABS (DIAGNOSTICS)

Step Check Yes No

CHECK OUTPUT OF ABS SENSOR USING Ioes the speed indicated on 30 to step 2. Go to step 8.
SELECT MONITOR. he display change in response
1)Select “Current data display & Save” on the 3 the speedometer reading
select monitor. luring acceleration/decelera-
2)Read the ABS sensor output corresponding ion when the steering wheel is
to the faulty system in the select monitor data I the straight-ahead position?
display mode.
CHECK INSTALLATION OF ABS SENSOR. ire the ABS sensor installation 30 to step 3. Tighten the ABS
Tightening torque: ,olts tightened securely? sensor installation
32 N.m (3.3 kgf-m, 24 ft-lb) bolts securely.
CHECK ABS SENSOR GAP. s the gap within the specifica- 30 to step 4. Adjust the gap.
Measure the tone wheel to ABS sensor piece ions? NOTE:
gap over entire perimeter of the wheel. Adjust the gap us
front wheel ing spacers (Pal
-
0.3 - 0.8 mm (0.012 0.031 in) No. 26755AA000:
Rear wheel If spacers cannc
-
0.7 - 1.2 mm (0.028 0.047 in) correct the gap, re
place the wori
sensor or wori
tone wheel.
.CHECK TONE WHEEL RUNOUT. s the runout less than 0.05 30 to step 5. Replace the tone
Measure the tone wheel runout. nm (0.0020 in)? wheel. Front:
<Ref. to ABS-21,
Front Tone
Wheel.> Rear:
<Ref. to ABS-22,
Rear Tone
Wheel.>
CHECK POOR CONTACT IN CONNECTORS. s there poor contact in con- 3epair the con- Go to step 6.
Turn the ignition switch to OFF. lectors between ABSCM&H/U lector.
ind ABS sensor?
CHECK ABSCM&HN. s the same diagnostic trouble 3eplace the Go to step 7.
1)Connect all connectors. :ode as in the current diagno- SBSCM&H/U.
2)Erase the memory. ;is still being output? :Ref. to ABS-7,
3)Perform the inspection mode. 4BS Control Mod-
4)Read out the diagnostic trouble code. Ae and Hydraulic
2ontrol Unit
ABSCM&H/U).>
CHECK ANY OTHER DIAGNOSTICTROU- ire other diagnostic trouble ’roceed with the A temporary poor
BLE CODES APPEARANCE. :odes being output? jiagnosis corre- contact.
sponding to the NOTE:
liagnostic trouble Check harnes
:ode. and connector
between AE
SCM&H/U an
ABS sensor.
I CHECK ABS SENSOR. s the resistance between 1 30 to step 9. Replace the ABS
1)Turn the ignition switch to OFF. ind 1.5 kR? sensor. Front:
2)Disconnect the connector from ABS sensor. <Ref. to ABS-14,
3)Measure the resistance of ABS sensor con- Front ABS Sen-
nector terminals. sor.> Rear: <Ref.
Terminal to ABS-18, Rear
front RH No. 1 -No. 2: ABS Sensor.>
front LH No. 1 -No. 2:
Rear RH No. 1 - No. 2:
-
Rear LH No. 1 No. 2:

ABS-I 07
 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICS)

Step Check Yes No

9 CHECK BATTERY SHORT OF ABS SEN- s the voltage less than 1 V? i o to step 10. Replace the ABS
SOR. sensor. Front:
1)Disconnect the connector from ABSCM& <Ref. to ABS-14,
H/U. Front ABS Sen-
2)Measure the voltage between ABS sensor sor.> Rear: <Ref.
and chassis ground. to ABS-I 8, Rear
Terminal ABS Sensor.>
Front RH No. 1 (+) - Chassis ground (-)
Front LH No. 1 (+) - Chassis ground (-)
Rear RH No. 1 (+) - Chassis ground (-):
Rear LH No. 1 (+) - Chassis ground (-):
IO CHECK BAlTERY SHORT OF ABS SEN- s the voltage less than 1 V? ;o to step 11. Replace the ABS
SOR. sensor. Front:
1)Turnthe ignition switch to ON. <Ref. to ABS-14,
2)Measure the voltage between ABS sensor Front ABS Sen-
and chassis ground. sor.> Rear: <Ref.
Terminal to ABS-I 8, Rear
Front RH No. 1 (+) - Chassis ground (-) ABS Sensor.>
Front LH No. 1 (+) - Chassis ground (-)
Rear RH No. 1 (+) - Chassis ground (-):
Rear LH No. 1 (+) - Chassis ground (-):
I1 CHECK HARNESSKONNECTOR BETWEEN s the resistance between 1 ;o to step 12. Repair harness/
'nBSCM&HlU AND ABS SENSOR. ind 1.5 kR? sonnector
1)Turnthe ignition switch to OFF. Detween
2)Connect the connector to ABS sensor. 4BSCM&H/U and
3)Measure the resistance between 4BS sensor.
ABSCM&H/U connector terminals.
Connector & terminal
DTC 21 / (F49) NO. 11 - NO. 12:
DTC 23 / (F49) NO. 9 - NO. 10:
DTC 25 / (F49) NO. 14 - NO. 15:
DTC 2 7 / (F49) NO. 7 - NO. 8:
12 CHECK BAlTERY SHORT OF HARNESS. s the voltage less than 1 V? i o to step 13. Repair harness
Measure the voltage between ABSCM&H/U 3etween
connector and chassis ground. 4BSCM&H/U and
Connector & terminal 4BS sensor.
DTC 21 /(F49) No. 11 (+) - Chassis
ground (-):
DTC 23 / (F49) No. 9 (+) - Chassis
ground (-):
DTC 25 / (F49) No. 14 (+) - Chassis
ground (-):
DTC 27 / (F49) No. 7 (+) - Chassis
ground (-):
13 CHECK BAlTERY SHORT OF HARNESS. s the voltage less than 1 V? i o to step 14. 3epair harness
1)Turn the ignition switch to ON. ietween
2)Measure the voltage between ABSCM&H/U 4BSCM&H/U and
connector and chassis ground. 4BS sensor.
Connector & terminal
DTC 21 /(F49) No. 11 (+) - Chassis
ground (-):
DTC 23 / (F49) No. 9 (+) - Chassis
ground (-):
DTC 25 / (F49) No. 14 (+) - Chassis
groundI)-(
DTC 2 7 / (F49) No. 7 (+) - Chassis
ground (-):
14 CHECK INSTALLATION OF ABS SENSOR. Ire the ABS sensor installation io to step 15. righten the ABS
Tightening torque: iolts tightened securely? sensor installation
32 N.m (3.3 kgf-m, 24 ft-lb) iolts securely.

ABS-I 08
 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICS)

Step Check Yes No

CHECK ABS SENSOR GAP. ;the gap within the specifica- io to step 16. Adjust the gap.
Measure the tone wheel to ABS sensor piece ons? NOTE:
gap over entire perimeter of the wheel. Adjust the gap us.
front wheel ing spacers (Pad
-
0.3 - 0.8 mm (0.012 0.031 in) No. 26755AAOOO).
Rear wheel If spacers cannol
0.7- 1.2 mm (0.028 - 0.047 in) correct the gap, re-
place the worr
sensor or wow
tone wheel.
CHECK TONE WHEEL RUNOUT. 3 therunout less than 0.05 20 to step 17. Replace the tone
Measure the tone wheel runout. nm (0.0020 in)? wheel. Front:
<Ref. to ABS-21,
Front Tone
Wheel.> Rear:
<Ref. to ABS-22,
Rear Tone
Wheel.>
CHECK GROUND SHORT OF ABS SENSOR s the resistance more than 1 20 to step 18. Replace the ABS
1)Turn the ignition switch to ON. An? sensor and
2)Measure the resistance between ABS sen- ABSCM&H/U.
sor and chassis ground. Front: <Ref. to
Terminal ABS-14, Front
Front RH No. 1 - Chassis ground: ABS Sensor.>
Front LH No. 1 - Chassis ground: Rear: <Ref. to
Rear RH No. 1 - Chassis ground: ABS-18, Rear
Rear LH No. 1 - Chassis ground: ABS Sensor.>
and <Ref. to
ABS-7, ABS Con-
trol Module and
Hydraulic Control
Unit (ABSCM&H/
U).>
CHECK GROUND SHORT OF HARNESS. s the resistance more than 1 30 to step 19. Repair harness
1)Turnthe ignition switch to OFF. nn? between
2)Connect the connector to ABS sensor. ABSCM&H/U and
3)Measure the resistance between ABS sensor.
ABSCM&H/U connector terminal and chassis And replace the
ground. ABSCM&H/U.
Connector & terminal <Ref. to ABS-7,
DTC 21 /(F49) No. 11 - Chassis ground ABS Control Mod-
DTC 23 / (F49) No. 9 - Chassis ground: ule and Hydraulic
DTC 25 / (F49) No. 14 - Chassis ground Control Unit
DTC 27/(F49) No. 7 - Chassis ground: (ABSCM&H/U).>
CHECK POOR CONTACT IN CONNECTORS s there poor contact in con- 3epair the con- Go to step 20.
lectors between ABSCM&H/U lector.
md ABS sensor?
CHECK ABSCM&H/U. s the same diagnostic trouble 3eplace the Go to step 21.
1)Connect all connectors. ;ode as in the current diagno- 4BSCM&H/U.
2)Erase the memory. ;is still being output?
3)Perform the inspection mode.
4)Read out the diagnostic trouble code.
~

CHECK ANY OTHER DIAGNOSTIC TROU- 4re other diagnostic trouble Droceed with the A temporary poor
BLE CODES APPEARANCE. :odes being output? diagnosis corre- contact.
sponding to the NOTE:
jiagnostic trouble Check harnes!
:ode. and connector!
between AB
SCM&H/U anc
ABS sensor.

ABS-I 09
 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICS)

G: DTC22
FRONT RIGHT ABNORMAL ABS SENSOR SIGNAL
NOTE:
For the diagnostic procedure, refer to DTC 28. <Ref. to ABS-111, DTC 28 REAR LEFT ABNORMAL ABS
SENSOR SIGNAL, Diagnostics Chart with Subaru Select Monitor.>

H: DTC24
FRONT LEFT ABNORMAL ABS SENSOR SIGNAL
NOTE:
For the diagnostic procedure, refer to DTC 28. <Ref. to ABS-111, DTC 28 REAR LEFT ABNORMAL ABS
SENSOR SIGNAL, Diagnostics Chart with Subaru Select Monitor.>

I: DTC26
REAR RIGHT ABNORMAL ABS SENSOR SIGNAL
NOTE:
For the diagnostic procedure, refer to DTC 28. <Ref. to ABS-1 11, DTC 28 REAR LEFT ABNORMAL ABS
SENSOR SIGNAL, Diagnostics Chart with Subaru Select Monitor.>

ABS-I 10
I m
DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICS)
_ _ _ _ _ ~

J: DTC28
REAR LEFT ABNORMAL ABS SENSOR SIGNAL
DIAGNOSIS:
Faulty ABS sensor signal (noise, irregular signal, etc.)
Faulty harnesskonnector
1 TROUBLE SYMPTOM:
1

t ABS does not operate.

i

ABS-1 11
 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICS)

WIRING DIAGRAM:

@ ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT

1
I-
I
I
I
I
I- c
I I
I I f I

I I
I I
I I
I
I
I
I
I-
I I I
I I I I

I""
I I I
I I I I
I I I I
I I I I
I I I I
I I I I
I I I I
I I I I
I I
I I
I SHIELD JOINT
I
I
I
I
I I ,
I CONNECTOR
I I
I I
I I
I I I I
I I
I I
I I I I
I
I
I
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I I I I I I I I
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I I I I I I I I
I I I I I I I I
I I
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 I
I I
I I
I I
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I I
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I I
I I
I I
I I I I
I I I I
I.
I I I I I I
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I I I I I I
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.
I I I I I I

5. - I
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5
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5. -
I
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1 1 ~

I 1
I I

FRONT U U
FRONT
ABS ABS REAR REAR
SENSOR LH SENSOR RH ABS ABS
SENSOR LH SENSOR RH

BR0084

ABS-I 12
 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICS)

~~
~

Step Check Yes No

CHECK OUTPUT OF ABS SENSOR USING Ioes the speed indicated on io to step 2. i o to step 8.
SELECT MONITOR. he display change in response
1)Select "Current data display & Save" on the o the speedometer reading
select monitor. luring acceleration/decelera-
2)Read the ABS sensor output corresponding ion when the steering wheel is
to the faulty system in the select monitor data n the straight-ahead position?
display mode.
CHECK POOR CONTACT IN CONNECTORS. s there poor contact in con- iepair the con- So to step 3.
Turn the ignition switch to OFF. lectors between ABSCM&H/U lector.
ind ABS sensor?
1 CHECK SOURCES OF SIGNAL NOISE. s the car telephone or the i o to step 4. 'roperly install the
vireless transmitter properly :ar telephone or
nstalled? he wireless trans-
nitter.
CHECK SOURCES OF SIGNAL NOISE. 4re noise sources (such as an istall the noise ;o to step 5.
mtenna) installed near the 8ourcesapart from
iensor harness? l e sensor har-
less.
I CHECK SHIELD CIRCUIT. s the resistance less than 0.5 So to step 6. 3epair the shield
1)Turnthe ignition switch to OFF. 3? iarness.
02)Connectall connectors.
3)Measure the resistance between shield con-
nector and chassis ground.
Connector & terminal
DTC 26 / (B200) No. 11 - Chassis
ground:
DTC 28 / (8200) No. 3 - Chassis ground.
NOTE:
For the DTC 22 and 24:
Go to step 6.
i CHECK ABSCM&HIU. s the same diagnostic trouble 3eplace the 30 to step 7.
1)Connect all connectors. :ode as in the current diagno- 4BSCM&H/U.
2)Erase the memory. sis still being output? :Ref. to ABS-7,
3)Perform the inspection mode. 4BS Control Mod-
4)Read out the diagnostic trouble code. rle and Hydraulic
2ontrol Unit
ABSCM&H/U).>
r CHECK ANY OTHER DIAGNOSTICTROU- 4re other diagnostic trouble 'roceed with the 1 temporary noise
BLE CODES APPEARANCE. :odes being output? iiagnosis corre- nterference.
;ponding to the
iiagnostic trouble
:ode.
I CHECK INSTALLATIONOF ABS SENSOR. 4re the ABS sensor installation o
; to step 9. righten the ABS
Tightening torque: iolts tightened securely? sensor installation
32 N.m (3.3 kgf-m, 24 ft-lb) iolts securely.
3 CHECK ABS SENSOR GAP. Is the gap within the specifica- o; to step 10. 4djust the gap.
Measure the tone wheel to ABS sensor piece !ions? VOTE:
gap over entire perimeter of the wheel. 4djust the gap us.
Front wheel ng spacer (Par
0.3 - 0.8 mm (0.012 - 0.031 in) 10. 26755AA000)
. Rearwheel f spacers canno
0.7- 1.2" (0.028-0.047in) :orrect the gap, re-
ilace the worn
sensor or worn
:one wheel.
IO PREPARE OSCILLOSCOPE. Is an oscilloscope available? 30 to step 11.

ABS-I 13
 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICS)

Step Check Yes No

1 CHECK ABS SENSOR SIGNAL. s the oscilloscope pattern $0to step 15. So to step 12.
1)Raise all four wheels of ground. mooth, as shown in the fig-
2)Turn the ignition switch OFF. Ire?
3)Connect the oscilloscope to the connector.
4)Turn the ignition switch ON.
5)Rotate the wheels and measure voltage at
specified frequency. <Ref. to ABS-I 7,WAVE-
FORM, Control Module 110 Signal.>
NOTE:
When this inspection is completed, the AB
SCM&H/U sometimes stores the DTC 29.
Connector & terminal
DTC 22 /(F95) NO. 1 (+) - NO. 2 (-):
DTC 24 / (F94) NO. 1 (+) - NO.2 (-):
DTC 26/(899) NO. 9 (+) - NO. 70 (-):
DTC 28 / (899) NO. 4 (+)- NO. 5 (-):
2 CHECK CONTAMINATION OF ABS SENSOR s the ABS sensor piece or the -horoughly 30 to step 13.
OR TONE WHEEL. one wheel contaminated by emove dirt or
Remove the disc rotor or drum from hub in lirt or other foreign matter? Ither foreign mat-
accordance with diagnostic trouble code. e r.
3 CHECK DAMAGE OF ABS SENSOR OR Ire there broken or damaged leplace the ABS $0to step 14.
TONE WHEEL. n the ABS sensor piece or the iensor or tone
one wheel? vheel. Front: <Ref.
3 ABS-14, Front
iBS Sensor.>
lear: <Ref. to
iBS-18, Rear
\BS Sensor.>
ind Front: <Ref.
3 ABS-21, Front
one Wheel.>
lear: <Ref. to
rBS-22, Rear
one Wheel.>
4 CHECK TONE WHEEL RUNOUT. s the runout less than 0.05 ;o to step 15. leplace the tone
Measure the tone wheel runout. nm (0.0020 in)? vheel. Front:
:Ref. to ABS-21,
:rant Tone
Yheel.> Rear:
:Ref. to ABS-22,
lear Tone
Yheel.>
5 CHECK RESISTANCE OF ABS SENSOR. s the resistance between 1 i o to step 16. leplace the ABS
1)Turn the ignition switch OFF. n d 1.5 kR? lensor. Front:
2)Disconnect the connector from ABS sensor. :Ref. to ABS-14,
3)Measure the resistance between ABS sen- :rant ABS Sen-
sor connector terminals. ;or.> Rear: <Ref.
Terminal Q ABS-18, Rear
Front RH No. 1 -No. 2: iBS Sensor.>
Front LH No. 1 -No. 2:
-
Rear RH No. 1 No. 2:
Rear LH No. 1 - No. 2:
6 CHECK GROUND SHORT OF ABS SENSOR s the resistance more than 1 i o to step 17. leplace the ABS
Measure the resistance between ABS sensor VIR? ;ensor. Front:
and chassis ground. :Ref. to ABS-I 4,
Terminal :rant ABS Sen-
-
Front RH No. 1 Chassis ground: ,or.> Rear: <Ref.
-
Front LH No. 1 Chassis ground: 3 ABS-I 8, Rear
-
Rear RH No. 1 Chassis ground: iBS Sensor.>
-
Rem LH No. 1 Chassis ground:

ABS-I 14
 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS /DIAGNOSTICS)

Step Check Yes No

7 CHECK HARNESS/CONNECTOR BETWEEN s the resistance between 1 io to step 18. iepair harness/
ABSCM&H/U AND ABS SENSOR. 3nd 1.5 kR? onnector
1)Connect the connector to ABS sensor. letween
2)Disconnect the connector from ABSCM& rBSCM&H/U and
H/U. rBS sensor.
3)Measure the resistance at ABSCM&H/U
connector terminals.
Connector & terminal
-
DTC 22/(F49) NO. 11 NO. 12:
-
DTC 24 / (F49) No. 9 No. 10:
DTC 26 / (F49) NO. 14 - NO. 15:
-
DTC 28 / (F49) NO. 7 NO. 8:
8 CHECK GROUND SHORT OF HARNESS. s the resistance more than 1 io to step 19. iepair harness/
Measure the resistance between ABSCM&H/U WR? onnector
connector and chassis ground. letween
Connector & terminal rBSCM&H/U and
DTC 22 / (F49) No. 11 - Chassis ground: iBS sensor.
-
DTC 24 / (F49) No. 9 Chassis ground:
-
DTC 26 / (F49) No. 14 Chassis ground:
DTC 28 / (F49) No. 7 - Chassis ground:
9 CHECK GROUND CIRCUIT OF ABSCM&H/U. Is the resistance less than 0.5 i o to step 20. iepair the
Measure the resistance between ABSCM&H/U D? \BSCM&H/U
And chassis ground. iround harness.
Connector & terminal
(F49) NO. 23- GND:
0 CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in con- iepair the con- io to step 21.
nectors between ABSCM&H/U lector.
and ABS sensor?
1 CHECK SOURCES OF SIGNAL NOISE. Is the car telephone or the i o to step 22. 'roperly install the
vvireless transmitter properly :ar telephone or
installed? he wireless trans-
nitter.
2 CHECK SOURCES OF SIGNAL NOISE. Are noise sources (such as an istall the noise $0to step 23.
antenna) installed near the ources apart from
sensor harness? l e sensor har-
less.
13 CHECK SHIELD CIRCUIT. Is the resistance less than 0.5 i o to step 24. 3epair the shield
1)Connect all connectors. n? tarness.
2)Measure the resistance between shield con-
nector and chassis ground.
Connector & terminal
DTC 26 / (6200) No. 11 - Chassis
ground:
DTC 28 / (8200) No. 3 - Chassis ground:
NOTE:
For the DTC 22 and 24:
Go to step 24.
!4 CHECK ABSCM&HN. Is the same diagnostic trouble ieplace the 20 to step 25.
1)Connect all connectors. code as in the current diagno- \BSCM&H/U.
2)Erase the memory. sis still being output? :Ref. to ABS-7,
3)Perform the inspection mode. IBS Control Mod-
4)Read out the diagnostic trouble code. ile and Hydraulic
:ontrol Unit
ABSCM&H/U).>
15 CHECK ANY OTHER DIAGNOSTICTROU- Are other diagnostic trouble 'roceed with the 4 temporary noise
BLE CODES APPEARANCE. codes being output? liagnosis corre- nterference.
,pending to the
liagnostic trouble
:ode.

ABS-I 15
 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICS)

ABS-I 16
 3
DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICS)

K: DTC29
ABNORMAL ABS SENSOR SIGNAL ON ANY ONE OF FOUR SENSOR
DIAGNOSIS:
Faulty ABS sensor signal (noise, irregular signal, etc.)
Faulty tone wheel
Wheels turning freely for a long time
TROUBLE SYMPTOM:
ABS does not operate.

ABS-I 17
 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICS)

WIRING DIAGRAM:

\
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I
I
I
I
I
I
I
I
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I
ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT

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I I SHIELD JOINT
CONNECTOR

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FRONT
ABS REAR REAR
SENSOR LH SENSOR RH ABS ABS
SENSOR LH SENSOR RH

0R0084

ABS-I 18
 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICS)

Step Check Yes No

CHECK IF THE WHEELS HAVE TURNED Check if the wheels have been The ABS is nor- 30 to step 2.
FREELY FOR A LONG TIME. turned freely for more than onemal. Erase the
minute, such as when the vehi- diagnostic trouble
code.
cle is jacked-up, under full-lock
cornering or when tire is not in
NOTE:
contact with road surface. When the wheels
tum freely for a
long time, such as
when the vehicle is
towed or jacked-
up, or when steer-
ing wheel is contin-
uously turned all
the way, this diag-
nostic trouble code
may sometimes
occur.
I CHECK TIRE SPECIFICATIONS. Are the tire specifications cor- Go to step 3. Replace the tire.
Turn the ignition switch to OFF. rect?
I CHECK WEAR OF TIRE. Is the tire worn excessively? Replace the tire. Go to step 4.
I CHECK TIRE PRESSURE. Is the tire pressure correct? Go to step 5. Adjust the tire
pressure.
I CHECK INSTALLATION OF ABS SENSOR. Are the ABS sensor installation Go to step 6. Tighten the ABS
Tightening torque: bolts tightened securely? sensor installation
32 N.m (3.3 kgf-m, 24 fl-lb) bolts securely.
i CHECK ABS SENSOR GAP. Is the gap within the specifica- Go to step 7. Adjust the gap.
Measure the tone wheel to ABS sensor piece tions? NOTE:
gap over entire perimeter of the wheel. Adjust the gap us
Front wheel ing spacer (Par
- -
0.3 0.8 mm (0.012 0.031 in) No. 26755AAOOO)
Rear wheel If spacers canno
0.7 - 1.2 mm (0.028 - 0.047 in) correct the gap, re
place the won
sensor or wori
tone wheel.
? PREPARE OSCILLOSCOPE. Is an oscilloscope available? Go to step 8. Go to step 9.

ABS-1 19
 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICS)
~~ ~~ ~ ~~~~ ~~~

Step No
I CHECK ABS SENSOR SIGNAL. o
; to step 9.
1)Raise all four wheels of ground. 3s shown in the figure?
2)Turn the ignition switch OFF.
3)Connect the oscilloscope to the connector
(B99), (F95) or (F94) in accordance with trou-
ble code.
4)Turn the ignition switch ON.
5)Rotate the wheels and measure voltage at
specified frequency. <Ref. to ABS-17, WAVE-
FORM, Control Module I/O Signal.>
NOTE:
When this inspection is completed, the AB
SCM&H/U sometimes stores the DTC 29.
Connector & terminal
Front RH
(F95) NO. 1 (+) - NO. 2 (-):
Front LH
(F94) NO. 1 (+) - NO. 2I)-(
Rear RH
(699) NO. 9 (+)- NO. 10I)-(
Rear LH
(699) NO. 4 (+) - NO. 5 (-):
I CHECK CONTAMINATIONOF ABS SENSOR s the ABS sensor piece or the Thoroughly 30 to step 10.
OR TONE WHEEL. one wheel contaminated by remove dirt or
Remove the disc rotor from hub. lirt or other foreign matter? other foreign mat-
ter.
0 CHECK DAMAGE OF ABS SENSOR OR 4re there broken or damaged Replace the ABS so to step 11.
TONE WHEEL. eeth in the ABS sensor piece sensor or tone
i r the tone wheel? wheel. Front: <Ref.
to ABS-14, Front
ABS Sensor.>
Rear: <Ref. to
ABS-18, Rear
ABS Sensor.>
and Front: <Ref.
to ABS-21, Front
Tone Wheel.>
Rear: <Ref. to
ABS-22, Rear
Tone Wheel.>
I
1 CHECK TONE WHEEL RUNOUT.
Measure the tone wheel runout. nm (0.0020 in)? wheel. Front:
<Ref. to ABS-21,
Front Tone
Wheel.> Rear:
<Ref. to ABS-22,
Rear Tone
Wheel.>
2 CHECK ABSCM&H/U. s the same diagnostic trouble Replace the Go to step 13.
1)Turn the ignition switch to OFF. :ode as in the current diagno- ABSCM&H/U.
2)Connect all connectors. ;is still being output? <Ref. to ABS-7,
3)Erase the memory. ABS Control Mod-
4)Perform the inspection mode. ule and Hydraulic
~ 5)Read out the diagnostic trouble code. Control Unit
(ABSCM&H/U).>
3 CHECK ANY OTHER DIAGNOSTICTROU- ire other diagnostic trouble Proceed with the A temporary poor
BLE CODES APPEARANCE. :odes being output? diagnosis corre- contact.
sponding to the
diagnostic trouble
code.
 I
DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICS)

L: DTC31
FRONT RIGHT INLET VALVE MALFUNCTION
NOTE:
For the diagnostic procedure, refer to DTC 37. <Ref. to ABS-121, DTC 37 REAR LEFT INLET VALVE MAL-
FUNCTION, Diagnostics Chart with Subaru Select Monitor.>

M: DTC33
FRONT LEFT INLET VALVE MALFUNCTION
NOTE:
For the diagnostic procedure, refer to DTC 37. <Ref. to ABS-121, DTC 37 REAR LEFT INLET VALVE MAL-
FUNCTION, Diagnostics Chart with Subaru Select Monitor.>

N: DTC35
REAR RIGHT INLET VALVE MALFUNCTION
NOTE:
For the diagnostic procedure, refer to DTC 37. <Ref. to ABS-121, DTC 37 REAR LEFT INLET VALVE MAL-
FUNCTION, Diagnostics Chart with Subaru Select Monitor.>

0: DTC37
REAR LEFT INLET VALVE MALFUNCTION
DIAGNOSIS:
Faulty harnesskonnector
Faulty inlet solenoid valve
TROUBLE SYMPTOM:
ABS does not operate.

ABS-I 21
 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICS)

WIRING DIAGRAM:

BATTERY

ABS-I 22
 m
DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICS)

Step Check Yes No

I CHECK INPUT VOLTAGE OF RELAY HOLD Is the voltage more than 10 V? 30 to step 2. Repair open circuit
ER. in harness
1)Turn the ignition switch to OFF. setween battery
2)Remove the fuse. snd relay holder
3)Measure the voltage between ABS relay sonnector.
connector and chassis ground.
Connector & terminal
(8225) No. 5 (+) - Chassis ground (-):
2 CHECK RELAY HOLDER. Is the fuse blown out? 3eplace the fuse. Go to step 3.
3 CHECK INPUT VOLTAGE OF ABS RELAY. Is the voltage more than 10 V? 30 to step 4. Repair open circuit
1)lnstall the fuse. in harness
2)Remove the ABS relay. between battery
3)Turn the ignition switch to ON. and relay holder
4)Measure the voltage between ABS relay sonnector.
connector and chassis ground.
Connector & terminal
(8264) No. 2 (+) - Chassis ground (-):
1 CHECK INPUT VOLTAGE OF ABS RELAY. Is the voltage more than 10 V? 30 to step 5. Repair harness
Measure the voltage between ABS relay con- connector
nector and chassis ground. between battery,
Connector & terminal ignition switch and
(8264) No. 1 (+) - Chassis ground (-): ABS relay.
5 CHECK GROUND CIRCUIT OF ABS RELAY Is the resistance less than 5 30 to step 6. Repair open circuit
1)Turn the ignition switch to OFF. a? between ABS
2)Measure the resistance between ABS relay relay and chassis
connector and chassis ground. ground.
Connector & terminal
(8264) No. 3 (+) - Chassis ground:
6 CHECK ABS RELAY. Is the resistance less than 10 30 to step 7. Replace the ABS
1)Connect the battery to ABS relay terminal Q? relay.
No. 1 and 3.
2)Measure the resistance between ABS relay
terminals.
7 CHECK INPUT VOLTAGE OF ABSCM&WU. Is the voltage between 10 and Go to step 8. Repair harness
1)Turn the ignition switch to OFF. 15 V? connector
2)Disconnect the connector from ABSCM& between battery,
H/U. ignition switch and
3)Run the engine at idle. ABSCM&H/U.
4)Measure the voltage between ABSCM&H/U
connector and chassis ground.
Connector & terminal
(F49) No. 1 (+)- Chassis ground (-):
B CHECK GROUND CIRCUIT OF ABSCM&H/U Is the resistance less than 0.5 Go to step 9. Repair the
1)Turn the ignition switch to OFF. Q? ABSCM&H/U
2)Measure the resistance between ground harness.
ABSCM&H/U connector and chassis ground.
Connector & terminal
(F49) No. 23 - Chassis ground:
9 CHECK POOR CONTACT IN CONNECTORS Isthere poorcontact in con- Repair the con- Go to step 10.
nectors between generator, nector.
battery and ABSCM&H/U?
lo ~
CHECK ABSCM&WU. Is the same diagnostic trouble Replace the Go to step 11.
1)Connect all connectors. code as in the current diagno- ABSCM&H/U.
2)Erase the memory. sis still being output? <Ref. to ABS-7,
3)Perform the inspection mode. ABS Control Mod-
4)Read out the diagnostic trouble code. ule and Hydraulic
Control Unit
(ABSCM&H/U).>

ABS-I 23
 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICS)

Step Check Yes No

11 CHECK ANY OTHER DIAGNOSTIC TROU- Are other diagnostic trouble Proceed with the A temporary poor
BLE CODES APPEARANCE. codes being output? diagnosis corre- contact.
sponding to the
diagnostic trouble
code.

ABS-124
 m

DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR

ABS (DIAGNOSTICS)

P: DTC32
FRONT RIGHT OUTLET VALVE MALFUNCTION
NOTE:
For the diagnostic procedure, refer to DTC 38. <Ref. to ABS-125, DTC 38 REAR LEFT OUTLET VALVE
MALFUNCTION, Diagnostics Chart with Subaru Select Monitor.>

Q: DTC34
FRONT LEFT OUTLET VALVE MALFUNCTION
NOTE:
For the diagnostic procedure, refer to DTC 38. <Ref. to ABS-125, DTC 38 REAR LEFT OUTLET VALVE
MALFUNCTION, Diagnostics Chart with Subaru Select Monitor.>

R: DTC36
REAR RIGHT OUTLET VALVE MALFUNCTION
NOTE:
For the diagnostic procedure, refer to DTC 38. <Ref. to ABS-125, DTC 38 REAR LEFT OUTLET VALVE
MALFUNCTION, Diagnostics Chart with Subaru Select Monitor.>

S: DTC38
REAR LEFT OUTLET VALVE MALFUNCTION
DIAGNOSIS:
Faulty harnesskonnector
Faulty outlet solenoid valve
TROUBLE SYMPTOM:
ABS does not operate.

ABS-I 25
 n
DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS IDIAGNOSTICS)

WIRING DIAGRAM:

BATTERY

RELAY
HOLDER

ABS
RELAY

I @ ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT I

I
n I516171819
B 11213141
I
10111112113114 15 116117118119120

BR0085

ABS-126
 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICS)

Step Check Yes No

CHECK INPUT VOLTAGE OF RELAY HOLD s the voltage more than 10 V? Go to step 2. Repair open circuit
ER. in harness
1)Turnthe ignition switch to OFF. between battery
2)Remove the fuse. and relay holder
3)Measure the voltage between ABS relay connector.
connector and chassis ground.
Connector & terminal
(6225) No. 5 (+) - Chassis ground (-):
CHECK RELAY HOLDER. Is the fuse blown out? Replace the fuse. Go to step 3.
CHECK INPUT VOLTAGE OF ABS RELAY. Is the voltage more than 10 V? Go to step 4. Repair open circuit
1)lnstall the fuse. in harness
2)Remove the ABS relay. between battery
3)Turn the ignition switch to ON. and relay holder
4)Measure the voltage between ABS relay connector.
connector and chassis ground.
Connector & terminal
(6264) No. 2 (+) - Chassis ground (-):
CHECK INPUT VOLTAGE OF ABS RELAY. Is the voltage more than 10 V? Go to step 5. Repair harness
Measure the voltage between ABS relay con- connector
nector and chassis ground. between battery,
Connector & terminal ignition switch and
. (6264) No. 1 (+) - Chassis ground (-): ABS relay.
CHECK GROUND CIRCUIT OF ABS RELAY Is the resistance less than 5 Go to step 6. Repair open circuii
1)Turn the ignition switch to OFF. n? between ABS
2)Measure the resistance between ABS relay relay and chassis
connector and chassis ground. ground.
Connector & terminal
(6264) No. 3 (+) - Chassis ground:
CHECK ABS RELAY. Is the resistance less than 10 Go to step 7. Replace the ABS
1)Connectthe battery to ABS relay terminal n? relay.
No. 1 and 3.
2)Measure the resistance between ABS relay
terminals.
CHECK INPUT VOLTAGE OF ABSCM&WU. Is the voltage between 10 and Go to step 0. Repair harness
1)Turn the ignition switch to OFF. 15 V? connector
2)Disconnect the connector from ABSCM& between battery,
H/U. ignition switch and
3)Run the engine at idle. ABSCM&H/U.
4)Measure the voltage between ABSCM&H/U
connector and chassis ground.
Connector & terminal
(F49) No. 1 (+) - Chassis ground (-):
CHECK GROUND CIRCUIT OF ABSCM&H/U Is the resistance less than 0.5
1)Turn the ignition switch to OFF. n? ABSCM&H/U
2)Measure the resistance between ground harness.
ABSCM&H/U connector and chassis ground.
Connector & terminel
-
(F49) No. 23 Chassis ground:
CHECK POOR CONTACT IN CONNECTORS Is there poor contact in con- Repair the con- Go to step 10.
nectors between generator, nector.
battery and ABSCM&H/U?
I ~ CHECK ABSCM&W. Is the same diagnostic trouble Replace the Go to step 11.
1)Connect all connectors. code as in the current diagno- ABSCM&H/U.
2)Erase the memory. sis still being output? <Ref. to ABS-7,
3)Perform the inspection mode. ABS Control Mod-
4)Read out the diagnostic trouble code. ule and Hydraulic
Control Unit
(ABSCM&H/U).>

ABS-I 27
 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICS)

Check

BLE CODES APPEARANCE. codes being output? diagnosis corre- contact.

sponding to the
diagnostic trouble
code.

ABS-1 28
DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICS)

ABS-I 29
 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICS)

T: DTC41
ABS CONTROL MODULE MALFUNCTION
DIAGNOSIS:
Faulty ABSCM&H/U
TROUBLE SYMPTOM:
ABS does not operate.
WIRING DIAGRAM:

ABS CONTROL MODULE AND

HYDRAULIC CONTROL UNIT

I
II I

B4M1457

ABS-I 30
 3

DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR

ABS ( DIAG NOSTlCS)

Step Check Yes No

I CHECK GROUND CIRCUIT OF ABSCM&H/U Is the resistance less than 0.5 $0to step 2. Repair the
1)Turn the ignition switch to OFF. R? ABSCM&H/U
2)Disconnect the connector from ABSCM& ground harness.
H/U.
3)Measure the resistance between
ABSCM&H/U and chassis ground.
Connector 81terminal
(F49) No. 23 - Chassis ground:
2 CHECK POOR CONTACT IN CONNECTORS Is there poor contact in con- 3epair the con- Go to step 3.
nectors between battery, igni- lector.
tion switch and ABSCM&H/U?
3 CHECK SOURCES OF SIGNAL NOISE. Is the car telephone or the ;o to step 4. Properly install the
wireless transmitter properly car telephone or
installed? the wireless trans-
mitter.
1 CHECK SOURCES OF SIGNAL NOISE. Are noise sources (such as an nstall the noise Go to step 5.
antenna) installed near the ;ources apart from
sensor harness? he sensor har-
less.
~

5 CHECK ABSCM&WU. Is the same diagnostic trouble qeplace the Go to step 6.

01)Turnthe ignition switch to OFF. code as in the current diagno- iBSCM&H/U.
2)Connect all connectors. sis still being output? :Ref. to ABS-7,
3)Erase the memory. 4BS Control Mod-
4)Perform the inspection mode. ile and Hydraulic
5)Read out the diagnostic trouble code. ;ontrol Unit
ABSCM&H/U).>
6 CHECK ANY OTHER DIAGNOSTICTROU- Are other diagnostic trouble Voceed with the A temporary poor
BLE CODES APPEARANCE. codes being output? liagnosis corre- contact.
iponding to the
liagnostic trouble
:ode.

ABS-1 31
 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICS)

U: DTC42
POWER SUPPLY VOLTAGE TOO LOW
DIAGNOSIS:
Power source voltage of the ABSCM&H/U is low.
TROUBLE SYMPTOM:
ABS does not operate.
WIRING DIAGRAM:

BATTERY

R E LAY
HOLDER

ABS
RELAY

BR0085

ABS-I 32
 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICS)

Step Check Yes No

I CHECK GENERATOR. s the voltage between 10 and ;o to step 2. Repair the genera
1)Start the engine. I5 V? tor. <Ref. to SC-
2)ldling after warm-up. 13, Generator.>
3)Measure the voltage between generator B
terminal and chassis ground.
Terminal
-
Generator B terminal Chassis ground
! CHECK BATTERY TERMINAL. \re the positive and negative 30 to step 3. Tighten the clamp
Turn the ignition switch to OFF. iattery terminals tightly of terminal.
Aamped?
I CHECK INPUT VOLTAGE OF ABSCM&H/U. s the voltage between 10 and o
; to step 4. Repair harness
1)Disconnect the connector from ABSCM& I5 V? connector
H/U. between battery,
2)Run the engine at idle. ignition switch anc
3)Measure the voltage between ABSCM&H/U ABSCM&H/U.
connector and chassis ground.
Connector & terminal
-
(F49) No. 1 (+) Chassis ground (-):
I CHECK GROUND CIRCUIT OF ABSCM&H/U s the resistance less than 0.5 i o to step 5. Repair the
1)Turnthe ignition switch to OFF. n? ABSCM&H/U
2)Measure the resistance between ground harness.
ABSCM&H/U connector and chassis ground.
Connector & terminal
i
-
(F49) No. 23 Chassis ground:
b CHECK POOR CONTACT IN CONNECTORS s there poor contact in con- 3epair the con- Go to step 6.
lectors between generator, lector.
iattery and ABSCM&H/U?
i CHECK ABSCM&H/U. s the same diagnostic trouble 3eplace the Go to step 7.
1)Connect all connectors. :ode as in the current diagno- 4BSCM&H/U.
2)Erase the memory. ;is still being output? :Ref. to ABS-7,
3)Perform the inspection mode. 4BS Control Mod-
4)Read out the diagnostic trouble code. ile and Hydraulic
;ontrol Unit
ABSCM&H/U).>
? CHECK ANY OTHER DIAGNOSTIC TROU- \re other diagnostic trouble 'roceed with the A temporary poor
BLE CODES APPEARANCE. :odes being output? jiagnosis corre- contact.
iponding to the
iiagnostic trouble
:ode.

ABS-I 33
 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICS)

V: DTC42
POWER SUPPLY VOLTAGE TOO HIGH
DIAGNOSIS:
Power source voltage of the ABSCM&H/U is high.
TROUBLE SYMPTOM:
ABS does not operate.
WIRING DIAGRAM:

RELAY
HOLDER

ABS
RELAY

I ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT

I
il21314l n 1 516171819
101111121131 14 I 15 116117]18]19]20

0R0005

ABS-134
 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICS)

Step Check Yes No

CHECK GENERATOR. s the voltage between 10 and 30 to step 2. Repair the genera
1)Start the engine. 7 V? tor. <Ref. to SC-
2)ldling after warm-up. 13, Generator.>
3)Measure the voltage between generator B
terminal and chassis ground.
Terminal
Generator 6 terminal - Chassis ground:
CHECK BATTERY TERMINAL. ire the positive and negative 30 to step 3. Tighten the clamp
Turn the ignition switch to OFF. Iattery terminals tightly of terminal.
:lamped?
CHECK INPUT VOLTAGE OF RELAY HOLD- s the voltage more than 10 V? 30 to step 4. Repair open circuit
ER. in harness
1)Turnthe ignition switch to OFF. between battery
2)Remove the fuse. and Relay holder
3)Measure the voltage between ABS relay connector.
connector and chassis ground.
Connector & terminal
(6225) No. 5 (+) - Chassis ground (-):
I CHECK RELAY HOLDER. s the fuse blown out? 3eplace the fuse. Go to step 5.
I CHECK INPUT VOLTAGE OF ABS RELAY. s the voltage more than 10 V? So to step 6. Repair open circuil
1)lnstall the fuse. in harness
2)Remove the ABS relay. between battery
3)Turn the ignition switch to ON. and Relay holder
4)Measure the voltage between ABS relay connector.
connector and chassis ground.
Connector & terminal
(8264) No. 2 (+) - Chassis ground (-):
i CHECK INPUT VOLTAGE OF ABS RELAY. s the voltage more than 10 V? So to step 7. Repair harness
Measure the voltage between ABS relay con- connector
nector and chassis ground. between battery,
Connector & terminal ignition switch and
(8264) No. 1 (+) - Chassis ground (-): ABS relay.
I
CHECK GROUND CIRCUIT OF ABS RELAY. s the resistance less than 5 Go to step 8. Repair open circui'
1)Turnthe ignition switch to OFF. R? between ABS
2)Measure the resistance between ABS relay relay and chassis
connector and chassis ground. ground.
Connector & terminal
(6264) No. 3 (+) - Chassis ground:
I CHECK ABS RELAY. s the resistance less than 10 Go to step 9. Replace the ABS
1)Connect the battery to ABS relay terminal R? relay.
No. 1 and 3.
2)Measure the resistance between ABS relay
terminals.
3 CHECK INPUT VOLTAGE OF ABSCM&H/U. Is the voltage between 10 and Go to step 10. Repair harness
1)Disconnectthe connector from ABSCM& 17 V? connector
HIU. between battery,
2)Run the engine at idle. ignition switch anc
3)Measure the voltage between ABSCM&H/U ABSCM&H/U.
connector and chassis ground.
Connector & terminal
(F49) No. 1 (+) - Chassis ground (-):
CHECK GROUND CIRCUIT OF ABSCM&H/U Is the resistance less than 0.5 Go to step 11. Repair the
lo
ABSCM&H/U
~

1)Turn the ignition switch to OFF. R?

2)Measure the resistance between ground harness.
ABSCM&H/U connector and chassis ground.
Connector & terminal
1F49)No. 23 - Chassis around:

ABS-1 35
 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICS)

Step Check Yes No

11 CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in con- Repair the con- Go to step 12.
nectors between generator, nector.
battery and ABSCM&H/U?
12 CHECK ABSCM&H/U. Is the same diagnostic trouble Replace the Go to step 13.
1)Connect all connectors. code as in the current diagno- ABSCM&H/U.
2) Erase the memory. sis still being output? <Ref. to ABS-7,
3)Perform the inspection mode. ABS Control Mod-
4)Read out the diagnostic trouble code. ule and Hydraulic
Control Unit
(ABSCM&H/U).>
13 CHECK ANY OTHER DIAGNOSTIC TROU- Are other diagnostic trouble Proceed with the A temporary poor
BLE CODES APPEARANCE. codes being output? diagnosis corre- contact.
sponding to the
diagnostic trouble
code.

ABS-I 36
DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICS)

ABS-I 37
 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICS)

W: DTC44
ABS-AT CONTROL (NON CONTROLLED)
DIAGNOSIS:
Combination of AT control faults
TROUBLE SYMPTOM:
ABS does not operate.
WIRING DIAGRAM:

I
Ic

TI
NA : NON-TURBO ENGINE MODEL

A:

8
854

8 : 655 TCM

BR008f

ABS-I 38
 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICS)

Step Check Yes No

1 CHECK SPECIFICATIONSOF THE AB- s an ABSCM&H/U for AT Replace the Go to step 2.
SCM&H/U. model installed on a MT ABSCM&H/U.
Check specifications of the mark to the nodel? <Ref. to ABS-7,
ABSCM&H/U. ABS Control Mod-
CC: AT ule and Hydraulic
CD: MT Control Unit
(ABSCM&H/U).>
2 CHECK GROUND SHORT OF HARNESS. Is the resistance more than 1 Go to step 3. Repair harness
1)Turn the ignition switch to OFF. MQ? between TCM and
2)Disconnect two connectors from TCM. ABSCM&H/U.
3)Disconnect the connector from ABSCM&
H/U.
4)Measure the resistance between
ABSCM&H/U connector and chassis ground.
Connector & terminal
(F49)No. 3 - Chassis ground:
3 CHECK TCM. Is the voltage between 10 and Go to step 5. Go to step 4.
1)Connect all connectors to TCM. 15 V?
2)Turn the ignition switch to ON.
3)Measure the voltage between TCM connec-
,tor terminal and chassis ground.
Connector & terminal
NON-TURBO MODEL:
(854) No. 19 (+) - Chassis ground (-):
TURBO MODEL:
-
(B55) No. 21 (+) Chassis ground (-):
4 CHECK AT. Is the AT functioning normally? Replace the TCM. Repair the AT.
5 CHECK OPEN CIRCUIT OF HARNESS. Is the voltage more than IO V? Go to step 6. Repair harness/
Measure the voltage between ABSCM&H/U connector
connector and chassis ground. between TCM and
Connector & terminal ABSCM&H/U.
-
(F49)No. 3 (+) Chassis ground (-):
(F49)No. 31 (+) - Chassis ground (-):
6 CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in con- Repair the con- Go to step 7.
nectors between TCM and nector.
ABSCM&H/U?
7 CHECK ABSCM&HN. Is the same diagnostic trouble Replace the Go to step 8.
1)Connect all connectors. code as in the current diagno- ABSCM&H/U.
2)Erase the memory. sis still being output? <Ref. to ABS-7,
3)Perform the inspection mode. ABS Control Mod-
4)Read out the diagnostic trouble code. ule and Hydraulic
Control Unit
(ABSCM&H/U).>
8 CHECK ANY OTHER DIAGNOSTICTROU- Are other diagnostic trouble Proceed with the A temporary poor
BLE CODES APPEARANCE. codes being output? diagnosis corre- contact.
sponding to the
diagnostic trouble
code.

ABS-I 39
 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICSI

X: DTC44
ABS-AT CONTROL (CONTROLLED)
DIAGNOSIS:
Combination of AT control faults
TROUBLE SYMPTOM:
ABS does not operate.
WIRING DIAGRAM:

: TURBO ENGINE MODEL

m
a 7

z a
m T

+ (u
m

BR0086

ABS-I 40
 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICS)

Step Check Yes No

t CHECK BATTERY SHORT OF HARNESS. Is the voltage less than 1 V? Go to step 2. Repair harness
1)Turnthe ignition switch to OFF. between TCM and
2)Disconnect two connectors from TCM. ABSCM&H/U.
3)Disconnect the connector from ABSCM&
HIU.
4)Measure the voltage between ABSCM&H/U
connector and chassis ground.
Connector & terminal
(F49) No. 3 (+)- Chassis ground (-):
2 CHECK BAlTERY SHORT OF HARNESS. Is the voltage less than 1 V? Go to step 3. Repair harness
1)Turn the ignition switch to ON. between TCM and
2)Measure the voltage between ABSCM&H/U ABSCM&H/U.
connector and chassis ground.
Connector & terminal
(F49) No. 3 (+) - Chassis ground (-):
3 CHECK OPEN CIRCUIT OF HARNESS. Is the voltage between 10 and Go to step 4. Repair harness/
1)Turn the ignition switch to OFF. 13 V? connector
2)Connect all connectors to TCM. between TCM and
3)Turn the ignition switch to ON. ABSCM&H/U.
4)Measure the voltage between ABSCM&H/U
connector and chassis ground.
Connector & terminal
(F49) No. 3 (+)- Chassis ground (-):
-
(F49) No. 31 (+) Chassis ground (-):
Q CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in con- Repair the con- Go to step 5.
Turn the ignition switch to OFF. nectors between TCM and qector.
ABSCM&H/U?
5 CHECK ABSCM&H/U. Is the same diagnostic trouble Replace the Go to step 6.
1)Connect all connectors. code as in the current diagno- ABSCM&H/U.
2)Erase the memory. sis still being output? <Ref. to ABS-7,
3)Perform the inspection mode. ABS Control Mod-
4)Read out the diagnostic trouble code. ule and Hydraulic
Control Unit
(ABSCM&H/U).>
6 CHECK ANY OTHER DIAGNOSTIC TROU- Are other diagnostic trouble Proceed with the A temporary poor
BLE CODES APPEARANCE. codes being output? diagnosis corre- contact.
sponding to the
diagnositc trouble
code.

ABS-1 41
 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICS)

ABS-142
 3
DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICS)

Y: DTC51
VALVE RELAY MALFUNCTION
DIAGNOSIS:
Faulty valve relay
i TROUBLE SYMPTOM:
ABS does not operate.

ABS-143
 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICS)

WIRING DIAGRAM:

BATTERY
SBF-1
(3c

r
t
U.
m

m
0
z r 1

PI
IGNITION
SWITCH

RELAY

-
ABS RELAY@

rl
r!l

- @
(u l

I
I '
tIIIIIIIII II I

ABS CONTROL MODULE AND

HYDRAULIC CONTROL UNIT

BR0087

ABS-1 44
 3

DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR

ABS (DIAGNOSTICS)
~~ ~

Step Check Yes No

I CHECK INPUT VOLTAGE OF RELAY HOLD- Is the voltage more than 10 V? 30 to step 2. 3epair open circuit
ER. n harness
1)Turnthe ignition switch to OFF. ietween battery
2)Remode the fuse. 3nd Relay holder
3)Measure the voltage between ABS relay :onnector.
connector and chassis ground.
Connector & terminal
(8225)No. 5 (+) - Chassis ground (-):
2 CHECK RELAY HOLDER. Is the fuse blown out? 3eplace the fuse. So to step 3.
3 CHECK INPUT VOLTAGE OF ABS RELAY. Is the voltage more than 10 V? 30 to step 4. Repair open circuit
1)lnstall the fuse. in harness
2)Remove the ABS relay. between battery
3)Turn the ignition switch to ON. snd Relay holder
4)Measure the voltage between ABS relay sonnector.
connector and chassis ground.
Connector & terminal
(8264)No. 2 (+) - Chassis ground (-):
1 CHECK INPUT VOLTAGE OF ABS RELAY. Is the voltage more than 10 V? 30 to step 5. Repair harness
Measure the voltage between ABS relay con- connector
nector and chassis ground. between battery,
Connector & terminal ignition switch and
. (6264)No. 1 (+) - Chassis ground (-): ABS relay.
Repair open circuit
5 CHECK GROUND CIRCUIT OF ABS RELAY. Is the resistance less than 5 So to step 6.
1)Turnthe ignition switch to OFF. a? between ABS
2)Measure the resistance between ABS relay relay and chassis
connector and chassis ground. ground.
Connector & terminal
(6264)No. 3 (+) - Chassis ground:
6 CHECK ABS RELAY. Is the resistance less than 10 So to step 7. Replace the ABS
1)Connect the battery to ABS relay terminal Q? relay.
No. 1 and 3.
2)Measure the resistance between ABS relay
terminals.
7 CHECK INPUT VOLTAGE OF ABSCM&H/U. Is the voltage between 10 and Go to step 8. Repair harness
1)Turnthe ignition switch to OFF. 15 V? connector
2)Disconnect the connector from ABSCM& between battery
HIU. and ABSCM&H/U.
3)Run the engine at idle.
4)Measure the voltage between ABSCM&H/U
connector and chassis ground.
Connector & terminal
(F49)No. 1 (+) - Chassis ground (-):
-
(F49)No. 24 (+) Chassis ground (-):
B CHECK GROUND CIRCUIT OF ABSCM&H/U Is the resistance less than 0.5 Go to step 9. Repair the
1)Turnthe ignition switch to OFF. Q? ABSCM&H/U
2)Measure the resistance between ground harness.
ABSCM&H/U connector and chassis ground.
Connector & terminal
(F49)No. 23 - Chassis ground:
9 CHECK POOR CONTACT IN CONNECTORS Is there poor contact in con- Repair the con- Go to step 10.
nectors between generator, nector.
battery and ABSCM&H/U?
10 CHECK ABSCM&H/U. Is the same diagnostic trouble Replace the Go to step 11.
1)Connect all connectors. code as in the current diagno- ABSCM&H/U.
2)Erase the memory. sis still being output? <Ref. to ABS-7,
3)Perform the inspection mode. ABS Control Mod-
4)Read out the diagnostic trouble code. ule and Hydraulic
Control Unit
(ABSCM&H/U).>

ABS-I 45
 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS IDIAGNOSTICS)

Step
11 CHECK ANY OTHER DIAGNOSTIC TROU-
BLE CODES APPEARANCE. codes being output? diagnosis corre- contact.
sponding to the
diagnostic trouble
code.

ABS-1 46
 I
DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICS)

Z: DTC 51
VALVE RELAY ON FAILURE
DIAGNOSIS:
Faulty valve relay
TROUBLE SYMPTOM:
ABS does not operate.

ABS-I 47
 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICS)

WIRING DIAGRAM:

RATTFRY

SBF-3
-
T
SBF-1

RELAY
HOLDER
i IGNITION
SWITCH

ABS CONTROL MODULE AND

HYDRAULIC CONTROL UNIT

I I
M-
-

BR0087

ABS-148
 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
-
ABS IDIAGNOSTICS)
~~
~

Step Check Yes No

I CHECK VALVE RELAY IN ABSCM&HIU. ,sthe resistance more than 1 Go to step 2. 3eplace the
Measure the resistance between ABSCM&H/U wn? 4BSCM&H/U.
terminals. :Ref. to ABS-7,
Terminals 9BS Control Mod-
NO. 23 (+) - NO. 24 (-): Jle and Hydraulic
Zontrol Unit
:ABSCM&H/U).>
2 CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in con- Repair the con- 30 to step 3.
nectors between generator, nector.
battery and ABSCM&H/U?
3 CHECK ABSCM&H/U. Is the same diagnostic trouble Replace the 30 to step 4.
1)Connect all connectors. code as in the current diagno- ABSCM&H/U.
2)Erase the memory. sis still being output? <Ref. to ABS-7,
3)Perform the inspection mode. ABS Control Mod-
4)Read out the diagnostic trouble code. ule and Hydraulic
Control Unit
(ABSCM&H/U).>
I CHECK ANY OTHER DIAGNOSTICTROU- Are other diagnostic trouble Proceed with the A temporary poor
BLE CODES APPEARANCE. codes being output? diagnosis corre- contact.
sponding to the
diagnostic trouble
code.

ABS-I 49
I DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICSI

ABS-I 50
 =
DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICS)

AA:DTC 52
OPEN CIRCUIT IN MOTOR RELAY CIRCUIT
DIAGNOSIS:
Faulty motor
Faulty motor relay
Faulty harness connector
TROUBLE SYMPTOM:
ABS does not operate.

ABS-I 51
 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICS)

WIRING DIAGRAM:

BATTERY
SBF-l
a

, 1)
m

=
ABS RELAY 8225

ABS CONTROL MODULE AND

HYDRAULIC CONTROL UNIT

ABS-I 52
 I

DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR

ABS (DIAGNOSTICS)
~~ ~

Step Check Yes No

1 CHECK INPUT VOLTAGE OF ABSCM&H/U. Is the voltage between 10 and 30 to step 2. Repair harness/
1)Turnthe ignition switch to OFF. 13 V? connector
2)Disconnect the connector from ABSCM& between battery
H/U. and ABSCM&H/U
3)Turn the ignition switch to ON. and check fuse
4)Measure the voltage between ABSCM&H/U SBFG.
connector and chassis ground.
Connector & terminal
(F49) No. 25 (+) - Chassis ground (-):
2 CHECK GROUND CIRCUIT OF MOTOR. Is the resistance less than 0.5 Go to step 3. Repair the
1)Turn the ignition switch to OFF. Q? ABSCM&H/U
2)Measure the resistance between ground harness.
ABSCM&H/U connector and chassis ground.
Connector & terminal
-
(F49) No. 26 Chassis ground:
3 CHECK MOTOR OPERATION. Can the motor revolution noise Go to step 4. Replace the
Operate the sequence control. <Ref. to ABS- (buzz) be heard when carrying ABSCM&H/U.
11, ABS Sequence Control.> out the check sequence? <Ref. to ABS-7,
NOTE: ABS Control Mod-
Use the diagnosis connector to operate the se, ule and Hydraulic
quence control. Control Unit
(ABSCM&H/U).>
4 %HECK POOR CONTACT IN CONNECTORS Is there poor contact in con- Repair the con- Go to step 5.
Turn the ignition switch to OFF. nector between hydraulic unit, nector.
relay box and ABSCM&H/U?
5 CHECK ABSCM&H/U. Is the same diagnostic trouble Replace the Go to step 6.
1)Connect all connectors. code as in the current diagno- ABSCM&H/U.
2)Erase the memory. sis still being output? <Ref. to ABS-7,
3)Perform the inspection mode. ABS Control Mod-
4)Read out the diagnostic trouble code. ule and Hydraulic
Control Unit
(ABSCM&H/U).>
6 CHECK ANY OTHER DIAGNOSTICTROU- Are other diagnostic trouble Proceed with the A temporary poor
BLE CODES APPEARANCE. codes being output? diagnosis corre- contact.
sponding to the
diagnostic trouble
code.

ABS-I 53
 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICS)

ABS-I 54
E DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
I

ABS (DIAGNOSTICS)

AB:DTC 52
MOTOR RELAY ON FAILURE
DIAGNOSIS:
Faulty motor
Faulty motor relay
Faulty harness connector
f TROUBLE SYMPTOM:
I
1 ABS does not operate.

ABS-155
 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICS)

WIRING DIAGRAM:

-
a
SBF-1
3 c

-
I II
ABS CONTROL MODULE AND
HYDRAULIC CONTROL UNIT

n
r
VALVE RELAY
L
MOTOR RELAY
'd
k!3
a
1

ABS-I 56
 m
DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICS)

Step Check No
I CHECK MOTOR RELAY IN ABSCM&H/U. ?eplace the
Measure the resistance between ABSCM&H/U 4BSCM&H/U.
terminals. :Ref. to ABS-7,
Terminals 4BS Control Mod-
NO. 25 - NO. 26: Jle and Hydraulic
Zontrol Unit
:ABSCM&H/U).>
2 CHECK MOTOR OPERATION. Replace the
Operate the sequence control. <Ref. to ABS- (buzz) be heard when carrying 4BSCM&H/U.
11, ABS Sequence Control.> out the sequence control? <Ref. to ABS-7,
NOTE: 4BS Control Mod-
Use the diagnosis connector to operate the se de and Hydraulic
quence control. Zontrol Unit
(ABSCM&H/U).>
3 CHECK POOR CONTACT IN CONNECTORS Is there poor contact in con- Repair the con- Go to step 4.
Turn the ignition switch to OFF. nector between hydraulic unit, nector.
relay box and ABSCM&H/U?
1 CHECK ABSCM&HN. Is the same diagnostic trouble Replace the Go to step 5.
1)Connect all connectors. code as in the current diagno- ABSCM&H/U.
2)Erase the memory. sis still being output? <Ref. to ABS-7,
3)Perform the inspection mode. ABS Control Mod-
4)Read out the diagnostic trouble code. ule and Hydraulic
Control Unit
(ABSCM&H/U).>
5 CHECK ANY OTHER DIAGNOSTICTROU- Are other diagnostic trouble Proceed with the A temporary poor
BLE CODES APPEARANCE. codes being output? diagnosis corre- contact.
sponding to the
diagnostic trouble
code.

ABS-I 57
1 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICS)

ABS-I 58
I I

DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR

ABS (DIAGNOSTICS)

AC:DTC 52
MOTOR MALFUNCTION
DIAGNOSIS:
Faulty motor
Faulty motor relay
Faulty harness connector
r TROUBLE SYMPTOM:
i
t
ABS does not operate.

ABS-159
 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICS)

WIRING DIAGRAM:

-
BATTERY
SBF-1
3 c

!
T
I

9
0
U
W

I
m
I

II I II
T
'Q
I d
ABS CONTROL MODULE AND
HYDRAULIC CONTROL UNIT

--
VALVE RELAY MOTOR RELAY I
3
a

I
I 1

11213141 n I 516171819
I
10]11]121131 14 15

ABS-I 60
 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICS)
~~ ~~

Step Check Yes NO

CHECK INPUT VOLTAGE OF ABSCM&H/U. Is the voltage between 10 and to step 2. Repair harness/
1)Turn the ignition switch to OFF. 13 V? connector
2)Disconnect the connector from ABSCM& between battery
H/U. and ABSCM&H/U
3)Turn the ignition switch to ON. and check fuse
4)Measure the voltage between ABSCM&H/U SBFG.
connector and chassis ground.
Connector & terminal
(F49) No. 25 (+)- Chassis ground (-):
CHECK GROUND CIRCUIT OF MOTOR. Is the resistance less than 0.5 to step 3. Repair the
1)Turn the ignition switch to OFF. R? ABSCM&H/U
2)Measure the resistance between ground harness.
ABSCM&H/U connector and chassis ground.
Connector & terminal
-
(F49) No. 26 Chassis ground:
CHECK INPUT VOLTAGE OF ABSCM&H/U. Is the voltage between 10 and to step 4. Repair harness
1)Run the engine at idle. 15 V? connector
2)Measure the voltage between ABSCM&H/U between battery,
connector and chassis ground. ignition switch and
Connector & terminal ABSCM&H/U.
(F49) No, 1 (+) - Chassis ground (-):
.CHECK GROUND CIRCUIT OF ABSCM&H/U. Is the resistance less than 0.5 to step 5. Repair the
1)Turn the ignition switch to OFF. R? ABSCM&H/U
2)Measure the resistance between ground harness.
ABSCM&H/U connector and chassis ground.
Connector & terminal
(F49) No. 23 - Chassis ground:
CHECK MOTOR OPERATION. Can the motor revolution noise to step 6. Replace the
Operate the sequence control. <Ref. to ABS- (buzz) be heard when carrying ABSCM&H/U.
11, ABS Sequence Control.> out the sequence control? <Ref. to ABS-7,
NOTE: ABS Control Mod-
Use the diagnosis connector to operate the se. ule and Hydraulic
quence control. Control Unit
(ABSCM&H/U).>
CHECK POOR CONTACT IN CONNECTORS, Is there poor contact in con- Dair the con- Go to step 7.
Turn the ignition switch to OFF. nector between generator, bat- :tor.
tery and ABSCM&H/U?
CHECK ABSCM&H/U. Is the same diagnostic trouble Aace the Go to step 8.
1)Connect all connectors. code as in the current diagno- SCM&H/U.
2)Erase the memory. sis still being output? ef. to ABS-7,
3)Perform the inspection mode. S Control Mod-
4)Read out the diagnostic trouble code. and Hydraulic
itrol Unit
ECM&H/U).>
CHECK ANY OTHER DIAGNOSTIC TROU- Are other diagnostic trouble ceed with the A temporary poor
BLE CODES APPEARANCE. codes being output? gnosis corre- contact.
mding to the
gnostic trouble
le.

ABS-I 61
 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICS)

AD:DTC 54
STOP LIGHT SWITCH SIGNAL CIRCUIT MALFUNCTION
DIAGNOSIS:
Faulty stop light switch
TROUBLE SYMPTOM:
ABS does not operate.
WIRING DIAGRAM:

BATTERY

+=L I

STOP LIGHT
SWITCH

ABS CONTROL MODULE AND

HYDRAULIC CONTROL UNIT

m il213ITl nI 516171819
101111121131 14 I 15 ]16117118]19120

BR0089

ABS-1 62
 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAG NOSTlCS)

Step Check Yes No

I CHECK OUTPUT OF STOP LIGHT SWITCH Is the reading indicated on Go to step 2. 30 to step 3.
USING SELECT MONITOR. monitor display less than 1.5
1)Select “Current data display & Save” on the V?
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. 30 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. 3epair the stop
Depress the brake pedal. ights circuit.
I CHECK OPEN CIRCUIT IN HARNESS. Is the voltage between 10 and Go to step 5. 3epair harness
1)Turnthe ignition switch to OFF. 15 V? Detween stop light
2)Disconnectthe connector from ABSCM& switch and
H/U. 4BSCM&H/U con-
3)Depress the brake pedal. lector.
4)Measure the voltage between ABSCM&H/U
.connector and chassis ground.
Connector & terminal
-
(F49) No. 2 Chassis ground:
5 CHECK POOR CONTACT IN CONNECTORS Is there poor contact in con- Repair the con- 30 to step 6.
nector between stop light nector.
switch and ABSCM&H/U?
5 CHECK ABSCM&HRI. Is the same diagnostic trouble Replace the 30 to step 7.
1)Connect all connectors. code as in the current diagno- ABSCM&H/U.
2)Erase the memory. sis still being output? <Ref. to ABS-7,
3)Perform the inspection mode. ABS Control Mod-
4)Read out the diagnostic trouble code. ule and Hydraulic
Control Unit
(ABSCM&H/U).>
r CHECK ANY OTHER DIAGNOSTICTROU- Are other diagnostic trouble Proceed with the 4 temporary poor
BLE CODES APPEARANCE. codes being output? diagnosis corre- :ontact.
sponding to the
diagnostic trouble
code.

ABS-1 63
 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICS)

ABS-I 64
 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICS)

AE:DTC 56
OPEN OR SHORT CIRCUIT IN G SENSOR CIRCUIT
DIAGNOSIS:
Faulty G sensor output voltage
TROUBLE SYMPTOM:
ABS does not operate.

ABS-I 65
 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICSI

WIRING DIAGRAM:

\
@ ABS CONTROL MODULE AND
HYDRAULIC CONTROL UNIT

SHIELD JOINT
CONNECTOR

I
I
I
I

1
7 -
~

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t 2

ABS
G SENSOR

BR0090

ABS-1 66
 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICS)

Step Check Yes No

CHECK OUTPUT OF G SENSOR USING SE- Is the G sensor output on the $0to step 2. Go to step 5.
LECT MONITOR. monitor display between 2.1
1)Select “Current data display & Save” on the and 2.5 V when the G sensor
select monitor. is in horizontal position?
2)Read the G sensor output in select monitor
data display.
! CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in con- Iepair the con- Go to step 3.
nectar between ABSCM&H/U lector.
and G sensor?
I CHECK ABSCM&H/U. Is the same diagnostic trouble 3eplace the Go to step 4.
1)Connect all connectors. code as in the current diagno- 4BSCM&H/U.
2)Erase the memory. sis still being output? :Ref. to ABS-7,
3)Perform the inspection mode. 4BS Control Mod-
4)Read out the diagnostic trouble code. ile and Hydraulic
:ontrol Unit
ABSCM&H/U).>
I CHECK ANY OTHER DIAGNOSTICTROU- Are other diagnostic trouble ’roceed with the A temporary poor
BLE CODES APPEARANCE. codes being output? fiagnosis corre- contact.
iponding to the
iiagnostic trouble
:ode.
i CHECK INPUT VOLTAGE OF G SENSOR. Is the voltage between 4.75 30 to step 6. Repair harness/
1)Turnthe ignition switch to OFF. and 5.25 V? connector
2)Remove the console box. between G sensoi
3)Disconnect the G sensor from body. (Do not and ABSCM&H/U
disconnect connector.)
4)Turn the ignition switch to ON.
5)Measure the voltage between G sensor con-
nector terminals.
Connector & terminal
(8292) NO. 1 (+)- NO. 3 (-):
i CHECK OPEN CIRCUIT IN G SENSOR OUT- Is the resistance between 4.3 30 to step 7. Repair harness/
PUT HARNESS AND GROUND HARNESS. and 4.9 kR? connector
1)Turn the ignition switch to OFF. between G sensoi
2)Disconnect the connector from ABSCM& and ABSCM&H/U
H/U.
3)Measure the resistance between
ABSCM&H/U connector terminals.
Connector & terminal
(F49) NO. 6 - NO. 28:
T CHECK GROUND SHORT IN G SENSOR IS the resistance more than 1 30 to step 8. Repair harness
OUTPUT HARNESS. MR? between G sensoi
1)Disconnectthe connector from G sensor. and ABSCM&H/U
2)Measure the resistance between
ABSCM&H/U connector and chassis ground.
Connector & terminal
(F49) No. 6 - Chassis ground:
j CHECK G SENSOR. Is the voltage between 2.1 and 30 to step 9. Replace the G
1)Connect the connector to G sensor. 2.5 V when G sensor is hori- sensor. <Ref. to
2)Connect the connector to ABSCM&H/U. zontal? ABS-23, G Sen-
3)Turn the ignition switch to ON. sor.>
. 4)Measure the voltage between G sensor con-
nector terminals.
Connector & terminal
(8292) NO. 2 (+)- NO. 3 (-):

ABS-I 67
 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICS)

Step Check Yes No

9 CHECK G SENSOR. Is the voltage between 3.7 and Go to step 10. Replace the G
Measure the voltage between G sensor con- 4.1 V when G sensor is sensor. <Ref. to
nector terminals. inclined forwards to go"? ABS-23, G Sen-
Connector & terminal so r.>
(6292) NO. 2 (+) - NO. 3I)-(
10 CHECK G SENSOR. Is the voltage between 0.5 and Go to step 11. Replace the G
Measure the voltage between G sensor con- 0.9 V when G sensor is sensor. <Ref. to
nector terminals. inclined backwards to go"? ABS-23, G Sen-
Connector & terminal so r.>
(6292) NO. 2 (+) - NO. 3 (-):
11 CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in con- Repair the con- Go to step 12.
Turn the ignition switch to OFF. nector between ABSCM&H/U nector.
and G sensor?
12 CHECK ABSCM&H/U. Is the same diagnostic trouble Replace the Go to step 13.
1)Connect all connectors. code as in the current diagno- ABSCM&H/U.
2)Erase the memory. sis still being output? <Ref. to ABS-7,
3)Perform the inspection mode. ABS Control Mod-
4)Read out the diagnostic trouble code. ule and Hydraulic
Control Unit
(ABSCM&H/U).>
13 CHECK ANY OTHER DIAGNOSTIC TROU- Are other diagnostic trouble Proceed with the A temporary poor
. BLE CODES APPEARANCE. codes being output? diagnosis corre-
sponding to the
contact.

diagnostic trouble
I
code.

ABS-1 68
 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICS)
~

AF:DTC 56
BATTERY SHORT IN G SENSOR CIRCUIT
DIAGNOSIS:
Faulty G sensor output voltage
TROUBLE SYMPTOM:
ABS does not operate.

ABS-I 69
 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICS)

WIRING DIAGRAM:

ABS CONTROL MODULE AND

HYDRAULIC CONTROL UNIT

SHIELD JOINT
CONNECTOR

+g 8200

L
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t 3

P
U
BS
0 NSOR

11213141 nI 5 16 17 18 19
101111121131 14 I 15 116117[18119120

BR0090

ABS-I 70
 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICS)
~~ ~

Step Check Yes No

CHECK OUTPUT OF G SENSOR USING SE- 5 the G sensor output on the ;o to step 2. Go to step 5.
LECT MONITOR. ionitor display between 2.1
1)Select “Current data display & Save” on the n d 2.5 V when the G sensor
select monitor. j in horizontal position?

2)Read the G sensor output in select monitor

data display.
! CHECK POOR CONTACT IN CONNECTORS, 5 there poor contact in con- 3epair the con- Go to step 3.
lector between ABSCM&H/U lector.
ind G sensor?
I CHECK ABSCM&H/U. 3 the same diagnostic trouble 3eplace the Go to step 4.
1)Connect all connectors. :ode as in the current diagno- 4BSCM&H/U.
2)Erase the memory. #isstill being output? :Ref. to ABS-7,
3)Perform the inspection mode. 4BS Control Mod-
4)Read out the diagnostic trouble code. ile and Hydraulic
2ontrol Unit
ABSCM&H/U).>
I CHECK ANY OTHER DIAGNOSTICTROU- ire other diagnostic trouble ’roceed with the A temporary poor
BLE CODES APPEARANCE. :odes being output? iiagnosis corre- contact.
iponding to the
liagnostic trouble
:ode.
i CHECK FREEZE FRAME DATA. s the front right wheel speed 50 to step 6. Go to step 16.
1)Select “Freeze frame data” on the select In monitor display 0 km?
monitor.
2)Read the front right wheel speed on the
select monitor display.
i CHECK FREEZE FRAME DATA. s the front left wheel speed on 50 to step 7. Go to step 16.
Read the front left wheel speed on the select nonitor display 0 km?
monitor display.
T CHECK FREEZE FRAME DATA. s the rear right wheel speed 30 to step 8. Go to step 16.
Read the rear right wheel speed on the select )n monitor display 0 km?
monitor display.
5 CHECK FREEZE FRAME DATA. s the rear left wheel speed on 30 to step 9. Go to step 16.
Read the rear left wheel speed on the select nonitor display 0 km?
monitor display.
B CHECK FREEZE FRAME DATA. s the G sensor output on mon- 20 to step 10. Go to step 16.
Read the G sensor output on the select moni- tor display more than 3.65 V?
tor display.
IO CHECK OPEN CIRCUIT IN G SENSOR OUT. s the resistance between 4.3 20 to step 11. Repair harness/
PUT HARNESS AND GROUND HARNESS. ind 4.9 w1? connector
1)Turn the ignition switch to OFF. between G sensoi
2)Disconnectthe connector from ABSCM8 and ABSCM&H/U
H/U.
3)Measure the resistance between
ABSCM&H/U connector terminals.
Connector & terminal
-
(F49)NO. 6 NO. 28:
I1 CHECK BATTERY SHORT OF HARNESS. s the voltage less than 1 V? 30 to step 12. Repair harness
1)Turn the ignition switch to OFF. between G senso
2)Remove the console box. and ABSCM&H/U
3)Disconnect the connector from G sensor.
~ 4)Disconnect the connector from ABSCM&
H/U.
5)Measure the voltage between ABSCM&
H/U connector and chassis ground.
Connector & terminal
(F49) No. 6 (+) - Chassis ground (-):

ABS-171
 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICS)
~~ ~

Step Check Yes No

12 CHECK BATTERY SHORT OF HARNESS. Is the voltage less than 1 V? Go to step 13. Repair harness
1)Turnthe ignition switch to ON. between G sensor
2)Measure the voltage between ABSCM&H/U and ABSCM&H/U.
connector and chassis ground.
Connector & terminal
(F49)No. 6 (+) - Chassis ground (-):
13 CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in con- Repair the con- Go to step 14.
nector between ABSCM&H/U nector.
and G sensor?
14 CHECK ABSCM&H/U. Is the same diagnostic trouble Replace the Go to step 15.
1)Connect all connectors. code as in the current diagno- ABSCM&H/U.
2)Erase the memory. sis still being output? <Ref. to ABS-7,
3)Perform the inspection mode. ABS Control Mod-
4)Read out the diagnostic trouble code. ule and Hydraulic
Control Unit
(ABSCM&H/U).>
15 CHECK ANY OTHER DIAGNOSTICTROU- Are other diagnostic trouble Proceed with the A temporary poor
BLE CODES APPEARANCE. codes being output? diagnosis corre- contact.
sponding to the
diagnostic trouble
code.
16 CHECK INPUT VOLTAGE OF G SENSOR. Is the voltage between 4.75 Go to step 17. Repair harness/
1)Turnthe ignition switch to OFF. and 5.25 V? connector
2)Remove the console box. between G sensor
3)Disconnect the G sensor from body. (Do not and ABSCM&H/U.
disconnect connector.)
4)Turn the ignition switch to ON.
5)Measure the voltage between G sensor con-
nector terminals.
Connector & terminal
(6292)NO. 1 (+) - NO. 3 (-):
17 CHECK OPEN CIRCUIT IN G SENSOR OUT- Is the resistance between 4.3 Go to step 18. Repair harness/
PUT HARNESS AND GROUND HARNESS. and 4.9 kn? connector
1)Turn the ignition switch to OFF. between G sensor
2)Disconnect the connector from ABSCM& and ABSCM&H/U.
H/U.
3)Measure the resistance between
ABSCM&H/U connector terminals.
Connector & terminal
(F49)NO. 6 - NO. 28:
18 CHECK G SENSOR. Is the voltage between 2.1 and Go to step 19. Replace the G
1)Connect the connector to G sensor. 2.5 V when G sensor is hori- sensor. <Ref. to
2)Connect the connector to ABSCM&H/U. zontal? ABS-23, G Sen-
3)Turn the ignition switch to ON. sor.>
4)Measure the voltage between G sensor con-
nector terminals.
Connector & terminal
(6292)NO. 2 (+) -NO. 3 (-):
19 CHECK G SENSOR. Is the voltage between 3.7and Go to step 20. Replace the G
Measure the voltage between G sensor con- 4.1 V when G sensor is sensor. <Ref. to
nector terminals. nclined forwards to 90°? ABS-23, G Sen-
Connector & terminal so r.>
(6292)NO. 2 (+) - NO. 3 (-):
!O CHECK G SENSOR. s the voltage between 0.5 and Go to step 21. Replace the G
Measure the voltage between G sensor con- 1.9 V when G sensor is sensor. <Ref. to
nector terminals. nclined backwards to go"? ABS-23, G Sen-
Connector & terminal sor.>
(6292)NO. 2 (+) - NO. 3 (-):

ABS-I 72
 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICS)

Step I Check Yes No

21 CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in con- Repair the con- Go to step 22.
Turn the ignition switch to OFF. nector between ABSCM&H/U nector.
and G sensor?
22 CHECK ABSCM&H/U. Is the same diagnostic trouble Replace the Go to step 23.
1)Connect all connectors. code as in the current diagno- ABSCM&H/U.
2)Erase the memory. sis still being output? <Ref. to ABS-7,
3)Perform the inspection mode. ABS Control Mod-
4)Read out the diagnostic trouble code. ule and Hydraulic
Control Unit
(ABSCM&H/U).>
23 CHECK ANY OTHER DIAGNOSTICTROU- Are other diagnostic trouble Proceed with the A temporary poor
BLE CODES APPEARANCE. codes being output? diagnosis corre- contact.
sponding to the
diagnostic trouble
code.

ABS-I73
 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICS)

ABS-1 74
 I
DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICS)

AG:DTC 56
ABNORMAL G SENSOR HIGH p OUTPUT
DIAGNOSIS:
Faulty G sensor output voltage
TROUBLE SYMPTOM:
ABS does not operate.

Y
 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICS)

WIRING DIAGRAM:

@ ABS CONTROL MODULEAND

HYDRAULIC CONTROL UNIT

I
I

SHIELD JOINT
CONNECTOR

*
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t 2

ABS
G SENSOR

BR0090

ABS-I 76
 m
DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICS)

Step Check No
CHECK OUTPUT OF G SENSOR USING SE- 30 to step 6.
LECT MONITOR. ‘or display 2.3k0.2 V when the
1)Select “Current data display & Save” on the :sensor is in horizontal posi-
select monitor. ion?
2)Read the G sensor output on the select mon-
itor display.
CHECK POOR CONTACT IN CONNECTORS. s there poor contact in con- Repair the con- 30 to step 3.
Turn the ignition switch to OFF. lector between ABSCM&HlU nector.
ind G sensor?
CHECK ABSCM&H/U. s the same diagnostic trouble Replace the 30 to step 4.
1)Connect all connectors. :ode as in the current diagno- ABSCM&H/U.
2)Erase the memory. ;is still being output? <Ref. to ABS-7,
3)Perform the inspection mode. ABS Control Mod-
4)Read out the diagnostic trouble code. ule and Hydraulic
Control Unit
(ABSCM&H/U).>
CHECK ANY OTHER DIAGNOSTIC TROU- \re other diagnostic trouble Proceed with the 4 temporary poor
BLE CODES APPEARANCE. :odes being output? diagnosis corre- :ontact.
sponding to the
diagnostic trouble
code.
CHECK OPEN CIRCUIT IN G SENSOR OUT- s the resistance between 4.3 Go to step 6. 3epair harness1
PUT HARNESS AND GROUND HARNESS. ind 4.9 kR? :onnector
1)Turn the ignition switch to OFF. 3etween G sensor
2)Disconnect the connector from ABSCM& m d ABSCM&H/U.
HIU.
3)Measure the resistance between
ABSCM&H/U connector terminals.
Connector & terminal
-
(F49) NO. 6 NO. 28:
, CHECK GROUND SHORT OF HARNESS. s the resistance more than 1 30 to step 7. Repair harness
Measure the resistance between ABSCM&HlU m? Detween G sensor
connector and chassis ground. m d ABSCM&H/U.
Connector & terminal aeplace
-
(F49) No. 28 Chassis ground: 4BSCM&H/U.
<Ref. to ABS-7,
4BS Control Mod-
ule and Hydraulic
Sontrol Unit
(ABSCM&H/U).=.
CHECK G SENSOR. s the voltage between 2.1 and 30 to step 8. Replace the G
1)Remove the console box. !.5 V when G sensor is hori- sensor. <Ref. to
2)Remove the G sensor from vehicle. rontal? ABS-23, G Sen-
3)Connect the connector to G sensor. sor.>
4)Connect the connector to ABSCM&H/U.
5)Turn the ignition switch to ON.
6)Measure the voltage between G sensor con-
nector terminals.
Connector & terminal
(6292) NO.2 (+) - NO. 3 (-):
I CHECK G SENSOR. s the voltage between 3.7 and 30 to step 9. Replace the G
~

Measure the voltage between G sensor con- &.IV when G sensor is sensor. <Ref. to
nector terminals. nclined forwards to go”? ABS-23, G Sen-
Connector & terminal so r.>
(8292) NO. 2 (+) - NO. 3 (-):

ABS-177
I

DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR

ABS (DIAGNOSTICS)

Step Check Yes No

9 CHECK G SENSOR. Is the voltage between 0.5 and Go to step 10. Replace the G
Measure the voltage between G sensor con- 0.9 V when G sensor is sensor. <Ref. to
nector terminals. inclined backwards to 90°? ABS-23, G Sen-
Connector 8i terminal sor.>
(8292) NO. 2 (+) - NO. 3 (-):
10 CHECK ABSCM&W. Is the same diagnostic trouble Replace the Go to step 11.
1)Turn the ignition switch to OFF. code as in the current diagno- ABSCM&H/U.
2)Connect all connectors. sis still being output? <Ref. to ABS-7,
3)Erase the memory. ABS Control Mod-
4)Perform the inspection mode. ule and Hydraulic
5)Read out the diagnostic trouble code. Control Unit
(ABSCM&H/U).>
11 CHECK ANY OTHER DIAGNOSTICTROU- Are other diagnostic trouble Proceed with the A temporary poor
BLE CODES APPEARANCE. codes being output? diagnosis corre- contact.
sponding to the
diagnostic trouble
code.

ABS-170
 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICS)

AH:DTC 56
DETECTION OF G SENSOR STICK
DIAGNOSIS:
Faulty G sensor output voltage
TROUBLE SYMPTOM:
ABS does not operate.

ABS-I 79
 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICS)

WIRING DIAGRAM:

@ ABS CONTROL MODULE AND

HYDRAULIC CONTROL UNIT

SHIELD JOINT
CONNECTOR

f
I
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t 7

ABS
G SENSOR

BR0090

ABS-I 80
 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICS)
-
Step Check Yes No
I CHECK ALL FOUR WHEELS FOR FREE lave the wheels been turned The ABS is nor- 30 to step 2.
TURNING. ireely such as when the vehicle nal. Erase the
s lifted up, or operated on a jiagnostic trouble
rolling road? :ode.
! CHECK OUTPUT OF G SENSOR USING SE- Is the G sensor output on the 30 to step 3. 30 to step 8.
LECT MONITOR. monitor display between 2.1
1)Select ”Current data display 8 Save” on the 2nd 2.5 V when the vehicle is
select monitor. in horizontal position?
2)Read the select monitor display.
5 CHECK OUTPUT OF G SENSOR USING SE- Is the G sensor output on the 30 to step 4. 3eplace the G
LECT MONITOR. monitor display between 3.7 sensor. <Ref. to
1)Turn the ignition switch to OFF. and 4.1 V when G sensor is 465-23, G Sen-
2)Remove the console box. inclined forwards to go”? sor.>
3)Remove the G sensor from vehicle. (Do not
disconnect connector.)
4)Turn the ignition switch to ON.
5)Select “Current data display & Save” on the
select monitor.
6)Read the select monitor display.
1 CHECK OUTPUT OF G SENSOR USING SE- Is the G sensor output on the 20 to step 5. Replace the G
LECT MONITOR. monitor display between 0.5 sensor. <Ref. to
Read the select monitor display. and 0.9 V when G sensor is ABS-23, G Sen-
inclined backwards to go“? sor.>
5 CHECK POOR CONTACT IN CONNECTORS, Is there poor contact in con- Repair the con- Go to step 6.
Turn the ignition switch to OFF. nector between ABSCM&H/U lector.
and G sensor?
6 CHECK ABSCM&H/U. ISthe same diagnostic trouble Replace the Go to step 7 .
1)Connect all connectors. code as in the current diagno- 4BSCM&H/U.
2)Erase the memory. sis still being output? <Ref. to ABS-7,
3)Perform the inspection mode. ABS Control Mod-
4)Read out the diagnostic trouble code. ule and Hydraulic
Control Unit
(ABSCM&H/U).>
7 CHECK ANY OTHER DIAGNOSTIC TROU- Are other diagnostic trouble Proceed with the A temporary poor
BLE CODES APPEARANCE. codes being output? diagnosis corre- contact.
sponding to the
diagnostic trouble
code.
B CHECK OPEN CIRCUIT IN G SENSOR OUT- Is the resistance between 4.3 Go to step 9. Repair harness/
PUT HARNESS AND GROUND HARNESS. and 4.9 kR? connector
1)Turnthe ignition switch to OFF. between G sensor
2)Disconnect the connector from ABSCM& and ABSCM&H/U.
H/U.
3)Measure the resistance between
ABSCM&H/U connector terminals.
Connector & terminal
(F49) NO. 6 - NO. 28:
9 CHECK G SENSOR. Is the voltage between 2.1 and Go to step 10. Replace the G
1)Remove the console box. 2.5 V when G sensor is hori- sensor. <Ref. to
2)Remove the G sensor from vehicle. zontal? ABS-23, G Sen-
~

3)Connect the connector to G sensor. sor.>

4)Connect the connector to ABSCM&H/U.
5)Turn the ignition switch to ON.
6)Measure the voltage between G sensor con-
nector terminals.
Connector & terminal
(8292) NO. 2 (+) - NO. 3I)-(

ABS-I 81
 DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR
ABS (DIAGNOSTICS)

Step Check Yes

10 CHECK G SENSOR. Is the voltage between 3.7 and Go to step 11.
Measure the voltage between G sensor con- 4.1 V when G sensor is sensor. <Ref. to
nector terminals. inclined forwards to 90°? ABS-23, G Sen-

11
Connector & terminal
(8292) NO. 2 (+) - NO. 3 (-):
CHECK G SENSOR. Is the voltage between 0.5 and Go to step 12.
sor.>
I
Measure the voltage between G sensor con- 0.9 V when G sensor is sensor. <Ref. to
nector terminals. inclined backwards to 90°? ABS-23, G Sen-
Connector & terminal sor.>
-
(8292) NO. 2 (+) NO. 3 (-):
12 CHECK ABSCM&W. Is the same diagnostic trouble Replace the Go to step 13.
1)Turn the ignition switch to OFF. code as in the current diagno- ABSCM&H/U.
2)Connect all connectors. sis still being output? <Ref. to ABS-7,
3)Erase the memory. ABS Control Mod-
4)Perform the inspection mode. ule and Hydraulic
5)Read out the diagnostic trouble code. Control Unit
(ABSCM&H/U).>
13 CHECK ANY OTHER DIAGNOSTICTROU- Are other diagnostic trouble Proceed with the A temporary poor
BLE CODES APPEARANCE. codes being output? diagnosis corre- contact.
sponding to the
diagnostic trouble
code.

ABS-I 82
 GENERAL DIAGNOSTICS TABLE
ABS (DIAGNOSTICS)

14.General Diagnostics Table

A: INSPECTION
Symptom Probable faulty units/parts
-~
ABSCM&H/U (solenoid valve)
9 ABS sensor
Brake (caliper & piston, pads)
Vehicle pulls to either side. Wheel alignment
Tire specifications, tire wear and air pressures
Incorrect wiring or piping connections
dehicle instability during braking Road surface (uneven, camber)
ABSCM&H/U (solenoid valve)
ABS sensor
Vehicle spins. Brake (pads)
Tire specifications,tire wear and air pressures
Incorrect wiring or Piping connections
~~

ABSCM&H/U (solenoid valve)

Brake (pads)
Long brakinglstopping distance Air in brake line
Tire specifications,tire wear and air pressures
Incorrect wiring or piping connections
ABSCM&H/U (solenoid valve, motor)
Wheel locks. ABS sensor
Incorrect wiring or piping connections
9 ABSCM&H/U (solenoid valve)

ABS sensor
Master cylinder
Brake dragging Brake (caliper & piston)
Parking brake
Poor braking 9 Axle & wheels

Brake pedal play

9 Air in brake line
Long brake pedal stroke
Brake Pedal Play
*-Suspension play or fatigue (reduced damping)
Vehicle pitching Incorrect wiring or piping connections
* Road surface (uneven)
9 ABSCM&H/U (solenoid valve)
ABS sensor
9 Brake (caliper & piston, pads)
Unstable or uneven braking
9 Tire specifications, tire wear and air pressures

9 Incorrect wiring or piping connections

Road surface (uneven)

ABS-I83
 GENERAL DIAGNOSTICS TABLE
ABS (DIAGNOSTICS)
Symptom
Excessive pedal vibration
Noise from ABSCM&H/U
Vibration and/or noise
Noise from front of vehicle
(while driving on slippery roads)
Noise from rear of vehicle
ABS-I 84
Probable faulty unitslparts
Incorrect wiring or piping connections
Road surface (uneven)
ABSCM&H/U (mount bushing)
ABS sensor
Brake piping
ABSCM&H/U (mount bushing)
ABS sensor
Master cylinder
Brake (caliper & piston, pads, rotor)
Brake piping
Brake booster & check valve
Suspension play or fatigue
ABS sensor
Brake (caliper & piston, pads, rotor)
Parking brake
Brake piping
Suspension play or fatigue
 .
BRAKE

BR
Page
1. General Description .................................................................................... 2
2. Front Brake Pad ........................................................................................ 16
3. Front Disc Rotor ........................................................................................ 18
4. Front Disc Brake Assembly ....................................................................... 19
5. Rear Brake Pad......................................................................................... 24
6. Rear Disc Rotor ......................................................................................... 25
7. Rear Disc Brake Assembly ....................................................................... 27
8. Rear Drum Brake Shoe ............................................................................. 30
9. Rear Drum Brake Drum ............................................................................ 32
10. Rear Drum Brake Assembly...................................................................... 33
11. Master Cylinder ......................................................................................... 36
12. Brake Booster ........................................................................................... 38
13. Proportioning Valve ................................................................................... 43
14. Brake Fluid ................................................................................................ 44
15. Air Bleeding ............................................................................................... 46
16. Brake Hose ............................................................................................... 48
17. Brake Pipe................................................................................................. 50
18. Brake Pedal............................................................................................... 51
19. Stop Light Switch ...................................................................................... 55
20. General Diagnostics.................................................................................. 57
 GENERAL DESCRIPTION
BRAKE

1. General Description
A: SPECIFICATIONS
I Non-turbo I
Sedan and Turbo
Other
0UTBACK
Size 15 inch 16 inch
Type Disc (Floating type, ventilated)
Effective disc diameter 228 mm (8.98 in) 247 mm (9.72 in)

Front disc brake

Disc thickness x Outer diameter 1 24 x 277 mm
(0.94 x 10.91 in) 1I
24 x 294 mm
10.94 x 11.57 in)
Effective cylinder diameter 42.8 mm (1.685 in) x 2
Pad dimensions 105.0~50.5xl1.0mm 112.3 x 50.0 x 11.0 mm
(lenath x width x thickness) (4.134 x 1.989 x 0.433 in) (4.421 x 1.969 x 0.433 in)
Clearance adjustment Automatic adjustment
Type - Disc (Floating type)
Effective disc diameter - 230 mm (9.06 in)
- 10 x 266 mm
Disc thickness x Outer diameter
(0.39 x 10.47 in)
Rear disc brake
Effective cylinder diameter - 38.1 mm (1.500 in)
Pad dimensions - 82.4 x 33.7 x 9.0 mm
(length x width x thickness) (3.244 x 1.327 x 0.354 in)
Clearance adjustment - Automatic adjustment
Drum -
Type (Leading-Trailing type)
Effective drum diameter 228.6 mm (9 in) -
Rear drum brake Effective cylinder diameter 19.0 mm (0.689 in) -
Lining dimensions 219.3 x 35.0 x 4.1 mm -
(length x width x thickness) (8.63 x 1.378 x 0.161 in)
Clearance adiustment Automatic adjustment -
Type Tandem
Effective diameter 26.99 mm (1-1/16 in)
Master cylinder
Reservoir type Sealed type
Brake fluid reservoir capacity 205 cm3 (12.51 cu in)
TvDe
<.
Vacuum suspended
Brake booster 205 + 230 mm
Effective diameter
(8.07 + 9.06 in)
1,961 kPa
Proportioning Split point
(20 kg/cm2, 285 psi)
valve
-
Reducina ratio I
0.3
Brake line Dual circuit system
Brake fluid FMVSS No. 116, DOT3 or DOT4
NOTE:
Refer to “PB section” for parking brake SPECIFICATIONS. <Ref. to PB-2, SPECIFICATIONS, General De-
scription.>

BR-2
 GENERAL DESCRIPTION
BRAKE

I 1 . 3 111111 ( U . L i l 3 Ill]
I
Front brake Disc thickness 24 mm (0.94 in) 22 mm (0.87 in)
Disc runout - 0.075 mm (0.0030 in)
Pad thickness
R~~~b r ane
p [viab
tn
:..
- ksn-\
I
I
(including
' - back metal) I I J
iypc)
I Disc thickness I 10 mm (0.39 in) I 8.5 mm (0.335 in)
Disc runout - 0.07 mm (0.0028 in)
Inside diameter 228.6 mm (9 in) 230.6 mm (9.08 in)
Rear brake (Drum type)
Linina 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)
,yp= p a RII vy,
Lining thickness 3.2 mm (0.126 in) 1.5 mm (0.059 in)
Parking brake Lever stroke 7 to 8 notchesil96 N (20 kgf, 44

Non-turbo I
Turbo
147 N 588 kPa
Brake fluid pressure without (15 kgf, 33 Ib) (6 kg/cm2, 85 psi)
engine running 294 N 1,471 kPa
(30 kgf, 66 Ib) (15 kg/cm2,213 psi)
Brake booster
147 N 5,296 kPa 5,688 kPa
Brake fluid pressure with engine (15kgf, 33 Ib) (54 kg/cm2, 768 psi) (58 kg/cm2, 825 psi)
running and vacuum at 66.7 kPa
(500 mmHg, 19.69 inHg) 294 N 9,120 kPa
(30 kaf. 66 Ib) (93 ka/cm2. 1.323 Dsi)

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 kgf, 2 Ib).]

BR-3
 GENERAL DESCRIPTION
BRAKE

B: COMPONENT
1. FRONT DISK BRAKE
NON-TURBO MODEL

BR0097

Caliper body Support (1 7) Lock pin sleeve

Air bleeder screw Pad clip
Guide pin (Green) Outer shim
Pin boot Inner shim Tightening torque: N-m (kgf-m, ft-lb)
Piston seal Pad (Outside) T1: 8 (0.8, 5.8)
Piston Pad (Inside) T2: lS(1.8, 13.0)
Piston boot Disc rotor T3: 26.5 (2.70, 19.5)
Lock pin (Yellow) Disc cover T4: 80 (8.2. 59)

BR-4
 GENERAL DESCRIPTION
BRAKE

TURBO MODEL

(1) Caliper body (9) Lock pin (Yellow) (17) Disc cover
(2) Air bleeder screw (10) Support (18) Bush
(3) Guide pin (Green) (11) Pad clip
(4) Pin boot (12) Outer shim Tightening torque: N.m (kgf-m, ff-lb)
(5) Piston seal (13) Inner shim T I : 8 (0.8, 5.8)
(6) Piston (14) Pad (Outside) T2: 18(1.8, 13.0)
(7) Piston boot (15) Pad (Inside) T3: 37 (3.8,27.5)
(8) Boot ring (16) Disc rotor T4: 80 (8.2, 59)

BR-5
 GENERAL DESCRIPTION
BRAKE

2. REAR DISC BRAKE

Caliper body Shim (27) Primary shoe return spring

Air bleeder screw Shoe hold-down pin (28) Adjusting spring
Guide pin (Green) Cover (29) Adjuster
Pin boot Back plate (30) Shoe hold-down cup
Piston seal Retainer (31) Shoe hold-down spring
Piston Spring washer (32) Disc rotor
Piston boot Parking brake lever (33) Bush
Boot ring Parking brake shoe (Secondary)
(9) Lock pin (Yellow) (22) Parking brake shoe (Primary) Tightening torque: N.m (kgf-m, ft-lb)
(IO) Support (23) Strut T1: 8 (0.8, 5.8)
(11) Pad clip (24) Strut shoe spring T2: 37 (3.8,27.5)
(12) Inner pad (25) Shoe guide plate T3: 53 (5.4, 39.1)
(13) Outer pad (26) Secondary shoe return spring

BR-6
 GENERAL DESCRIPTION
BRAKE

3. REAR DRUM BRAKE

B4M1120,

(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
(5) CUP (15) Brake shoe (Trailing) Tightening torque: N.m (kgf-m, ft-lb)
(6) Spring (16) Brake shoe (Leading) T7: 8 (0.8, 5.8)
(7) Wheel cylinder body (17) Shoe hold-down spring 72: 10 (1.0, 7.2)
(8) Pin (18) CUP T3: 53 (5.4, 39.7)
(9) Plug (19) Adjusting lever
(10) Back plate (20) Adjuster

BR-7
k
GENERAL DESCRIPTION
BRAKE

4. MASTER CYLINDER

84M03250

(1) Cap (6) Secondary piston Tightening torque: N.m (kgf-m, ft-lb)
(2) Filter (7) Cylinder body T1: 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
 GENERAL DESCRIPTION
BRAKE

5. FRONT BRAKE PIPES AND HOSE

(1) Front brake pipe assembly (6) Gasket Tightening torque: N.m (kgf-m, ft-lb)
(2) Proportioning valve (7) ABS control module and hydraulic T1: 15 (1.5, 10.8)
(3) Front brake hose RH control unit T2: l B ( 1 . 8 , 13.0)
(4) Front brake hose LH (8) Bracket T3: 32 (3.3, 23.6)
(5) Clamp (9) Master Cylinder

B R-9
 GENERAL DESCRIPTION
BRAKE

6. CENTER AND REAR BRAKE PIPES AND HOSE

(1)

' /-
I/-

BR0078

(1) Clamp (6) Rear brake hose RH (Drum brake (9) Gasket
(2) Center brake pipe assembly model)
(3) Two-way connector (7) Rear brake hose LH (Disc brake Tightening torque: N-m (kgf-m, ft-lb)
(4) Rear brake pipe assembly model) T1: 15 (1.5, 10.8)
(5) Rear brake hose RH (Disc brake (8) Rear brake hose LH (Drum brake T2; 18 (1.8, 13.0)
model) model)

BR-IO
 GENERAL DESCRIPTION
BRAKE

7. BRAKE BOOSTER

(1) Push rod (5) Filter (9) Valve body

(2) Return spring (6) Silencer (10) Plunger valve
(3) Reaction disc (7) Operating rod (1 1) Diaphragm plate
(4) Key (8) Poppet valve (12) Valve return spring

BR-I 1
 GENERAL DESCRIPTION
BRAKE

8. BRAKE PEDAL
MT Model

B4M2345A

(1) Stopper (12) Clutch clevis pin (23) Clutch switch (Starter interlock)
(2) Bushing (13) Assist rod A (24) Clutch switch (With cruise control)
(3) Spring pin (14) Clip (25) Stop light switch
(4) Snap pin (15) Assist spring (26) Pedal bracket
(5) Brake pedal pad (16) Assist bushing (27) Clutch master cylinder bracket
(6) Brake pedal (17) Assist rod B (28) Lever
(7) Clevis pin (18) Spring S
(8) Brake pedal spring (19) Rod S Tightening torque: N-m (kgf-m, ff-lb)
(9) Clutch pedal pad (20) Bushing S T1: 8 (0.8, 5.8)
(10) Clutch pedal (21) O-ring T2: lS(1.8, 13.0)
(11) Bushing C (22) Clip

BR-12
 GENERAL DESCRIPTION
BRAKE

AT Model

BR000;

(1) Stopper (6) Brake pedal pad Tightening torque: N.m (kgf-m, ft-lb)
(2) Bushing (7) Brake pedal T1: 8 (0.8, 5.8)
(3) Pedal bracket (8) Clevis pin T2: lS(1.8, 13.0)
(4) Stop light switch (9) Brake pedal spring T3: 29 (3.0,21.7)
(5) Snap pin

BR-13
 GENERAL DESCRIPTION
BRAKE

C: CAUTION
Wear working clothing, including a cap, protec-
tive goggles, and protective shoes during opera-
tion.
Remove contamination including dirt and corro-
sion before removal, installation or disassembly.
Keep the disassembled parts in order and pro-
tect them from dust or dirt.
Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary re-
moval, installation, disassembly, and replacement.
Be careful not to burn your hands, because each
part in the vehicle is hot after running.
Use SUBARU genuine grease etc. or the equiv-
alent. Do not mix grease etc. with that of another
grade or from other manufacturers.
Be sure to tighten fasteners including bolts and
nuts to the specified torque.
Place shop jacks or safety stands at the specified
points.
Apply grease onto sliding or revolution surfaces
before installation.
Before installing O-rings or snap rings, apply suf-
ficient amount of grease to avoid damage and de-
formation.
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.
Do not put fluid on body. If the body is tainted,
wash away with water.

BR-14
 GENERAL DESCRIPTION
BRAKE

D: PREPARATION TOOL
1. SPECIAL TOOLS

ILLUSTRATION I TOOLNUMBER DESCRIPTION REMARKS

926460000 NHEEL CYLINDER Jsed for installing cup onto wheel cylinder piston
3/4”ADAPTER :Size 11/16 in).

B4M2
-
6

2. GENERAL PURPOSE TOOLS

TOOL NAME REMARKS

SNAP RING PLIERS Used for removing and installing snap ring.

BR-15
 FRONT BRAKE PAD
BRAKE

2. Front Brake Pad (4) Attach a rod of less than 12 mm (0.47 in) dia.
to the shaded area of the brake pad, and strike
A: REMOVAL the rod with a hammer to drive brake pad out of
1) Set the vehicle on the lift. place.
2) Loosen the wheel nuts.
3) Jack-up the vehicle, and remove the front wheel.
4) Remove the lock pin.
5) Raise the caliper body.
6) Remove the pad.

u
B: INSTALLATION
B4M2231

1) Apply a thin coat of Molykote AS880N (Part No.

26298AC000) to the frictional portion between pad
and pad clip.
2) Apply a thin coat of Molykote AS880N (Part No.
NOTE: . 26298AC000) to the frictional portion between pad
and pad inner shim.
If the brake pad is difficult to remove, proceed as
follows:
(1) Remove the caliper body and fasten it provi-
sionally to coil spring.
(2) Remove the support.
(3) Place the support in a vise between wooden
blocks.

3) Install the pads on support.

4) Install the caliper body on support.
Tightening torque:
Non-turbo model:
26.5 N.m (2.70 kgf-m, 19.5 ft-lb)
(5) B4M2230E
Turbo model:
(1) Support
37 N.m (3.8 kgf-m, 27.5 ft-lb)
(2) Wooden blocks NOTE:
If it is difficult to push the piston during pad replace-
ment, loosen the air bleeder to facilitate work.
5) Install the front wheel.

BR-I 6
 m
FRONT BRAKE PAD
BRAKE

C: INSPECTION
Check the pad thickness A.
I

I BROI 0

I Pad thickness I Standard value I 17 mm (0.67 in) I

metal) Wear limit 7.5 mm (0.295 in)

CAUTION:
Always replace the pads for both the left and
right wheels at the same time. Also replace the
pad clips if they are twisted or worn.
A wear indicator is provided on the inner disc
brake pad. If the pad wears down to such an ex-
tent 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, re-
place the pad.
Replace the pad if there is oil or grease on it.

BR-17
 FRONT DISC ROTOR
BRAKE

3. Front Disc Rotor C: INSPECTION

1) Install the disc rotor by tightening the five wheel
A: REMOVAL nuts.
1) Set the vehicle on the lift. 2) Set a dial gauge on the disc rotor. Turn the disc
2) Loosen the wheel nuts. rotor to check runout.
3) Jack-up the vehicle, and remove the front wheel.
4) Remove the caliper body from housing, and sus-
pend it from strut using a wire. I dl

NOTE:
RR007Fi Make sure the dial gauge is set 5 mm (0.20in) in-
ward of rotor outer perimeter.
5) Remove the disc rotor. If the runout of disc rotor exceeds the limit, check
NOTE: . for abnormal free play at hub bearing and runout in
the thrust direction. <Ref. to DS-22, INSPECTION,
If the disc rotor seizes up within the hub, drive the
disc rotor out by installing an 8-mm bolt in holes B Front Axle.>
on the rotor. If the hub bearing is okay, replace the disc rotor.
Disc rotor runout limit:
0.075 mm (0.0030 in)
3 ) Measure the disc rotor thickness.
If the thickness of disc rotor is below runout limit, re-
place the disc rotor.

G4M0365 I
6) Clean mud and foreign particles from the caliper
body assembly and support.
B: INSTALLATION
1) Install the disc rotor. G4M0365 I
2) Install the caliper body on housing.
NOTE:
Tightening torque: Make sure the micrometer is set 5 mm (0.20 in) in-
80 N-m (8.2 kgf-m, 59 ft-lb) ward of rotor outer perimeter.
3) Install the wheel.

1I I
Standard Service Disc outer
value limit diameter
24.0mm 22.0mm 277mm
Disc rotor (0.945 in) ~ (0.866in) (10.91 in)
thickness A 24.0mm 22.0mm 294mm
(0.945 in) (0.866in) (11.57in)

BR-18
 FRONT DISC BRAKE ASSEMBLY
4. Front Disc Brake Assembly
A: REMOVAL
1) Set the vehicle on the lift.
2) Loosen the wheel nuts.
3) Jack-up the vehicle, and remove the front wheel.
4) Remove the union bolt and disconnect the brake
hose from caliper body assembly.
w B4Mi844
5) Remove the bolt securing lock pin to caliper
body. . 3) Apply a thin coat of Molykote AS880N (Part No.
L
6) Raise the caliper body and move it toward the
vehicle center to separate it from support.
7) Remove the support from housing.
NOTE:
Remove the support only when replacing it or the
rotor. It need not be removed when servicing the
caliper body assembly.
8) Clean mud and foreign particles from the caliper
body assembly and support.
BR-19
BRAKE
B: INSTALLATION
1) Install the support on housing.
Tightening torque:
80 Nom(8.2 kgf-m, 59 ft-lb)
CAUTION:
Always replace the pads for both the left and
right wheels at the same time. Also replace the
pad clips if they are twisted or worn.
A wear indicator is provided on the inner disc
brake pad. If the pad wears down to such an ex-
tent 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, re-
place the pad.
When replacing the pads, replace the pads of
the right and left wheels at the same time.
2) Apply a thin coat of Molykote AS880N (Part No.
26298AC000) to the frictional portion between pad
and pad clip.
26298AC000) to the frictional portion between pad
and inner shim.
4) Install the pads on support.
5) Install the caliper body on support.
Tightening torque:
Non-turbo model:
26.5 N.m (2.70 kgf-m, 19.5 ft-lb)
Turbo model:
37 N*m (3.8 kgf-m, 27.5 ft-lb)
6) Connect the brake hose.
Tightening torque:
18 N-m (1.8 kgf-m, 13.0 ft-lb)
CAUTION:
Replace the brake hose gaskets with new ones.
7) Bleed air from the brake system. <Ref. to BR-46,
Air Bleeding.>
 FRONT DISC BRAKE ASSEMBLY
BRAKE

C: DISASSEMBLY 5) Remove the guide pin and boot from caliper

body.
1. NON-TURBO MODEL
2. TURBO MODEL
1) Clean mud and foreign particles from the caliper
body assembly and support. 1) Clean mud and foreign particles from the caliper
body assembly and support.
CAUTION:
Be careful not to allow foreign particles to enter CAUTION:
inlet (at brake hose connector). Be careful not to allow foreign particles to enter
2) Gradually supply compressed air via caliper inlet (at brake hose connector).
body brake hose to force piston out. 2) Using a standard screwdriver, remove the boot
ring from piston.
CAUTION:
Place a wooden block as shown in the figure
to prevent damage to piston.
Do not apply excessively high-pressure.

B4M1164C

(1) Boot ring

( 1 -)
B4M1165C 3) Remove the boot from piston end.
4) Gradually supply compressed air via caliper
( I ) Place a 30 mm (1.I8in) wide wooden block body brake hose to force piston out.
here.
CAUTION:
3) Remove the piston boot. Place a wooden block as shown in the figure to
prevent damage to piston.

BROlOt
( 1 ) - L 1 ,
B4M1165C
4) Remove the piston seal from caliper body sylin-
der. (1) Place a 30 mm (1.I8in) wide wooden block
here.

BR-20
 FRONT DISC BRAKE ASSEMBLY
BRAKE

5) Remove the piston seal from caliper body cylin- D: ASSEMBLY

der.
1. NON-TURBO MODEL
1) Clean the caliper body interior using brake fluid.
2) Apply a coat of brake fluid to the piston seal and
fit piston seal in groove on caliper body.
3) Apply a coat of brake fluid to the entire inner sur-
face of cylinder and outer surface of piston.
4) Apply a coat of specified grease to the boot and
fit in the groove on ends of cylinder and piston boot
onto cylinder.
Grease:
NIGLUBE RX-2 (Part No. 003606000)
(1 1 Piston pin 5) Insert the piston into cylinder.
6) Remove the lock pin boot and guide pin boot. CAUTION:
Do not force the piston into cylinder.
I

(1) Piston
(2) Piston boot

6) Position the boot in grooves on cylinder and pis-

ton.
,-.
(3)
7

RRnin:

(1) Piston
(2) Piston boot
(3) Caliper body
(4) Piston seal

7) Apply a coat of specified grease to the lock pin

and guide pin outer surface, cylinder inner surface,
and boot grooves.
Grease:
NIGLUBE RX-2 (Part No. 003606000)

BR-21
 FRONT DISC BRAKE ASSEMBLY

8) Install the lock and guide pin boot on support.
5) Apply a coat of specified grease to the boot and
fit in the groove on ends of cylinder and piston.
Grease:
NIGLUBE RX-2 (Part No. 003606000)
To facilitate installation,fit the boot starting with pis-
ton end.

BRQlQ

(1) Pin boot U

(2) Lock pin or guide pin
(3) Apply grease.
(2) (3) (4)
S4MQ448A
2. TURBO MODEL
1) Clean the caliper body interior using brake fluid. (1) Piston boot
2) Apply a coat of brake fluid to the piston seal and (2) Boot ring
fit piston seal in groove on caliper body. (3) Piston seal
3) Apply'a coat of brake fluid to the entire inner sur- (4) Caliper body
face of cylinder and outer surface of piston.
4) Insert the piston into cylinder. 6 ) Position the boot in grooves on cylinder and pis-
CAUTION: ton.
Do not force the piston into cylinder. 7) Install the boot ring. Be careful not to scratch the
boot.
8) Apply a coat of specified grease to lock pin and
guide pin, outer surface, cylinder inner surface, and
boot grooves.
Grease:
NIGLUBE RX-2 (Part No. 003606000)

B4M1176E

(1) Pin boot

(2) Lock pin or guide pin
(3) Apply grease.

9) Install the lock pin boot and guide pin boot on

support.

BR-22
 FRONT DISC BRAKE ASSEMBLY
BRAKE

E: INSPECTION
NOTE:
Repair or replace the faulty parts.
1) Check the caliper body and piston for uneven
wear, damage or rust.
2) Check the rubber parts for damage or deteriora-
tion.

BR-23
 REAR BRAKE PAD
BRAKE

5. Rear Brake Pad C: INSPECTION

Check the pad thickness A.
A: REMOVAL
1) Set the vehicle on the lift.
2) Loosen the wheel nuts.
3) Jack-up the vehicle, and remove the rear wheel.
4) Remove the lock pin.

I Pad thickness I Standard value I 14.0 mm (0.551 in) I

(including back
Wear limit 6.5 mm (0.256 in)

5) Raise the caliper body.
6) Remove the pad from support.
NOTE: . pad clips if they are twisted or worn.
If the brake pad is difficult to remove, use the same
procedure as for front disc brake pad.
<Ref. to BR-16, REMOVAL, Front Brake Pad.>
CAUTION:
Always replace the pads for both the left and
right wheels at the same time. Also replace the
A wear indicator is provided on the inner disc
brake pad. If the pad wears down to such an ex-
tent 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, re-
place the pad.
Replace the pad if there is oil or grease on it.

B: INSTALLATION
1) Apply a thin coat of Molykote AS880N (Part No.
26298AC000) to the frictional portion between pad
and pad clip.
2) Install the pad on support.
3) Install the caliper body on support.
Tightening torque:
37 N-m (3.8 kgf-m, 27.5 fi-lb)
NOTE:
If it is difficult to push the piston during pad replace-
ment, loosen the air bleeder to facilitate work.

BR-24
 I

REAR DISC ROTOR

BRAKE

(2) If the disc rotor seizes up within hub, drive

6. Rear Disc Rotor the disc rotor out by installing an 8-mm bolt in
A: REMOVAL holes B on the rotor.
1) Lift-up the vehicle and remove the wheels.
2) Remove the two mounting bolts and remove the
disc brake assembly.

G4MQ38:

B: INSTALLATION
1) Install in the reverse order of removal.
I I
2) Adjust the parking brake. <Ref. to PB-12, AD-
3) Suspend the disc brake assembly so that the JUSTMENT, Parking Brake Assembly (Rear Disc
hose is not stretched. Brake).>
4) Pull down and release the parking brake.
5) Remqve the disc rotor.
NOTE:
If the disc rotor is difficult to remove, try the follow-
ing two methods in order.
(1) Turn the adjusting screw using a slot-type
screwdriver until the brake shoe gets away
enough from the disc rotor.

S4MQ569A

(1) Adjusting screw

(2) Cover
(3) Slot-type screwdriver
(4) Back plate

BR-25
 REAR DISC ROTOR
BRAKE

C: INSPECTION
1) Set a dial gauge on the disc rotor. Turn the disc
rotor to check runout.
CAUTION:
Securely adjust the disc rotor to hub.

NOTE:
Make sure the dial gauge is set 5 mm (0.20 in) in-
ward of rotor outer perimeter.
If the runout of disc rotor exceeds the limit, check
for abnormal free play at hub bearing and runout in
the thrust direction. <Ref. to DS-31, INSPECTION,
Rear Axle.>
If the hub bearing is okay, replace the disc rotor.
Disc rotor runout limit:
0.07 mm (0.0028 in)
2) Measure the disc rotor thickness.
If the thickness of disk rotor is below runout limit, re-
place the disk rotor.

NOTE:
Make sure the micrometer is set 5 mm (0.20 in) in-
ward of rotor outer perimeter.
Standard value
10 mm (0.39 in)
Service limit
8.5 mm (0.335 in)

BR-26
 REAR DISC BRAKE ASSEMBLY
7. Rear Disc Brake Assembly
A: REMOVAL
CAUTION:
Do not allow brake fluid to come in contact with
the vehicle body; wipe off completely if spilled.
1) Set the vehicle on the lift.
2) Loosen the wheel nuts.
3) Lift-up the vehicle and remove the wheels.
4) Disconnect the brake hose from caliper body as-
sembly.
5 ) Remove the lock pin.
6) Raise the caliper body and move it toward the
vehicle center to separate it from support.
7) Remove the support from back plate.
NOTE:
Remove the support only when replacing it or the
rotor. It need not be removed when servicing the
caliper body assembly.
8) Clean mud and foreign particles from the caliper
body assembly and support.
CAUTION:
Be careful not to allow foreign particles to enter
inlet (at brake hose connector).
BR-27
BRAKE
-
B: INSTALLATION
1) Install the disc rotor on hub.
2) Install the support on back plate.
Tightening torque:
53 N-m (5.4 kgf-m, 39.1 ft-lb)
CAUTION:
Always replace the pads for both the left and
right wheels at the same time. Also replace the
pad clips if they are twisted or worn.
A wear indicator is provided on the inner disc
brake pad. If the pad wears down to such an ex-
tent 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, re-
place the pad.
Replace the pads if there is oil or grease on
them.
3) Apply a thin coat of Molykote AS880N (Part No.
26298AC000) to the frictional portion between pad
and pad clip.
4) Install the pads on support.
5 ) Install the caliper body on support.
Tightening torque:
37 N-m (3.8 kgf-m, 27.5 ft-lb)
6) Connect the brake hose.
Tighfening torque:
18 Nom(1.8 kgf-m, 13.0 ft-lb)
CAUTION:
The brake hose must be connected without
any twist.
Replace the brake hose gaskets with new
ones.
7) Bleed air from the brake system. <Ref. to BR-46,
Air Bleeding.>
 REAR DISC BRAKE ASSEMBLY
BRAKE

C: DISASSEMBLY 4) Remove the piston seal from caliper body cylin-

1) Remove the boot ring. der.

. .

(1) Boot ring

S4M0120B
- S4M0122

5) Remove the lock pin sleeve and boot from cali-

per body.
2) Remove the piston boot. 6) Remove the guide pin boot.
I

1 S4M0121

3) Gradually supply compressed air via inlet of cal-

iper body to force piston out.
CAUTION:
Place a wooden block as shown in the figure
to prevent damage to piston.
Do not apply excessively high-pressure.

(1 )-l-l--
B4M1174C

(1) Place a 30 mm (1.18 in) wide wooden block

here.

BR-28
 m
REAR DISC BRAKE ASSEMBLY
BRAKE
~~

D: ASSEMBLY 9) Install the lock pin boot on caliper body and in-
1) Clean the caliper body interior using brake fluid. sert lock pin sleeve into place.
2) Apply a coat of brake fluid to the piston seal and E: INSPECTION
fit piston seal in groove on caliper body.
3) Apply a coat of brake fluid to the entire inner sur- NOTE:
face of cylinder and outer surface of piston. Repair or replace the faulty parts.
4) Insert the piston into cylinder. 1) Check the caliper body and piston for uneven
wear, damage or rust.
CAUTION:
Do not force the piston into cylinder. 2) Check the rubber parts for damage or deteriora-
tion.
5) Apply a coat of specified grease to the boot and
fit in the groove on ends of cylinder and piston.
Grease:
NIGLUBE RX-2 (Part No. 003606000)
6 ) Install the piston boot to the caliper body, and at-
tach boot ring.
I

\-- I
"J

~ 4 ~ 0 4 4 8 ~

(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:
NIGLUBE RX-2 (Part No. 003606000)

~ _ _ _ ~

(1) Pin boot

(2) Lock pin or guide pin
(3) Apply grease.

8) Install the guide pin boot on caliper body.

BR-29
 REAR DRUM BRAKE SHOE
BRAKE

8. Rear Drum Brake Shoe 5 ) Disconnect the hold-down cup from hold-down
pin by rotating hold-down cup.
A: REMOVAL 6) Disconnect the lower shoe return spring from
1) Loosen the wheel nuts, jack-up the vehicle, sup- shoes.
port it with rigid racks, and remove the wheel.
2) Release the parking brake.
3) Remove the brake drum from brake assembly.
NOTE:
If it is difficult to remove the brake drum, remove
the adjusting hole cover from back plate, and then
turn the adjuster assembly pawls using a slot-type
screwdriver until the brake shoe separates from the
drum.

I I
wBack7) Remove the shoes one by one from back plate
Wheel cylinder with adjuster.
CAUTION:
Be careful not to bend the parking brake cable
Adjuster ASSY excessively when removing the brake shoes.
pawls

' +
Adjusting lever
Push
I Wheel cvlinder /Adjuster I
G4MQ242

If the brake drum is difficult to remove, drive it out

by installing an 8-mm bolt into bolt hole in brake
drum.

I Lower shoe retur; spring Pa;king lever

G4M0397

8) Disconnect the parking brake cable from parking

lever.

4) Hold the hold-down pin by securing rear of back

plate with your hand.
I

1- S4MO4.51A

(1) Hold-down cup

(2) Hold-down pin

BR-30
 =
REAR DRUM BRAKE SHOE
BRAKE

B: INSTALLATION 9) Set the outside diameter of brake shoes less

1) Clean the back plate and wheel cylinder. than 0.5 to 0.8 mm (0.020 to 0.031 in) in compari-
2) Apply grease to the portions indicated by arrows son with the inside diameter of brake drum.
in the figure. 10) Install the drum. <Ref. to BR-32, INSTALLA-
TION, Rear Drum Brake Drum.>
Brake grease:
Dow Corning Molykote No. 7439 (Part No. C: INSPECTION
725191460) 1) Measure the lining thickness.
Lining thickness:
Standard 4.1 mm (0.16 1 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.

3) Apply grease to the adjusting screw and both

ends of adjuster.
Brake grease:
Dow Corning Molykote No. 7439 (Part No.
72519 1460)

4) Connect the upper shoe return spring to shoes.

5) Connect the parking brake cable to parking le-
ver.
6) While positioning the shoes (one at a time) in
groove on wheel cylinder, secure shoes.

I Wheel cylinder
\

Shoe
(Trailing)

G4M040E

7) Fix the shoes by connecting hold-down cup to

hold-down pin.
8 ) Connect the lower shoe return spring.

BR-31
 REAR DRUM BRAKE DRUM
BRAKE

9. Rear Drum Brake Drum B: INSTALLATION

A: REMOVAL
1) Loosen the wheel nuts, jack-up the vehicle, sup-
port it with rigid racks, and remove the wheel.
2) Release the parking brake.
3) Remove the brake drum from brake assembly.
NOTE:
If it is difficult to remove the brake drum, remove
the adjusting hole cover from back plate, and then
turn adjuster assembly pawls using a slot-type
screwdriver until the brake shoe separates from the
drum.
Wheel cylinder
1) Set the outside diameter of brake shoes less
than 0.5 to 0.8 mm (0.020 to 0.031 in) in compari-
son with the inside diameter of brake drum.
2) Install the drum.
3) Install the rear wheel.
C: INSPECTION
1) If the inside surface of brake drum is streaked,
correct the surface. And, if it is unevenly worn, ta-
peringly streaked, or the outside surface of brake
drum is damaged, correct or replace it.
2) Measure the drum inner diameter.
Drum inner diameter: "L"
Standard 228 mm (9 in)
Service limit 230.6 mm (9.08 in)

Adjuster ASSY
pawls
Adjusting lever
' * Push
G4M0242

If the brake drum is difficult to remove, drive it out

by installing an 8-mm bolt into bolt hole in brake L
drum. G4M0403

I I

BR-32
 m
REAR DRUM BRAKE ASSEMBLY
BRAKE

10.Rear Drum Brake Assembly B: INSTALLATION

1) Clean the back plate and wheel cylinder.
A: REMOVAL 2) Install the wheel cylinder on back plate, and
1) Loosen the wheel nuts, jack-up the vehicle, sup- tighten bolts.
port it with rigid racks, and remove the wheel.
2) Release the parking brake.
Tightening torque:
3) Remove the brake drum from brake assembly. 10 N-m (1.0 kgf-m, 7.2 ft-16)
<Ref. to BR-32, REMOVAL, Rear Drum Brake
Drum.>
4) Remove the brake shoe. <Ref. to BR-30, RE-
MOVAL, Rear Drum Brake Shoe.>
5) Unscrew the brake hose flare nut and disconnect
the brake hose.

3) Apply grease to the portions indicated by arrows

in Figure.
Brake grease:
Dow Corning Molykote No. 7439 (Part No.
72519 1460)

6) Remove the hub.

<Ref. to DS-23, REMOVAL, Rear Axle.>
7) Disconnect the ABS sensor from back plate.
(only vehicle equipped ABS)
8) Remove the brake assembly.

4) install the brale assembly on hopusing, and

tighten bolts to install the back plate.
Tightening torque:
53 N m (5.4 kgf-m, 39.1 ft-l6)
G4M0400

9) Remove the bolts installing the wheel cylinder on

back plate, and remove it.

5 ) Install the hub. <Ref. to DS-26, INSTALLATION,

Rear Axle.>

BR-33
 REAR DRUM BRAKE ASSEMBLY
BRAKE

6) Connect the brake hose, and tighten the brake C: DISASSEMBLY

hose flange nut. 1) Remove the right and left dust boots from wheel
Tightening torque: cy1inder.
15 N-m (1.5 kgf-m, 10.8 ft-lb)
7) Connect the ABS sensor to back plate. (only ve-
hicle equipped with ABS)
Tightening torque:
32 N.m (3.3 kgf-m, 24 ft-lb)
8 ) Apply grease to the adjusting screw and both
ends of adjuster.
Brake grease:
Dow Corning Molykote No. 7439 (Part No. B4M1126B
725191460)
(1) Bleeder cap
(2) Bleeder screw
(3) Spring
(4) Cylinder
(5) CUP
(6) Piston
(7) Boot

2) Remove the piston, cup, spring and air bleeder

screw and cap.
k S4M04570 I
9) Install the brake shoe. <Ref. to BR-31, INSTAL-
LATION, Rear Drum Brake Shoe.>
10) Install brake drum. <Ref. to BR-32, INSTALLA-
TION, Rear Drum Brake Drum.>
11) After installing brake assembly, bleed air from
brake line. <Ref. to BR-46, Air Bleeding.>

BR-34
 I

REAR DRUM BRAKE ASSEMBLY

BRAKE

3) Apply rubber grease to the boot inside as shown

in figure.
CAUTION:
Never use brake grease.
Grease:
NIGLUBE RX-2 (Part No. 003606000)

Ih;l
S4M04568

Applicable size Part No. E: INSPECTION

19.0 mm (3/4 in) 926460000 1) Inspect the wheel cylinder for leakage.
2) If the deformation or wear of back plate, shoe,
etc. are notable, replace them.

BR-35
 MASTER CYLINDER
BRAKE

11.Master Cylinder 3) Pry up the pawl and remove the piston retainer.
NOTE:
A: REMOVAL Piston may jump out from master cylinder.
1) Thoroughly drain the brake fluid from reservoir
tank.
2) Disconnect the fluid level indicator harness con-
nector.
3) Remove the brake pipes from master cylinder.
4)Remove the master cylinder mounting nuts, and
take out master cylinder from brake booster.
CAUTION:
Be extremely careful not to spill the brake fluid.
Brake fluid spilt on the vehicle body will harm
the painted surface; wipe it off quickly if spilt. I
S4M0121

B: INSTALLATION 4) Extract the primary piston assembly and second-

1) To install the master cylinder to the body, re-
verse the sequence of removal procedure.
Tightening torque:
Master cylinder mounting nut
14 N-m (1.4 kgf-m, 10.1 t?-16)
Piping flare nut
15 N.m (1.5 kgf-m, 10.8 ff-16)
CAUTION:
Be sure to use recommended brake fluid.
2) Bleed air from the brake system. <Ref. to BR-46,
PROCEDURE, Air Bleeding.>
ary piston assembly.
CAUTION:
Do not disassemble the piston assembly;
otherwise, the spring set value may be
changed.
Use brake fluid or methanol to wash inside
wall of cylinder, pistons and piston cups. Be
careful not to damage parts when washing. If
methanol is used for washing, do not dip rub-
ber parts, such as piston cups, in it for more
than 30 seconds; otherwise, they may become
swelled.

C: DISASSEMBLY
1. PRECAUTIONS FOR DISASSEMBLING
1) Remove mud and dirt from the surface of brake
master cylinder.
2) Prepare the tools necessary for disassembly op-
eration, and arrange them neatly on work bench.
3) Clean the work bench.
2. DISASSEMBLING PROCEDURE
1) Remove the pin with drift pin which secures the
reserve tank to master cylinder.
2) Remove the cylinder pin with magnetic pick-up
tool while pushing in primary piston. (with ABS)
I

(-2 ,B
(1) Cylinder pin

BR-36
 I

MASTER CYLINDER
BRAKE

D: ASSEMBLY
1. PRECAUTIONS FOR ASSEMBLING
1) When assembling, be sure to use recommended
brake fluid.
2) Ensure that the inside wall of cylinder, pistons,
and piston cups are free from dirt when assem-
bling.
3) Be extremely careful not to damage, scratch, or
dent cylinder inside wall, pistons, and piston cups.
4) Do not drop the parts. Never attempt to use any
part that has been dropped accidentally.
2. ASSEMBLING PROCEDURE
1) Assembling piston assembly:
Apply recommended brake fluid to inside wall of
cylinder, and to outer surface of piston assembly,
and install the piston assemblies carefully into cyl-
inder.
2) Assembling cylinder pin:
3) Press the pawl and install the piston retainer into
the master cylinder.
E: INSPECTION
If any damage, deformation, wear, swelling, rust,
and other faults are found on the primary piston as-
sembly, secondary piston assembly, supply valve
stopper, or gasket, replace the faulty part.
CAUTION:
The primary and secondary pistons must be
replaced as complete assemblies.
The service limit of the clearance between
each piston and the master cylinder inner dia.
is 0.11 mm (0.0043 in).
When handling parts, be extremely careful
not to damage or scratch the parts, or let any
foreign matter get on them.

4) Install the seal to reservoir tank.

(1) Seal

5) Install the pin with drift pins which secures the

reservoir tank to master cylinder.

BR-37
 BRAKE BOOSTER
BRAKE

12.Brake Booster CAUTION:

If external force is applied from above when
A: REMOVAL brake booster is placed in this position, the res-
1) Remove or disconnect the following parts at en- in portion as indicated by “P”, may be dam-
gine compartment. aged.
(1) Disconnect the connector for brake fluid lev-
el indicator.
(2) Remove the brake pipes from master cylin-
der.
(3) Remove the master cylinder installing nuts.
(4) Disconnect the 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 the brake booster while shunning brake

pipes. (1) Force

NOTE:
Be careful not to drop the brake booster. Brake
booster should be discarded if it has been dropped.
Use special care when handling the operating
rod.
If excessive force is applied to operating rod, suffi-
cient to cause a change in the angle in excess of
f3”,it may result in damage to the power piston cyl-
inder.
Use care when placing the brake booster on the
floor.
Do not change the push rod length. If it has been
changed, reset the projected length “L” to the stan-
dard length.
Standard:
L = 10.4 mm (0.41 in)

G4M0424

BR-38
 I

BRAKE BOOSTER
BRAKE

B: INSTALLATION 7) Adjust the operating rod of brake booster.

1) Mount the brake booster in position. Standard: L
2) Connect the operating rod to brake pedal with LHD model:
clevis pin and snap pin. 144.6 mm (5.69 in)
RHD model:
7 73.2 mm (6.82 in)
If it is not in specified value, adjust it by adjusting
the brake booster operating rod.

L
k

MM0616P

8) Measure the clearance between threaded end of

stop light switch and stopper.
If it is not in specified value, adjust it by adjusting
the position of stop light switch.
CAUTION:
B4M0117C Be careful not to rotate the stop light switch.
Stop ljght switch clearance: A
(1) Nuts
0.3 mm (0.012 in)
(2) Clevis pin
(3) Snap pin
(4) Operating rod

3) Connect the vacuum hose to brake booster.

A

u- B4M0617H

9) Apply grease to operating rod connecting pin to

4) Mount the master cylinder onto brake booster.
5)Connect the brake pipes to master cylinder.
6) Connect the electric connector for brake fluid
level indicator.
prevent it from wearing.
10) Bleed air from the brake system.
Tightening torque (Air bleeder screw):
8 N.m (0.8 kgf-m, 5.8 ft-16)
11) Conduct road tests to ensure brakes do not
drag.

BR-39
 BRAKE BOOSTER
BRAKE

C: INSPECTION Operation check

1. OPERATION CHECK (WITHOUT GAUG-
ES)
CAUTION:
When checking operation, be sure to securely
apply the hand brake.
Checking without gauges
This method cannot determine the exact portion
which has failed, but it can provide a rough under-
standing of the nature of the failure if checking is
conducted in accordance with the following proce-
dures.
Air tightness check
Start the engine, and run it for 1 to 2 minutes, then
turn it off. Depress the brake pedal several times
applying the same pedal force as that used in ordi-
nary braking operations. The pedal stroke should
be greatest on the 1st depression, and it should be-
come smaller with each successive depression. If
no change occurs in the pedal height while in a de-
pressed state, the brake booster is faulty.
S4M0465A
(1) OK
(2) NOTOK
(3) 1st
(4) 2nd
(5) 3rd
1) With the engine off, depress the brake pedal
several times applying the same pedal force and
make sure that the pedal height does not vary with
each depression of the pedal.
S4M0466A
(1) When engine is stopped
(2) When engine is started
2) With the brake pedal depressed, start the en-
gine.
3) As engine starts, the brake pedal should move
slightly toward the floor. If no change occurs in the
pedal height, the brake booster is faulty.
NOTE:
If faulty, check precisely with gauges.
Loaded air tightness check
Depress the brake pedal while engine is running,
and turn off the engine while the pedal is still de-
pressed. Keep the pedal depressed for 30 sec-
onds; if no change occurs in the pedal height, the
brake booster is functioning normally; if the pedal
height increases, it is faulty.
NOTE:
If faulty, check precisely with gauges.

NOTE:
In the event of defective operation, inspect the
condition of the check valve and vacuum hose.
Replace them if faulty and conduct the test
again.
If no improvement is observed, check precisely
with gauges.

BR-40
 BRAKE BOOSTER
BRAKE

2. OPERATION CHECK (WITH GAUGES) Leak from the shell jointed portion or stud bolt
welded portion
CAUTION: Damaged diaphragm
When checking operation, be sure to securely Leak from valve body seal and bearing portion
apply the hand brake. Leak from plate and seal assembly portion
Checking with gauges Leak from poppet valve assembly portion
Connect gauges as shown in the figure. After Loaded air tightness check
bleeding air from pressure gauges, proceed to 1) Start the engine and depress the brake pedal
each check. with pedal force of 196 N (20 kgf, 44 Ib). Keep the
engine running until a vacuum of 66.7 kPa (500
mmHg, 19.69 inHg) = point B is indicated on vacu-
um gauge while the pedal is still depressed.
,B

(1 )- Pressure gauge
(2) Vacuum gauge S4M0469A I
(3) Adapter hose
(4) Vacuum hose (1) Pressure gauge
(5) Pedal force gauge (2) Vacuum gauge
(3) Pedal force gauge
Air tightness check (4) Depress
1) Start the engine and keep it running until a vac-
uum of 66.7 kPa (500 mmHg, 19.69 inHg) = point A 2) Stop the engine and watch vacuum gauge.
is indicated on vacuum gauge. Do not depress the If the vacuum drop range is less than 3.3 kPa (25
brake pedal. mmHg, 0.98 inHg) within 15 seconds after stopping
the engine, brake booster is functioning properly.
If defective, refer to “AIR TIGHTNESS CHECK’.
<Ref. to BR-40, INSPECTION, Brake Booster.>
Lack of boosting action check
Turn off the engine, and set the vacuum gauge
reading at “0”. Then, check the fluid pressure when
brake pedal is depressed. The pressure must be
greater than the standard value listed.
Brake pedal 147 N 294 N
force (1 5 kgf, 33 Ib) (30 kgf, 66 Ib)
588 kPa 1,471 kPa
Fluid pressure
(1) Pressure gauge (6 kcdcm’, 85 psi) (15 kg/cm2,213 psi)
(2) Vacuum gauge

2) Stop the engine and watch the gauge. If the vac-

uum drop range is less than 3.3 kPa (25 mmHg,
0.98 inHg) within 15 seconds after stopping the en-
gine, the brake booster is functioning properly.
If defective, the cause may be one of those listed
below.
Check valve malfunction
Leak from vacuum hose

BR-41
 BRAKE BOOSTER
BRAKE

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 de-
pressed. The pressure must be greater than the
standard value listed.

force
5,688 kPa
Fluid Turbo
pres-
sure

BR-42
 PROPORTIONING VALVE
m
BRAKE

13.Proportioning Valve C: INSPECTION

1) Install the oil.pressure gauges to measure the
A: REMOVAL 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 the figure.

“% BR0066

1) Remove the brake pipe from proportioning valve

at four places.
2) Remove the proportioningvalve from its bracket. are normal
CAUTION:
Do not disassemble or adjust the proportioning Master cylinder fluid pressure: Pz
BR0067
valve. (The proportioning valve must be re-
placed as an assembly.) 4) For the oil pressure in case of split point, refer to
“SPEC IFICAT1ONS”.
B: INSTALLATION <Ref. to BR-2, SPECIFICATIONS, General De-
1) Install the proportioning valve to bracket. scription.>
2) Connect the brake pipes correctly to proportion-
ing 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 ff-lb)

BR-43
 BRAKE FLUID
BRAKE

14.Brake Fluid 5) Install one end of a vinyl tube onto the air bleeder
and insert the other end of the tube into a container
A: INSPECTION to collect the brake fluid.
1) Check that the brake fluid level remains between
“MIN” and “MAX’. If out of the specified range, refill
or drain fluid. If fluid level becomes close to “MIN”,
refill fluid.
2) Check the fluid for discoloration. If fluid color has
excessively changed, drain the fluid and refill with
new fluid.
B: REPLACEMENT
CAUTION:
To always maintain the brake fluid character-
istics, replace the brake fluid according to
maintenance schedule or earlier than that when Am Air bleeder screw
used in severe condition.
The FMVSS No. 116, fresh DOT3 or 4 brake
fluid must be used.
Cover the bleeder with waste cloth, when
loosening it, to prevent brake fluid from being
splashed over surrounding parts.
Avoid mixing different brands of brake fluid
to prevent degrading the quality of the fluid.
Be careful not to allow dirt or dust to get into
the reservoir tank.
CAUTION:
NOTE: Brake fluid replacement sequence; (A) Front
During bleeding operation, keep the brake reser- right -+(8) Rear left + (C) Front left + (D) Rear
voir tank filled with brake fluid to eliminate entry of right
air.
Brake pedal operating must be very slow.
For convenience and safety, two people should
- r

do the work.
The amount of brake fluid required is approxi-
mately 500 m 0 (16.9 US fl oz, 17.6 Imp fl oz) for to-
tal brake system.
1) Either jack-up the vehicle and place a safety
stand under it, or lift up the vehicle.
2) Remove both front and rear wheels.
3) Draw out the brake fluid from master cylinder I S4M0475A
with syringe.
4) Refill the reservoir tank with recommended (1 ) Master cylinder
brake fluid. (2) Hydraulic unit
Recommended brake fluid: (3) Proportioning valve
FMVSS No. 116, fresh DOT3 or 4 brake fluid 6) Instruct your co-worker to depress the brake
pedal slowly two or three times and then hold it de-
pressed.
7) Loosen the bleeder screw approximately 1/4 turn
until a small amount of brake fluid drains into the
container, and then quickly tighten the screw.

BR-44
 Pls
BRAKE FLUID
BRAKE

8) Repeat steps 6) and 7) above until there are no

air bubbles in drained brake fluid and new fluid
flows through vinyl tube.
NOTE:
Add brake fluid as necessary while performing the
air bleed operation, in order to prevent the tank
from running short of brake fluid.
9 ) After completing the bleeding operation, hold the
brake pedal depressed and tighten the screw and
install bleeder cap.
Tightening torque (Bleeder screw):
8 N-m (0.8 kgf-m, 5.8 fi-lb)
10) Bleed air from each wheel cylinder using the
same procedures as described in steps 6) through
7) above.
11) Depress the brake pedal with a force of approx-
imately 294 N (30 kgf, 66 Ib) and hold it there for ap-
proximately 20 seconds. At this time check the
pedal to see if it shows any unusual movement.
Visually inspect the bleeder screws and brake pipe
joints to make sure that there is no fluid leakage.
12) Install the wheels, and drive vehicle for a short
distance between 2 to 3 km (1 to 2 miles) to make
sure that brakes are operating properly.

BR-45
 AIR BLEEDING
BRAKE
15.Air Bleeding
A: PROCEDURE
CAUTION:
The FMVSS No. 116, fresh DOT3 or 4 brake
fluid must be used.
Cover the bleeder with waste cloth when
loosening it to prevent brake fluid from being
splashed over surrounding parts.
Avoid mixing different brands of brake fluid
to prevent degrading the quality of the fluid.
Be careful not to allow dirt or dust to get into
the reservoir tank.
NOTE:
Start with the brakes (wheels) connected to the
secondary chamber of the master cylinder.
The time interval between two brake pedal oper-
ations (from the time when the pedal is released to
the time when it is depressed another time) shall be
approximately 3 seconds.
The air bleeder on each brake shall be released
for 1 to 2 seconds.
1. MASTER CYLINDER
NOTE:
If the master cylinder is disassembled or reser-
voir tank is empty, bleed the master cylinder.
During the bleeding operation, keep the brake
reservoir tank filled with brake fluid to eliminate en-
try of air.
Brake pedal operating must be very slow.
For convenience and safety, two people should
do the work.
1) Disconnect the brake line at primary and sec-
ondary sides.
2) Cover the master cylinder with vinyl bag.
3) Carefully depress and hold the brake pedal.
S4M0.540
BR-46
4) Close the outlet plug with your finger, and re-
lease the brake pedal.
I S4M0541
5) Repeat the above step3) and 4) until brake fluid
is completey bled from outlet plug.
6) Remove the vinyl bag, then connect the brake
pipe to master cylinder.
Tightening torque:
8 N-m (0.8 kgf-m, 5.8 ff-lb)
7) Using water, wash off the spilt brake fluid at the
master cylinder surrounding, then wipe up the wa-
ter.
8) Bleed air from the brake line. <Ref. to BR-46,
BRAKE LINE, PROCEDURE, Air Bleeding.>
2. BRAKE LINE
NOTE:
During the bleeding operation, keep the brake
reservoir tank filled with brake fluid to eliminate en-
try of air.
Brake pedal operating must be very slow.
For convenience and safety, two people should
do the work.
1) Make sure that there is no leak from joints and
connections of the brake system.
2) Fit one end of vinyl tube into the air bleeder and
put the other end into a brake fluid container.
W S4M0246

AIR BLEEDING
CAUTION:
Brake fluid replacement sequence; (A) Front
right (6) Rear left + (C) Front left + (D) Rear
right
I S4M0475A
(1) Master cylinder
(2) Hydraulic unit
(3) Proportioning valve
3) Slowly depress the brake pedal and keep it de-
pressed. Then, open the air bleeder to discharge
air together with the fluid.
Release the air bleeder for 1 to 2 seconds.
Next, with the bleeder closed, slowly release the
brake pedal.
Repeat these steps until there is no more air bub-
bles in the vinyl tube.
Allow 3 to 4 seconds between two brake pedal op-
erations.
CAUTION:
Cover the bleeder with waste cloth, when loos-
ening it, to prevent brake fluid from being
splashed over surrounding parts.
NOTE:
Brake pedal operating must be very slow.
4) Tighten the air bleeder securely when no air bub-
bles are visible.
Air bleeder tightening torque:
8 N.m (0.8 kgf-m, 5.8 ft-lb)
5 ) Perform these steps for the brakes connecting to
the secondary chamber of master cylinder, first,
and then for the ones connecting to primary cham-
ber. With all procedures completed, fully depress
the brake pedal and keep it in that position for ap-
proximately 20 seconds to make sure that there is
no leak evident in the entire system.
BR-47
is
BRAKE
6) 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
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.
\
S4M0476A
(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 specified, there is a
possibility that air is in the brake line. Bleed the
brake line until pedal stroke meets the specifica-
tion.
8) Operate the hydraulic control unit in the se-
quence control mode. (With ABS)
<Ref. to ABS-I 1, ABS Sequence Control.>
9) Recheck the brake stroke.
10) If the distance is more than specified, there is a
possibility air is in the inside of the hydraulic unit.
Repeat above steps 2) to 9) until pedal stroke
meets the specification.
11) Add brake fluid to the required level (MAX. lev-
el) of reservoir tank.
12) As a final step, test run the vehicle at low speed
and apply brakes relatively hard 2 to 3 times to en-
sure that brakes provide normal braking action on
all four wheels without dragging and uneven brak-
ing.
 BRAKE HOSE
BRAKE

16.Brake Hose B: INSTALLATION

A: REMOVAL 1. FRONT BRAKE HOSE
1) Route the end of brake hose (on caliper side)
1. FRONT BRAKE HOSE
through hole in brake hose bracket at strut location.
1) Separate the brake pipe from brake hose. 2) Tighten the end of brake hose at caliper using a
(Always use flare nut wrench and be careful not to union bolt.
deform flare nut.)
Tightening torque (Union bolt):
18 N.m (1.8 kgf-m, 13.0 ff-lb)

18438
-

(1) Brake hose I1844

(2) Brake pipe
2) Pull out the clamp to remove the brake hose.
3) Remove the bolt at strut and union bolt.
2. REAR BRAKE HOSE
1) Separate the brake pipe from brake hose.
NOTE:
Always use flare nut wrench and be careful not to
deform flare nut.
3) Secure the middle fitting of brake hose to bracket
at strut location using a clamp.
4) Position the disc in straight-forwarddirection and
route the brake hose through hole in bracket on
wheel apron side.
CAUTION:
Be sure the brake hose is not twisted.
5) Temporarily tighten the flare nut to connect
brake pipe and hose.
6) Fix the brake hose with clamp at wheel apron
bracket.
7) While holding the hexagonal part of brake hose
fitting with a wrench, tighten the flare nut to the
specified torque.
Tightening torque (Brake pipe flare nut):
15 N-m (1.5 kgf-m, 10.8 ff-lb)
8 ) Bleed air from the brake system. <Ref. to BR-46,
Air Bleeding.>

(1) Brake hose clip

(2) Brake hose
(3) Brake pipe

2) Unscrew the brake hose flare nut, and discon-

nect the brake hose.
3) Pull out the clamp to remove the brake hose.

BR-48
 ia
BRAKE HOSE
BRAKE

2. REAR BRAKE HOSE C: INSPECTION

1) Pass the brake hose through the hole of bracket, Ensure there are no cracks, breakage, or damage
and lightly tighten the flare nut to connect brake on hoses. Check the Joints for fluid leakage. If any
hose. cracks, breakage, damage or leakage is found, re-
2) Insert the clamp upward to fix brake hose. pair or replace the hose.
3) While holding the hexagonal part of brake hose
fitting with a wrench, tighten the flare nut to the
specified torque.
Tightening torque (Brake pipe flare nut):
75 N*m (7.5 kgf-m, 70.8 ft-lb)

(1) Brake hose clip

(2) Brake hose
(3) Brake pipe

4) Bleed air from the brake system. <Ref. to BR-46,

Air Bleeding.>

BR-49
 BRAKE PIPE
BRAKE

17.Brake Pipe C: INSPECTION

Ensure there are no cracks, breakage, or damage
A: REMOVAL on pipes. Check the joints for fluid leakage. If any
NOTE: cracks, breakage, damage or leakage is found, re-
Airbag system wiring harness is routed near the pair or replace the pipe.
center brake pipe. NOTE:
CAUTION: Use a mirror when inspecting the low-visible part or
All Airbag system wiring harness and con- back side.
nectors are colored yellow. Do not use electri-
cal test equipment on these circuits.
Be careful not to damage the Airbag system
wiring harness when servicing the center brake
pipe.
When removing the brake pipe, make sure
that it is not bent.
B: INSTALLATION
NOTE:
Airbag system wiring harness is routed near the
center brake pipe.
CAUTION:
All Airbag system wiring harness and con-
nectors are colored yellow. Do not use electri-
cal test equipment on these circuits.
Be careful not to damage the Airbag system
wiring harness when servicing the center brake
pipe.
When installing the brake pipe, make sure
that it is not bent.
After installing the brake pipe and hose,
bleed the air.
After installing the brake hose, make sure
that it does not touch the tire or suspension as-
sembly, etc.
Brake pipe tightening torque:
15 N*m (1.5 kgf-m, 10.8 ft-lb)

BR-50
 1
BRAKE PEDAL
BRAKE

18.Brake Pedal B: INSTALLATION

1 ) Install in the reverse order of removal.
A: REMOVAL CAUTION:
1. MT MODEL If the cable clamp is damaged, replace it with
a new one.
1) Remove the steering bolts. Never fail to cover the outer cable end with
2) Raise the vehicle on hoist and remove the two
bolts which secure steering unit to underside of
body.
.
boot.
Be careful not to kink the accelerator cable.
Always use new clevis pins.
3) Lower the vehicle to floor.
4) Remove the instrument panel lower cover from 2) Adjust the clutch pedal <Ref. to CL-27, ADJUST-
instrument panel. MENT, Clutch Pedal.>
5) Disconnect the following parts from pedal bra&- 3) Inspect after pedal installation <Ref. to BR-53,
et. INSPECTION, Brake Pedal.>
Operating rod of brake booster
Electrical connectors (for stop light switch, etc.)
6) Remove the clevis pin which secures lever to
push rod.
7) Remove the nut which secures clutch master
cylinder.
8) Remove the steering assembly.
9) Remove the accelerator pedal.
10) Remove the bolts and nuts which secure pedal
bracket.

2. ATMODEL
1 ) Disconnect the ground cable from battery.
2) Remove the instrument panel lower cover from
instrument panel.
3) Remove the clevis pin which secures brake ped-
al to brake booster operating rod. Also disconnect
the stop light switch connector.
4) Remove the two bolts and four nuts which se-
cure brake pedal to pedal.

BR-51
 BRAKE PEDAL
BRAKE

C: DISASSEMBLY 2. ATMODEL
1. MT MODEL 1) Remove the brake switch.
2) Unbolt, and then remove the brake pedal.
1) Remove the brake switch.
<Ref. to BR-55, REMOVAL, Stop Light Switch.>
2) Remove the clutch pedal.
<Ref. to CL-26, DISASSEMBLY, Clutch Pedal.>
3) Remove the clutch master cylinder bracket.

3) Remove the bush, spacer and spring.

4) Remove the bush, spring and stopper.

(1) Plug
(2) Stopper
(3) Brake pedal
\) B4M2350A (4) Brake pedal spring

(1) Stopper 4) Remove the brake pedal pad.

(2) Bushing
(3) Brake pedal
(4) Brake pedal spring

5) Remove the brake pedal pad.

BR-52
 1
BRAKE PEDAL
BRAKE

D: ASSEMBLY E: INSPECTION
1) Attach the stop light switch, etc. to pedal bracket 1) Move the brake and clutch pedal pads in the lat-
temporarily. eral direction with a force of approximately 10 N (1
2) Clean the inside of bores of clutch pedal and kgf, 2 Ib) to ensure pedal deflection is in specified
brake pedal, apply grease, and set bushings into range.
bores. CAUTION:
3) Align bores of pedal bracket, clutch pedal and If excessive deflection is noted, replace the
brake pedal, attach brake pedal return spring and bushings with new ones.
clutch pedal effort reducing spring (vehicle with hill
holder), and then install the pedal bolt. Deflection of brake and clutch pedal:
Service limit
NOTE: 5.0 mm (0.197 in) or less
Clean up inside of bushings and apply grease be-
fore installing the spacer.
Tightening torque:
T: 29 Nom(3.0 kgf-m, 21.7 ft-lb)

(1) Clutch pedal

(2) Brake pedal

4) Set the brake pedal position by adjusting the po-

sition 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)
&g F::

G4M0326

BR-53
 BRAKE PEDAL
BRAKE

2) Check the position of pedal pad.

Pedal height: L
148 mm (5.83 in)
Brake pedal free play: A
1 -3 mm (0.04 - 0.12 in) [Depress brake
pedal pad with a force of less than 10 N (1 kgf,
2 lb).]

B4M03668

(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 adjusting

the brake booster operating rod length.

BR-54
 STOP LIGHT SWITCH Is
BRAKE

19.Stop Light Switch C: INSPECTION

1) If the stop light switch does not operate properly
A: REMOVAL (or if it does not stop at the specified position), re-
1) Disconnect the ground terminal from battery. place with a new one.
2) Disconnect the stop light switch connector.
3) Loosen the nuts, and unscrew stop light switch Specified position: L
to remove. 2 mm (0.079 in)

7
A+-

I G4M0327

2) Measure the clearance between threaded end of

(1) Stop light switch stop light switch and stopper.
CAUTION:
B: INSTALLATION Be careful not to rotate the stop light switch.
1) Screw the stop light switch onto a bracket and
secure it temporarily with a nut. Stop light switch clearance: A
2) Adjust the stop light switch position, and then 0.3 mm (0.012 in)
tighten the nut.
<Ref. to BR-56, ADJUSTMENT, Stop Light
Switch.>
Tightening torque:
8 N.m (0.8 kgf-m, 5.8 ft-lb)

(,,--p3)
B4M0617E

(1) Stop light switch

(2) Stopper
(3) Brake pedal

3) If it is not in specified value, adjust it by adjusting

the position of stop light switch.
CAUTION:
Be careful not to rotate the stop light switch.

BR-55
 STOP LIGHT SWITCH
BRAKE

D: ADJUSTMENT
Loosen the lock nut, and adjust the stop light switch
position until the clearance between threaded end
of the stop light switch and the stopper becomes
0.3 mm (0.012 in). Then, tighten the lock nut.

Ir' B4M0617E

BR-56
 GENERAL DIAGNOSTICS
BRAKE

20.General Diagnostics
A: INSPECTION
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 1 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 cal- Correct or replace.
iDer, brake booster or check valve
2. Unstable or uneven (1) Fluid on the lining, drum or rotor Eliminate cause of fluid leakage, clean, or replace.
braking (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 I Retighten to normal tightening torque or replace.
(10) Trouble in the hydraulic system 1
Replace the cylinder, brake pipe or hose.
(11) Uneven effect of the parking brake 1
Check, adjust, or replace the rear brake and cable
I
system.
3. Excessive pedal (1) Entrv of air into the hvdraulic mechanism 1 Bleed the air.
stroke (2) Excessive play in the master cylinder push rod 1 Adjust.
(3) Fluid leakage from the hydraulic mechanism Repair or replace (cup, piston seal, piston boot,
master cylinder piston kit, pipe or hose).
(4) Improperly adjusted shoe clearance Adjust.
(5) ImDroDer linina contact or worn linina Correct or replace.
4. Brake dragging or
improper brake return (2) Improper master cylinder return 1 Clean or replace the cylinder.
(3) Clogged hydraulic system Replace.
(4) Improper return or adjustment of parking brake Correct or adjust.
(5) Weakened spring tension or breakage of shoe Replace the spring.
return sDrina
I Adiust the clearance.
~~~~~ ~ ~

(6) Excessively narrow shoe clearance

5. Brake noise (1)
(creak sound)
6. Brake noise (2)
(hissing sound)
( 7 ) lmprouer disc caliper operation
(8) Improper adjusted wheel bearing
(1) Hardened or deteriorated lining
(2) Worn lining
(3) Loosened back plate or the support installing
bolts
(4) Loose wheel bearing
(5) Dirty drum or rotor
(1) Worn lining
(2) ImDroDer installed shoe or Dad
(3) Loose or bent drum or rotor
1 Correct or replace.
Adjust or replace.
Replace the shoe assembly or pad.
Replace the shoe assembly or pad.
Retighten.
I Retighten to normal tightening torque.
Clean the drum or rotor, or clean and replace the
brake assembly.
Replace the shoe assembly or pad.
Correct or replace the shoe assembly or pad.
I Retighten or replace.

BR-57
 GENERAL DIAGNOSTICS
BRAKE

Trouble and possible cause Corrective action

7. Brake noise (3) In the case of the disc brake:
(click sound) (1) Excessively worn pad or the support I 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.
I
anchor

BR-58
PARKING BRAKE

~~ ~
PB
Page
1. General Description .................................................................................... 2
2. Parking Brake Lever.................................................................................... 6
3. Parking Brake Cable ................................................................................... 8
4. Parking Brake Assembly (Rear Disc Brake) ............................................. 10
5. General Diagnostic Table .......................................................................... 13

PARKING BRAKE
1 General Description
A: SPECIFICATIONS
Type
Model
Effective drum diameter
Lining dimensions
(length x width x thickness)
Clearance adjustment
Lever stroke
GENERAL DESCRIPTION
Rear drum brake Rear disc brake
Mechanical on rear brakes, drum in disc
1
mm (in) 228.6 (9) 170 (6.69)
21 9.3x 35.0x 4.1 163.1 x 30.0x 3.2
mm (in)
(8.63x 1.378x 0.161) (6.42x 1.181x 0.126)
Automatic adjustment Manual adjustment
notches/N (kgf, Ib) 7 to 8/196(20,44)
PB-2
 GENERAL DESCRIPTION
PARKING BRAKE

B: COMPONENT
1. PARKING BRAKE (REAR DISC BRAKE)

(1) Back plate (10) Primary return spring Tightening torque: N-m (kgf-m, ft-lb)
(2) Retainer (11) Secondary return spring T: 53 (5.4, 39)
(3) Spring washer (12) Adjusting spring
(4) Lever (13) Adjuster
(5) Parking brake shoe (Primary) (14) Shoe hold-down cup
(6) Parking brake shoe (Secondary) (15) Shoe hold down spring
(7) Strut spring (16) Shoe hold down pin
(8) Strut (17) Adjusting hole cover
(9) Shoe guide plate

PB-3
 GENERAL DESCRIPTION
PARKING BRAKE

2. PARKING BRAKE CABLE

(1 i
B4M0705B

(1) Parking brake lever (7) Clamp Tightening torque: N.m (kgf-m, ft-lb)
(2) Parking brake switch (8) Parking brake cable RH T1: 6 (0.6, 4.4)
(3) Lock nut (9) Cable guide T2: lS(1.8, 13.0)
(4) Adjusting nut (IO) Clamp (Rear disc brake model T3: 33 (3.4,24)
(5) Equalizer only)
(6) Bracket (11) Parking brake cable LH

PB-4
 GENERAL DESCRIPTION is
PARKING BRAKE

C: CAUTION
Wear working clothing, including a cap, protec-
tive goggles, and protective shoes during opera-
tion.
Remove contamination including dirt and corro-
sion before removal, installation or disassembly.
Keep the disassembled parts in order and pro-
tect them from dust or dirt.
Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary re-
moval, installation, disassembly, and replacement.
Be careful not to burn your hands, because each
part on the vehicle is hot after running.
Use SUBARU genuine grease etc. or the equiv-
alent. Do not mix grease etc. with that of another
grade or from other manufacturers.
Be sure to tighten fasteners including bolts and
nuts to the specified torque.
Place shop jacks or safety stands at the specified
points.
Apply grease onto sliding or revolution surfaces
before installation.
Before installing O-rings or snap rings, apply suf-
ficient amount of grease to avoid damage and de-
formation.
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.
Keep grease etc. away from parking brake
shoes.

PB-5
 PARKING BRAKE LEVER
PARKING BRAKE

2. Parking Brake Lever 8) Unbend the parking brake lever pawls and re-
move cable.
A: REMOVAL
1) Move the select lever to “P” position or gear shift
lever to 1st gear, then block the wheels.
2) Disconnect the battery ground terminal from bat-
tery.
3) Remove the console box. <Ref. to El-41, RE-
MOVAL, Console Box.>
4) Disconnect the connector of parking brake
switch.
5 ) Loosen the parking cable adjusting nut and con-
sole bracket.
6) Remove the parking brake lever.
(1) Parking brake lever
(2) Cable

B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
Parking brake lever;
18 N.m (1.8 kgf-m, 13.0 ft-lb)
Adjusting nut;
6 N-m (0.6 kgf-m, 4.4 ft-lb)
NOTE:
7) Remove the inner cable end from equalizer. Be sure to pass the cable through the guide in-
side tunnel.
Be sure to adjust the lever stroke. <Ref. to PB-7,
ADJUSTMENT, Parking Brake Lever.>

-
(1) Equalizer
(2) Inner cable end
S4M0473A

PB-6
 PARKING BRAKE LEVER 1
PARKING B R M F
~~~ ~
-
C: INSPECTION D: ADJUSTMENT
While pulling the parking brake lever upward, count 1) Remove the console box. <Ref. to El-41, RE-
the notches. MOVAL, Console Box.>
2) Forcibly pull the parking brake lever 3 to 5 times.
Lever stroke:
3) Adjust the parking brake lever by turning adjust-
7t0 8notches when with a force Of
er until the parking brake lever stroke is set at 7 to
N (20 kgf, 44 lb) 8 notches with an operating force of 196 N (20 kgf,
If incorrect, adjust the parking brake. 44 Ib).
<Ref. to PB-12, ADJUSTMENT, Parking Brake AS- 4) Tighten the lock nut.
sembly (Rear Disc Brake).>
Lever stroke:
7 to 8 notches when pulled with a force of 796
N (20 kgc 44 lb)
Tightening torque (Lock nut):
5.9 N-m (0.6 kgf-m, 4.3 ft-lb)

(1) Parking brake lever

(2) Locknut
(3) Adjusting nut

5 ) Install the console box. <Ref. to El-41, INSTAL-

LATION, Console Box.>

PB-7
I PARKING BRAKE CABLE
PARKING BRAKE

3. Parking Brake Cable 10) Pull out the parking brake cable from rear
brake.
A: REMOVAL Disc brake
1) Lift-up the vehicle. <Ref. to PB-10, REMOVAL, Parking Brake As-
2) Remove the rear tires and wheels. sembly (Rear Disc Brake).>
3) Remove the rear cushion. Drum brake
4) Remove the console box. <Ref. to El-41, RE- <Ref. to BR-33, Rear Drum Brake Assembly.>
MOVAL, Console Box.> 11) Pull out the clamp from rear brake.
5) Loosen the parking cable adjusting nut and con- 12) Remove the bolt and bracket from trailing link
sole bracket. bracket.
6) Remove the parking brake lever. 13) Remove the bolt and clamp from rear floor.

S4M0474A

7) Roll up the floor mat and remove clamps. (1) Grommet

(2) Parking brake cable

14) Detach the grommet from rear floor.

15) Remove the cable assembly from cabin by forc-
ibly pulling it backward.
16) Detach the parking brake cable from cable
guide at rear trailing link.

0R0030

8) Remove the equalizer cover.

9) Remove the inner cable end from equalizer.

2)

S4M0473A

(1) Equalizer
(2) Inner cable end

PB-8
 PARKING BRAKE CABLE a
PARKING BRAKE

B: INSTALLATION
Install the (new) parking brake assembly in the re-
verse order of removal.
NOTE:
Be sure to pass the cable through the cable
guide inside tunnel.
Be sure to adjust the lever stroke. <Ref. to PB-7,
ADJUSTMENT, Parking Brake Lever.>
C: INSPECTION
Check the removed cable and replace if damaged,
rusty or malfunctioning.
1) Check for smooth operation of the cable.
2) Check the inner cable for damage and rust.
3) Check the outer cable for damage, bends, and
cracks.
4) Check the boot for damage, cracks, and deterio-
ration.

PB-9
 PARKING BRAKE ASSEMBLY (REAR DISC BRAKE)
PARKING BRAKE

4. Parking Brake Assembly (2) If the disc rotor seizes up within the hub,
drive the disc rotor out by installing an 8-mm bolt
(Rear Disc Brake) in holes B on the rotor.
A: REMOVAL
1)Set the vehicle on a lift.
2) Disconnect the ground terminal from battery.
3) Loosen the wheel nuts.
4) Jack-up the vehicle, and remove wheel.
5) Remove the two mounting bolts and remove the
disc brake assembly.

G4M0383

9) Remove the primary and secondary return

spring from parking brake assembly.
IO) Remove the front shoe hold down spring and
pin with pliers.

(1) Disc brake ASSY

6) Suspend the disc brake assembly so that the

hose is not stretched.
7) Pull down and release the parking brake.
8) Remove the disc rotor.
NOTE:
If the disc rotor is difficult to remove try the following 11) Remove the strut and strut spring.
two methods in order. 12) Remove the rear shoe hold-down spring and
(1) Turn the adjusting screw using a slot-type pin with pliers.
screwdriver until the brake shoe gets away 13) Remove the adjuster assembly and adjusting
enough from the disc rotor. spring from parking brake assembly.
14) Remove the parking cable from parking lever.
15) Remove the brake shoe.

S4M0569A

(1) Adjusting screw

(2) Cover (rubber)
(3) Slot-type screwdriver (1) Parking brake cable
(4) Back plate (2) Parking brake lever

16) Using a standard screwdriver, raise the retain-

er. Remove the parking lever and washer from
brake shoe.

PB-10
 -
PARKING BRAKE ASSEMBLY (REAR DISC BRAKE)
PARKING BRAKE

B: INSTALLATION NOTE:
Ensure that the shoe return spring is installed as
CAUTION:
shown in Figure.
Be sure the lining surface is free from oil con-
tamination.
Brake grease:
Dow Corning Molykote No. 7439 (Part No.
I
72579 1460)
1) Apply brake grease to the following places.
Six contact surfaces of shoe rim and back plate
packing
Contact surface of shoe wave and anchor pin
Contact surface of lever and strut
Contact surface of shoe wave and adjuster as- S4M0462A
sembly
Contact surface of shoe wave and strut (1) Back plate
Contact surface of lever and shoe wave (2) Shoe guide plate
2) Install in the reverse order of removal. (3) Retainer
(4) Spring washer
CAUTION:
Use new retainers and clinch them when in- (5) Lever
stalling the brake shoes to levers. (6) Primary shoe return spring (Blue)
Ensure that the parking lever moves smooth- (7) Secondary shoe return spring (Yellow)
ly- (8) Parking brake shoe (Primary)
e Do not confuse the left parking lever with (9) Parking brake shoe (Secondary)
right one.
Do not confuse the left strut with right one. 3) Adjust the parking brakes. <Ref. to PB-12, AD-
JUSTMENT, Parking Brake Assembly (Rear Disc
NOTE: Brake).>
Ensure that the adjuster assembly is securely in-
stalled with the screw in the left side, facing vehicle CAUTION:
front. After replacing the parking brake lining, be sure
to drive the vehicle for “break-in” purposes.
(1) Drive the vehicle at about 35 km/h (22 MPH).
(2) With the parking brake release button
pushed in, pull the parking brake lever gently.
(3) Drive the vehicle for about 200 meter (0.12
mile) in this condition.
(4) Wait 5 to 10 minutes for the parking brake to
cool down. Repeat this procedure once more.
(5) After breaking-in, re-adjust the parking
brakes.
S4M0461A

(1) LEFT

PB-11
 PARKING BRAKE ASSEMBLY (REAR DISC BRAKE)
PARKING BRAKE

C: INSPECTION 2. LEVER STROKE

1) Measure the brake disc inside diameter. If the 1) Remove the console box lid.
disc is scored or worn, replace the brake disc. 2) Forcibly pull the parking brake lever 3 to 5 times.
Disc inside diameter: 3) Adjust the parking brake lever by turning adjust-
Standard er until the parking brake lever stroke is set at 6
170 mm (6.69 in) notches with operating force of 196 N (20 kgf, 44
Service limit Ib).
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:
BR0054
Replace the brake shoes on the right and left
brake assembly at the same time.
(1) Parking brake lever
D: ADJUSTMENT (2) Locknut
(3) Adjusting nut
1. SHOE CLEARANCE
1) Remove the adjusting hole cover from back 4) Tighten the lock nut.
plate. 5) Install the console box lid.
2) Turn the adjusting screw using a slot-type screw- Lever stroke:
driver until the brake shoe is in close contact with 7 to 8 notches when pulled with a force of 196
disc rotor. N (20 kgf, 44 16)
Tightening torque (Adjuster lock nut):
6 N-m (0.6 kgf-m, 4.4 ft-16)

S4M0463A I
(1) Adjusting screw
(2) Cover (rubber)
(3) Slot-type screwdriver
(4) Back plate

3) Turn back (downward) the adjusting screw 3 or 4

notches.
4) Install the adjusting hole cover to back plate.

PB-I 2
 GENERAL DIAGNOSTIC TABLE
PARKING BRAKE

5. General Diagnostic Table

A: INSPECTION
Possible cause Remedy
Parking brake lever is maladjusted. Adjustment.
Parkina brake cable does not move. Repair or replace.
Brake drag
Parkina brake shoe clearance is maladiusted. 1 Adjustment. I
Return spring is faulty. I Replace. I
Return spring is faulty. Replace.
Noise from brake
Shoe hold down spring is faulty. Replace.

PB-13
 GENERAL DIAGNOSTIC TABLE
PARKING BRAKE

PB-14
POWER ASSISTED SYSTEM
(POWER STEERING)

Page
1. General Description .................................................................................... 2
2. Steering Wheel .......................................................................................... 19
3. Universal Joint ........................................................................................... 20
4. Tilt Steering Column.................................................................................. 23
5. Steering Gearbox ...................................................................................... 26
6. Pipe Assembly .......................................................................................... 47
7. Oil Pump ................................................................................................... 55
8. Reservoir Tank .......................................................................................... 70
9. Power Steering Fluid................................................................................. 72
10. General Diagnostic Table .......................................................................... 74
 GENERAL DESCRIPTION
POWER ASSISTED SYSTEM (POWER STEERING)

1. General Description
A: SPECIFICATIONS
Non-TURBO
Model Sedan and TURBO
Others
OUTBACK
Minimum turning radius m (ft) 5.1 (16.7) 5.4(17.7)
Steering angle (Inside-Outside) 36'55' - 31 "35' 34'05' - 29'35'
Whole
Steering wheel diameter mm (in) 385 (15.16)
svstem
Overall gear ratio (Turns, lock to lock
- - -.. -box)
Gear
Type
-.. I 3.22
I
3.02
Rack and pinion, Integral
Gearbox Backlash 0 (Automatically adjustable)
Valve (Power steerina svsteml Rotary valve
1 TvDe I Vane pump
Oil tank Installed on body
output cm3 (cu in)/rev. 7.8(0.476) 7.2 (0.439)
Pump 7,164- 7,840 7,350- 8,036(75- 82,
Relief pressure kPa (kg/cm2, psi) (73- 80.1,040- 1,165) 1,067- 1,165)
(Power
steering 1 Hvdraulic fluid control I Dropping in response to increased engine revolutions

1
system)
Hydraulic fluid

Range of revolution
Q (US qt, Imp qt)

rPm
1,000rpm: 7 (7.4,
6.2)
3,000rpm: 5 (5.3,
4.4)
700 - 9,000
I
I
7.5(7.9,
7 (7.4,
I .
6.6)"
6.2)'*
I

Revolvina direction Clockwise

Working Name ATF DEXRON Ill
fluid Oil tank 0.3(0.3,0.3)
(Power Capacity
steering Q (US qt, Imp qt) Total 0.7(0.7,0.6)
system)

PS-2
 GENERAL DESCRIPTION
POWER ASSISTED SYSTEM (POWER STEERING)

Steering wheel Free play mm (in) 17 (0.67)

Inner tire & TURBO, OUTBACK, Non-TURBO sedan 34"05'+1.5"
wheel other 36"55'+1.5"
Turning angle
Outer tire & TURBO, OUTBACK, Non-TURBO sedan 29"35'+1.5"
wheel I other I 31"35'+1.5" I
Steering shaft
Clearance between steering wheel and
column
- - .-. . ... . cover
- - ..
mm (in) I 3.0 (0.1 18)

Sliding resistance N (kgf, Ib) 340 (35, 76) or less

~

Steering gear-
Rack shaft I Horizontal movement: I
play in radial 0.15 (0.0059) or less
box direction Left-turn steering mm (in)
Vertical movement:
(Power steer- 0.3 (0.012) or less
ing system)
Input shaft In radial direction mm (in) 0.18 (0.0071) or less
Play In axial direction mm (in) 0.5 (0.020) or less
Turning resistance N (kgf, Ib) Maximum allowable value: 12 (1.2, 2.7)
Radial play mm (in) I 0.4 (0.016) or less
I Non-TURBO mm (in) I 0.4 (0.016) or less
Pulley shaft
IAxial play I TURBO mm
I

(in) I
I ,

0.8 (0.031) or less I

I I
I
\ I ,

Oil pump I Ditch deflection mm (in) I 1.O (0.039) or less

(Power steer- Pulley
I s t a n c e torotation N (kqf, Ib) I 9.22 (0.94, 2.07) or less I
ing system)
Regular pressure kPa (kg/cm2,psi) 981 (IO,142) or less
Relief pres- "+TURBO kPa (kg/cm2, psi) 7,355 (75, 1,067)
sure TURBO kPa (kg/cm2, psi) 7,845 (80, 1,138)
Steeringwheel At standstill with engine idling on a con- 31.4 (3.2, 7.1) or less
crete road N (kgf, Ib)
effort
(Power steer- At standstill with engine stalled on a
N (kgf, Ib) 294.2 (30, 66.2) or less
ing system) concrete road

Recommended power steering fluid

ATF DEXRON Ill

La CALTEX

MOBIL

TEXACO

PS-3
 GENERAL DESCRIPTION
POWER ASSISTED SYSTEM (POWER STEERING)

CAUTION:
This table lists various clearances that must be correctly adjusted to ensure normal vehicle driving
without interfering noise, or any other faults.

Location Minimum allowance

(1) Crossmember - Pipe 5 mm (0.20 in)
(2) DOJ - Shaft or joint 14 mm (0.55 in)
(3) DOJ - Valve housing 11 mm (0.43 in)
(4) Pipe - Pipe 2 mm (0.08 in)
(5) Stabilizer - Pipe 5 mm (0.20 in)
(6) Exhaust pipe - Pipe 11 mm (0.43 in)
(7) Exhaust pipe - Gearbox bolt 15 mm (0.59 in)
(8) Side frame - Hose A and B 10 mm (0.39 in)
(9) Cruise control Dump - Hose A and B 15 mm (0.59 in)
(IO)Pipe portion of hose A - Pipe portion of hose B 1.5 mm (0.059 in)
(1 1) AT cooling hose - Joint 20 mm (0.79 in)

ST0081

PS-4
 GENERAL DESCRIPTION
POWER ASSISTED SYSTEM (POWER STEERING)

B: COMPONENT
1. STEERING WHEEL AND COLUMN

STO10'

(1) Bushing (6) Steering wheel Tightening torque: N.m (kgf-m, ft-lb)
(2) Knee protector (7) Airbag module T1: 1.2 (0.72, 0.9)
(3) Steering shaft (8) Lower steering wheel cover T2: 3.4 (0.35, 2.5)
(4) Steering roll connector T3: 25 (2.5, 18.1)
(5) Column cover T4: 44 (4.5, 32.5)

PS-5
 GENERAL DESCRIPTION
POWER ASSISTED SYSTEM (POWER STEERING)

2. POWER ASSISTED SYSTEM

I TURBOMODEL
I I

STOlO2

PS-6
 GENERAL DESCRIPTION
POWER ASSISTED SYSTEM (POWER STEERING)

(1) Eye bolt (27) Pinion and valve ASSY (53) Rack
(2) Pipe C (28) Oil seal (54) Rack bushing
(3) Gasket (29) Back-up washer (55) Rack stopper
(4) Clip (30) Ball bearing (56) Circlip
(5) Pipe D (31) Snap ring (57) Suction hose
(6) Clamp E (32) Locknut (58) Tie-rod end plate
(7) O-ring (33) Adjusting screw (59) Clamp plate
(8) Cap (34) Spring
(9) Reservoir tank (35) Sleeve Tightening torque: N-m (kgf-m, ff-lb)
Reservoir tank bracket Adapter T1: 6 (0.6, 4.3)
Pulley Clamp T2: 7.4 (0.75, 5.4)
Oil pump Cotter pin T3: 8 (0.8, 5.8)
Bracket Castle nut T4: 13 (1.3, 9.4)
Belt tension nut Dust cover T5: 15(1.5, 10.8)
Bush Clip T6: 15(1.5, 10.8)
Belt cover Tie-rod end T7: 15.7(1.6, 11.6)
Pipe E Clip T8: 22 (2.2, 15.9)
Pipe F Boot T9: 24 (2.4, 17.4)
Clamp plate Band T10: 25 (2.5, 18.1)
Universal joint Tie-rod T11: 25 (2.5, 18.1)
Dust seal Lock washer T12: 27(2.75, 19.9)
Valve housing Pipe B T13: 37.3 (3.8,27.5)
Gasket Pipe A T14: 39 (4.0,28.9)
Oil seal Steering body T15: 59 (6.0, 43)
Ball bearing Oil seal T16: 78 (8.0, 58)
Seal ring Piston ring T17: 83 (8.5, 61.5)
T18: 25 (2.5, 18.1)

PS-7
 GENERAL DESCRIPTION
POWER ASSISTED SYSTEM (POWER STEERING)

3. OILPUMP
NON-TURBO MODEL

(1) Pulley (10) Pressure switch (19) O-ring

(2) Oil seal (11) O-ring (20) Rear cover
(3) Shaft (12) O-ring (21) Suction connector
(4) Connector (13) Pressure plate
(5) O-ring (14) Straight pin Tightening torque: N.m (kgf-m, ft-lb)
(6) Spool valve (15) Vane T1: 21 (2.14, 15.5)
(7) Spring (16) Rotor T2: 49 (5.0, 36.2)
(8) O-ring (17) Cam ring T3: 52 (5.3, 38)
(9) Front casing (18) Retaining ring

PS-8
 GENERAL DESCRIPTION
POWER ASSISTED SYSTEM (POWER STEERING)

TURBO MODEL

STOOOl

Lead wire Front casing (17) O-ring

Pump switch Flow control spring
Rear cover Flow control valve Tightening torque: N.m (kgf-m, ft-lb)
O-ring Pulley T1: 9.8 (1.0, 7.2)
Cam Oil seal T2: 27 (2.75, 19.9)
Pressure plate Suction connector T3: 27.4 (2.8,20.3)
O-ring O-ring T4: 59 (6.0, 43)
Front casing Retaining ring T5: 11.8 (1.2, 8.7)

PS-9
I
GENERAL DESCRIPTION
POWER ASSISTED SYSTEM (POWER STEERING)

C: CAUTION
Wear working clothing, including a cap, protec-
tive goggles, and protective shoes during opera-
tion.
Remove contamination including dirt and corro-
sion before removal, installation or disassembly.
Keep the disassembled parts in order and pro-
tect them from dust or dirt.
Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary re-
moval, installation, disassembly and replacement.
Be careful not to burn your hands, because each
part on the vehicle is hot after running.
Use SUBARU genuine steering fluid, grease etc.
or the equivalent. Do not mix steering fluid, grease
etc. with that of another grade or from other manu-
fact urers.
Be sure to tighten fasteners including bolts and
nuts to the specified torque.
Place shop jacks or safety stands at the specified
points.
Apply steering fluid onto sliding or revolution sur-
faces before installation.
Before installing O-rings or snap rings, apply suf-
ficient amount of steering fluid to avoid damage
and deformation.
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.

PS-10
 1
GENERAL DESCRIPTION
POWER ASSISTED SYSTEM (POWER STEERING)

D: PREPARATION TOOL
1. SPECIAL TOOLS

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

I25700000 VRENCH Used for removing and installing tie-rod.
Apply this tool to rack.

B4M2411
325711000 'RESSURE Used for measuring oil pump pressure.
3AUGE

84M241: ~

926200000 STAND Used when inspecting characteristic of gearbox

assembly and disassembling it.

B4M241
34099AC010 ADAPTER HOSE A 1 Used with PRESSURE GAUGE (925711000).

PS-11
 GENERAL DESCRIPTION
POWER ASSISTED SYSTEM (POWER STEERING)

I ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

34099FA100 STAND BASE Used for assembling power steering gearbox.
For LHD model.

r G1H0273
34099AC020 ADAPTER HOSE B Used with PRESSURE GAUGE (925711000).

r 04M2415
326230000 SPANNER For the lock nut when adjusting backlash of
gearbox.

04M2416
~

34099PA100 SPANNER Measurement of rotating resistance of gear-

box assembly.

I ST0047

PS-12
 GENERAL DESCRIPTION
POWER ASSISTED SYSTEM (POWER STEERING)

ILLUSTRATION I TOOLNUMBER
134199AE020
For TURBO model.

B4M247 7
14199AE030 NSTALLER Jsed for installing oil seal into oil pump.

34199AE040 31L CHARGE K e d for charging power steering oil.

SUIDE

B4M241$
927640000 INSTALLER B Used for installing ball bearing into housing.

B4M242

PS-13
 GENERAL DESCRIPTION
POWER ASSISTED SYSTEM (POWER STEERING)

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

926370000 INSTALLER A Used for installing valve assembly into valve
housing assembly.
Used with STAND BASE (927630000).

84M2421
~~~ ~

926390001 COVER & Used for assembling rack assembly.

REMOVER ASSY

84M2422
926420000 PLUG When oil leaks from pinion side of gearbox
assembly, remove pipe B from valve housing,
attach this tool and check oil leaking points.

04M2423
926400000 GUIDE Right side of rack when installing rack bush.
Used with GUIDE (927660000).

84M2424

PS-14
 GENERAL DESCRIPTION
POWER ASSISTED SYSTEM (POWER STEERING)

ILLUSTRATION TOOL NUMBFR

-. . DESCRIPTION REMARKS
927660000 GUIDE Right side of rack when installing rack bush.
Used with GUIDE (926400000).

B4M242!
~

927620000 INSTALLER B b Used for installing oil seal of valve housing.

b Used with INSTALLER A (926360000).

B4M242E
326360000 INSTALLER A ' Used as a guide to install oil seal.
1 Used with INSTALLER B (927620000).

04M2420
INSTALLER Jsed for installing oil seal.

B4M2429

PS-15
 GENERAL DESCRIPTION
POWER ASSISTED SYSTEM (POWER STEERING)

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

34099FA120 INSTALLER AND Used for installing and removing valve housing
REMOVER SEAL oil seal.

SI H0030
34099FA130 INSTALLER SEAL Used for installing valve housing oil seal.
Used with INSTALLERAND REMOVER SEAL
(34099FA120).

ST0007
34199AE050 REMOVER OIL Used for removing back-up ring and oil seal.
SEAL

84M2432
34099AC030 INSTALLER A Used for installing retaining ring.
Used with INSTALLER B (34099AC040).
For non-turbo model.

H4M1408

PS-16
 GENERAL DESCRIPTION
POWER ASSISTED SYSTEM (POWER STEERING)

TOOL NUMBER DESCRIPTION REMARKS

ILLUSTRATION
34099AC040 INSTALLER B Used for installing retaining ring.
Used with INSTALLER A (34099AC030).
For non-turbo model.

H4M140E

PS-17
 GENERAL DESCRIPTION
POWER ASSISTED SYSTEM (POWER STEERING)

2. GENERAL PURPOSE TOOLS

~ -

Spring scale Used for measuring tightening torque.

Snap ring pliers Used for removina and installina snaD rina.
. . . I

I
I
I

Dial gauge I Used for measuring steering gearbox.

PS-18

STEERING WHEEL
2. Steering Wheel
A: REMOVAL
1) Disconnect the ground terminal from battery.
2) Set the tires to straight-ahead position.
3) Remove the airbag module. <Ref. to AB-12, RE-
MOVAL, Driver’s Airbag Module.>
WARNING:
Always refer to “Air Bag System” before per-
forming airbag module service. <Ref. to AB-12,
CAUTION, Driver’s Airbag Module.>
4) Remove the steering wheel nut, and then draw
out the steering wheel from the shaft using steering
puller.
NOTE:
Make the matching marks on the steering wheel
and steering column in advance.
(1) Matching mark
PS-19
I
POWER ASSISTED SYSTEM (POWER STEERING)
B: INSTALLATION
1) Align the center of roll connector. <Ref. to AB-17,
ADJUSTMENT, Roll Connector.>
2) Install in the reverse order of removal.
NOTE:
Align the matching marks on the steering wheel
and steering column.
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)
WARNING:
Always refer to “Air Bag System” before per-
forming airbag module service. <Ref. to AB-12,
CAUTION, Driver’s Airbag Module.>
CAUTION:
Insert the roll connector guide pin into the
guide hole on lower end of surface of steering
wheel to prevent damage. Draw out the airbag
system connector, horn connector and cruise
control connectors from the guide hole of
steering wheel lower end.
C: INSPECTION
1) Check the steering wheel for deformation. If the
deformation is excessive, replace the steering
wheel.
2) Check the splines on the steering wheel for dam-
age. If the damage is excessive, replace the steer-
ing wheel.
 UNIVERSAL JOINT
POWER ASSISTED SYSTEM (POWER STEERING)

3. Universal Joint B: INSTALLATION

1) Install the universal joint.
A: REMOVAL (1) Align the cutout at serrated section of the
1) Remove the steering wheel. <Ref. to PS-19, RE- column shaft and yoke, then insert the universal
MOVAL, Steering Wheel.>
2) Remove the universal joint bolts and then re-
move the universal joint.
CAUTION:
Scribe alignment marks on universal joint so
that it can be reassembled at the original serra-
tion.

(1) cutout
(2) Yoke
(3) Column shaft
(4) Column shaft side
(5) Gearbox side

(2) Align the bolt hole on the gearbox side of

universal joint with the cutout at the serrated
section of gearbox assembly. Lower the univer-
sal joint completely.
(3) Temporarily tighten the bolt on the gearbox
side. Raise the universal joint to make sure the
bolt is properly passing through the cutout at the
serrated section.
(4) Tighten the bolt.
Tightening torque:
24 N-m (2.4 kgf-m, 17.4 ff-lb)
CAUTION:
Make sure that universal joint bolt is tight-
ened through notch in shaft serration.
Excessively large tightening torque of uni-
versal joint bolts may lead to heavy steering
wheel operation.
Standard clearance between gearbox to DOJ:
Over 14 mm (0.55 in)

PS-20
 UNIVERSAL JOINT I
POWER ASSISTED SYSTEM (POWER STEERING)

2) Align the center of roll connector. <Ref. to AB-1 7,

ADJUSTMENT, Roll Connector.>
CAUTION:
Ensure that front wheel are set straight forward
direction.
3) Install the steering wheel and airbag module.
<Ref. to PS-19, INSTALLATION, Steering Wheel.>
WARNING:
Always refer to “Air Bag System” before per-
forming airbag module service. <Ref. to AB-12,
CAUTION, Driver’s Airbag Module.> and <Ref.
to AB-12, INSTALLATION, Driver‘s Airbag Mod-
ule.>

PS-21
 UNIVERSAL JOINT
POWER ASSISTED SYSTEM (POWER STEERING)

C: INSPECTION
Clean the disassembled parts with a cloth, and check for wear, damage, or any other faults. If necessary, re-
pair or replace faulty parts.

Inspection Corrective action

Free play
Swinging torque
Yawing torque
Looseness

1 Yawing torque

Replace if faulty.

Looseness
G4M0089

Standard value of universal joint free play: 0 mm (0 in)

Max. value of universal joint swinging torque: 0.3 N.m (0.03 kgf-m, 0.2 ft-lb)
Measurement of folding torque of universal joint is Service limit:
as shown in the figures. Maximum load; 7.3 N (0.74 kgf, 1.64 lb) or less
Service limit:
Maximum load; 7.3 N (0.74 kgc 1.64 lb) or less

S4M0445A

(1) Yoke (Steering column side)

S4M0443A

Service limit:
(1) Yoke (gearbox side)
Maximum load; 7.3 N (0.74 kgf, 1.64 lb) or less
Service limit:
Maximum load; 7.3 N (0.74 kgf, 1.64 lb) or less

S4M0446A

. ,, .
S4M0444A
(1) Yoke (Steering column side)

(1) Yoke (gearbox side)

PS-22
 TILT STEERING COLUMN I
POWER ASSISTED SYSTEM (POWER STEERING)

4. Tilt Steering Column

A: REMOVAL

ST0022

(1) Tilt steering column Tightening torque: N.m (kgf-m, ft-lb)

(2) Universal joint T1: 24 (2.4, 17.4)
12: 25 (2.5, 18.1)
1) Set the vehicle on the lift. 5 ) Remove the universal joint. .=Ref.to PS-20, RE-
2) Disconnect the battery ground terminal. MOVAL, Universal Joint.>
3) Remove the airbag module. <Ref. to AB-12, RE- 6) Remove the trim panel under instrument panel.
MOVAL, Driver’s Airbag Module.>
WARNING:
Always refer to “Air Bag System” before per-
forming airbag module service. <Ref. to AB-12,
CAUTION, Driver’s Airbag Module.>
4) Remove the steering wheel. <Ref. to PS-19, RE-
MOVAL, Steering Wheel.>

PS-23
I TILT STEERING COLUMN
POWER ASSISTED SYSTEM (POWER STEERING)
7) Remove the screw securing lower steering col-
umn cover.
1654
- w
8) Remove the knee bolster
9) Remove all connectors from the steering col-
umn.
10) Remove the two bolts under instrument panel
securing steering column.
11) Pull out the steering shaft assembly from the
hole on toe board.
CAUTION:
Be sure to remove the universal joint before re-
moving steering shaft assembly installingbolts
when removing steering shaft assembly or
when lowering it for servicing of other parts.
PS-24
B: INSTALLATION
1) Set the grommet to the toe board.
// B4M1656
2) Insert the end of steering shaft into the toe board
grommet.
3) Tighten the steering shaft mounting bolts under
instrument panel.
Tightening torque:
25 N-m (2.5 kgf-m, 78.7 fWb)
4) Install the knee bolster.
5) Connect all connectors under instrument panel.
6) Connect the airbag system connector at the har-
ness spool.
NOTE:
Make sure to apply double lock.
7) Install the lower column cover with tilt lever held
in the lowered position.
8) Install the universal joint. <Ref. to PS-20, IN-
STALLATION, Universal Joint.>
9) Align the center of roll connector. <Ref. to AB-17,
ADJUSTMENT, Roll Connector.>
CAUTION:
Ensure that front wheels are set in straight for-
ward direction.
 TILT STEERING COLUMN I
POWER ASSISTED SYSTEM (POWER STEERING)

10) Install the steering wheel. <Ref. to PS-19, IN- C: DISASSEMBLY

STALLATION, Steering Wheel.>
Set the steering wheel to neutral and install it onto
steering shaft.
CAUTION:
Insert roll connector guide pin into guide hole
on lower end of surface of steering wheel to
prevent damage. Draw out airbag system con-
nector, horn connector and cruise control con-
nectors from guide hole of steering wheel lower
end.
11) Install the airbag module to the steering wheel.
WARNING:
Always refer to “Air Bag System” before per-
forming the service operation. <Ref. to AB-12,
CAUTION, Driver’s Airbag Module.>
Remove the two screws securing upper steering
column covers, and the two screws securing com-
bination switch, then remove the related parts.
D: ASSEMBLY
1) Insert the combination switch to the upper col-
umn shaft, and install the upper column cover.
Then route the ignition key harness and combina-
tion switch harness between column cover mount-
ing bosses.
Tightening torque:
1.2 N.m (0.12 kgf-m, 0.9 ft-lb)
CAUTION:
Don’t overtorque the screw.

E: INSPECTION
1. BASIC INSPECTION
Clean the disassembled parts with a cloth, and check d r wear, damage, or any other faults. necessary, re-
pair or replace faulty parts.

Inspection Corrective action

Overall length of steering column
Measure overall length of steering column.
Standard overall length of steering column:

Replace steering col-

umn assembly.

825.7f1.5” (32.51+0.059in)

ST0024

2. AIRBAG MODEL INSPECTION

WARNING:
For airbag model inspection procedures, refer
to “Air Bag System”. <Ref. to AB-12, CAUTION,
Driver’s Airbag Module.> and <Ref. to AB-12,
INSPECTION, Driver’s Airbag Module.>

PS-25
 STEERING GEARBOX
POWER ASSISTED SYSTEM (POWER STEERING)

5. Steering Gearbox 10) Remove the one pipe joint at the center of gear-
box, and connect the vinyl hose to the pipe and
A: REMOVAL joint. Discharge the fluid by turning steering wheel
1) Set the vehicle on the lift. fully clockwise and counterclockwise. Discharge
2) Disconnect the battery ground terminal. the fluid similarly from the other pipe.
3) Loosen the front wheel nuts.
4) Lift the vehicle and remove the front wheels.
5) Remove the under cover.
6) Remove the sub frame. <Ref. to FS-16, RE-
MOVAL, Sub Frame.>
7) Remove the front exhaust pipe assembly. (Non-
TURBO model)
<Ref. to EX(S0HC)-5, REMOVAL, Front Exhaust
Pipe.>
WARNING:
Be careful, exhaust pipe is hot.
8) Using a puller, remove the tie-rod end from the (1) PipeA
knuckle arm after pulling off cotter pin and remov- (2) Pipe B
ing castle nut.
11) Remove the universal joint. <Ref. to PS-20,
REMOVAL, Universal Joint.>
12) Disconnect the pipes C and D from the pipe of
gearbox.
CAUTION:
Be careful not to damage these pipes.
NOTE:
Disconnect the upper pipe D first, and lower pipe C
second.

(1) Castle nut

(2) Tie-rod end
(3) Knuckle arm

9) Remove the jack-up plate and front stabilizer.

(1) Pipe C
(2) Pipe D

(1) Jack-up plate

PS-26
 STEERING GEARBOX
13) Remove the clamp bolts securing gearbox to
the crossmember, and remove the gearbox.
(1) Clamp
B: INSTALLATION
1) Insert the gearbox into the crossmember, being
careful not to damage gearbox boot.
2) Tighten the gearbox to the crossmember bracket
via clamp with bolt to the specified torque.
Tightening torque:
59 N-m (6.0 kgf-m, 43 ff-16)
(1) Clamp
3) Install the four pipes on the gearbox.
(1) Connect the pipes A and B to the four pipe
joints of gearbox. Connect the upper pipe B first,
and lower pipe A.
Tightening torque:
13 N.m (1.3 kgf-m, 9.4 ft-16)
PS-27
9
POWER ASSISTED SYSTEM (POWER STEERING)
(2) Connect the pipes C and D to the gearbox.
Connect the upper pipe D first, and lower pipe C
second.
Tightening torque:
15 N.m (1.5 kgf-m, 10.8 ft-16)
(1) Pipe C
(2) Pipe D
4) Install the universal joint. <Ref. to PS-20, IN-
STALLATION, Universal Joint.>
5 ) Connect the tie-rod end and knuckle arm, and
tighten with castle nut. Fit the cotter pin into the nut
and bend the pin to lock.
Castle nut tightening torque:
Tighten to 27.0 N.m (2.75 kgf-m, 19.9 ft-lb),
and tighten further within 60" until cotter pin
hole is aligned with a slot in the nut.
CAUTION:
When connecting, do not hit cap at the bottom
of tie-rod end with hammer.
/, S4M0379A
(1) Castle nut
(2) Tie-rod end
(3) Knuckle arm
6) Install the front stabilizer to vehicle.
7) Install the front exhaust pipe assembly.
8) Install the sub frame. <Ref. to FS-16, INSTALLA-
TION, Sub Frame.>
 STEERING GEARBOX
POWER ASSISTED SYSTEM (POWER STEERING)

9) Align the center of roll connector. <Ref. to AB-17, 1. RACK HOUSING ASSEMBLY
ADJUSTMENT, Roll Connector.>
1) Disconnect the four pipes from the gearbox.
CAUTION:
NOTE:
Ensure that front wheels are set in straight for-
Remove the pipes E and F as a single unit being
ward direction.
fixed at the clamp plate.
10) Install the steering wheel. <Ref. to PS-19, IN-
STALLATION, Steering Wheel.> 2) Secure the gearbox removed from the vehicle in
vice using ST.
11) Install the tires.
ST 926200000 STAND
12) Tighten the wheel nuts to the specified torque.
CAUTION:
Tightening torque: Secure the gearbox in a vice using the ST as
90 N-m (9.7 kgf-m, 66 ff-lb) shown. Do not attempt to secure it without this
13) Connect the ground terminal to battery. ST.
14) Pour the fluid into the oil tank, and bleed air.
<Ref. to PS-72, Power Steering Fluid.>
15) Check for fluid leaks.
16) Install the jack-up plate.
17) Lower the vehicle.
18) Check the fluid level in oil tank.
19) After adjusting toe-in and steering angle, tight-
en the lock nut on tie-rod end.
Tightening torque:
83 N-m (8.5 kgf-m, 61.5 ff-lb)
S4M0143A
CAUTION:
When adjusting toe-in, hold the boot as shown 3) Remove the tie-rod end plate.
to prevent it from being rotated or twisted. If
twisted, straighten it.

I ST0084

4) Remove the tie-rod end and lock nut from the

G4M0132 gearbox.
5 ) Remove the small clip from the boot using pliers,
C: DISASSEMBLY and move the boot to the tie-rod end side.
NOTE:
Parts requiring replacement are described in the
smallest unit of spare parts including damaged
parts and spare parts damaged. In actual disas-
sembly work, accidental damage as well as inevita-
ble damage to some related parts must be taken
into account, and spare parts for them must also be
prepared. However, it is essential to pinpoint the
cause of trouble, and limit the number of replace-
ment parts as much as possible.
I S4M01448

(1) Clip

PS-28
 1
STEERING GEARBOX
POWER ASSISTED SYSTEM (POWER STEERING)

6) Using standard screwdriver, remove the band 9) Tighten the adjusting screw until it no longer
from the boot. tightens.

S4M0145C S4M0140

10) Using a wrench [32mm (1.26in) width across

(1) Band
7) Extend the rack approximately 40 mm (1.57in)
out. Unlock the lock wire at lock washer on each
side of tie-rod end using a standard screwdriver.
CAUTION:
Be careful not to scratch rack surface as oil
leaks may result.
flats] or adjustable wrench, remove the tie-rod.
CAUTION:
Check ball joint for free play, and tie-rod for
bends. Replace if necessary.
Check dust seals used with tie-rod end ball
joint for damage or deterioration. Replace if
necessary.

-
40 mm (1.57 in)

S4M0146C
11) Loosen the adjusting screw and remove the
(1) Lock washer spring and sleeve.
8) Usina ST. loosen the lock nut. CAUTION:
ST 9F6230OOO SPANNER Replace spring and/or sleeve if damaged.
12)Remove the two bolts securing valve assembly.

S4M0147C
S4M0154

PS-29
I STEERING GEARBOX
a
POWER ASSISTED SYSTEM (POWER STEERING)

13) Carefully draw out the input shaft and remove
the valve assembly.
16) Remove the rack bushing and rack stopper
from the rack assembly.
CAUTION:
Do not reuse removed rack bushing and circlip.
17) Remove the oil seal from rack.
18) Insert ST from the pinion housing side and re-
move the oil seal using a press.
ST 34099FA110 INSTALLER

14) Using a sharp pointed pliers, rotate the rack

stopper in the direction of the arrow until the end of
the circlip comes out of the stopper. Rotate the cir-
clip in the opposite direction and pull it out.

(1) Rack stopper

L A S4M01638
15) Pull the rack assembly from the cylinder side,
and draw out the rack bushing and rack stopper to- (1) Press
gether with the rack assembly. (2) Oil seal
CAUTION:
NOTE:
Be careful not to contact rack to inner wall of
cylinder when drawing out. Any scratch on cyl- Discard the removed the oil seal.
inder inner wall will cause oil leakage.

(3)
S4M0402A

(1) Rack bushing

(2) RackASSY
(3) Rack stopper

PS-30
 1
STEERING GEARBOX
POWER ASSISTED SYSTEM (POWER STEERING)

2. CONTROL VALVE 5) Loosen the adjusting screw and remove the

spring and sleeve.
1) Disconnect the four pipes from the gearbox.
CAUTION:
NOTE:
Replace the spring and/or sleeve if damaged.
Remove the pipes E and F as a single unit being
fixed at the clamp plate. 6) Remove the two bolts securing valve assembly.
2) Secure the gearbox removed from the vehicle in
vice using ST.
ST 926200000 STAND
CAUTION:
Secure the gearbox in a vice using the ST as
shown. Do not attempt to secure it without this
ST.

I S4M0154 I

7) Carefully draw out the input shaft and remove

the valve assembly.

S4M0143P

3) Usina ST, loosen the lock nut.

ST 926230000 SPANNER

8) Slide the dust cover out.

T008!

4) Tighten the adjusting screw until it no longer

tightens.

S4M01568

(1) Dust cover

PS-31
I STEERING GEARBOX
POWER ASSISTED SYSTEM (POWER STEERING)

9) Using a press remove pinion and valve assem-
bly from the valve housing.
11) Remove the snap ring using snap ring pliers.
CAUTION:
Do not reuse removed snap ring.
Be careful not to scratch pinion and valve as-
sembly.

(3)-

S4M01578

(1) Valve ASSY

(2) Valve housing
(3) Cloth
12) Press out the bearing together with the back up
10) Using ST and press, remove the dust seal, oil washer using pipe of I.D. 38.5 to 39.5 mm (1.516 to
seal and special bearing from the valve housing. 1.555 in) and press.
ST 34099FA120 INSTALLER & REMOVER
SEAL CAUTION:
Do not reuse removed bearing.
CAUTION:
Do not apply a force to end surface of valve
housing.
Do not reuse oil seal after removal.

S4M0159B

(1) Oil seal

(2) Special bearing

S4M0403A

(1) Bearing
(2) Backing washer
(3) Oil seal
(4) Pipe

13) Remove the oil seal.

CAUTION:
Do not reuse removed oil seal.

PS-32
 m
STEERING GEARBOX
POWER ASSISTED SYSTEM (POWER STEERING)

D: ASSEMBLY Do not apply grease to threaded portion at

1. RACK HOUSING ASSEMBLY
CAUTION:
Use only SUBARU genuine grease for gearbox.
Specified grease for gearbox:
VALIANT GREASE M2 (Part No. 003608001)
1) Clean all parts and tools before reassembling.
2) Force-fit oil seal using ST.
ST 34099FA110 INSTALLER
CAUTION:
Be careful not to damage or scratch cylinder in-
ner wall.
NOTE:
Apply specified power steering fluid to oil seal.
Pay special attention not to install oil seal in
wrong direction.
Push oil seal until the stepped portion of A con-
tacts end face of B.
end of rack shaft.
Move rack shaft to stroke end two (2) or three
(3) times to squeeze grease which accumulates
on both ends. Remove grease to prevent it from
choking air passage hole.
4) Apply grease to the sleeve insertion hole.
5) Apply grease to the dust seal insertion hole.
CAUTION:
Apply clean grease with clean hands. If material
having a sharp edge is used for applying
grease, oil seal at the inside might be damaged.
6) Fixing rack housing
Fix the rack housing in vice using ST.
ST 926200000 STAND
CAUTION:
When fixing rack housing in vice, be sure to
use this special tool. Do not fix rack housing in
vice using pad such as aluminum plates, etc.
When using old rack housing, be sure to
clean and remove rust before assembling.
Check pinion housing bushing carefully.
7) Install the oil seal to rack.
8) Fit ST over toothed portion of rack assembly,
and check for binding or unsmooth insertion. If any
deformation is noted on flats at the end of rack,
shape bv using file, and wash with cleaning fluid.
ST 926390061
' COVER & REMOVER

(1)
S4M0406A

(1) Rack ASSY

S4M01648
9) Apply genuine grease to the teeth of thoroughly
washed rack assembly, and fit ST over the toothed
(1) Press
portion.
(2) Oil seal
CAUTION:
3) Apply grease to the teeth of rack so that the Be careful not to block air passage with
grease applied is about as high as teeth, and also grease. Remove excessive grease.
apply a thin film of grease to the sliding portion of After fitting cover, check air passage hole for
rack shaft. clogging. If clogged, open by removing grease
CAUTION: from the hole.
When moving rack to stroke end without tie- Check rack shaft for damage.
rod attached, prevent shocks from being ap- Apply specified power steering fluid to this
plied at the end. ST and surface of piston ring to prevent seal
from being damaged.

PS-33
 STEERING GEARBOX
POWER ASSISTED SYSTEM (POWER STEERING)

10) Insert the rack assembly into the rack housing 13) Insert the rack stopper into the rack housing,
from cylinder side, and remove ST after it has and wrap the circlip using a sharp pointed pliers to
passed completely through oil seal. secure the rack stopper in position.
NOTE: CAUTION:
Before inserting rack assembly, apply a coat of Be careful not to scratch rack while winding cir-
specified power steering fluid to surfaces of ST and clip.
rack piston. NOTE:
ST 926390001 COVER & REMOVER Rotate the wrench another 90 to 180" after the end
11) Fit ST1 and ST2 over the end of rack, and in- of circlip has been wrapped in.
stall rack bushing.
STl 926400000 GUIDE
ST2 927660000 GUIDE
CAUTION:
If burrs, or nicks are found on this guide and
rack shaft portion, remove by filing.
Dip rack bushing in specified power steering
fluid before installing, and pay attention not to
damage O-ring and oil seal.
S4M0167

14) Fit the mounting rubber onto the rack housing.

15) Apply the specified grease to the dust cover.

(1) Rack bushing ASSY

12) Insert the rack stopper into the cylinder tube un-
til internal groove (on cylinder side) is aligned with I S4M0166A I

external groove (on rack stopper). Turn the rack 16) Install the dust cover on the valve assembly.
stopper with ST so that the rack stopper hole is 17) Apply genuine grease to the pinion gear and
seen through cylinder slits. bearing of valve assembly.

G4M0158

PS-34
 STEERING GEARBOX
9
POWER ASSISTED SYSTEM (POWER STEERING)

18) Install the gasket on the valve assembly. Insert 21) Install the lock washers and tighten the left and
the valve assembly into the place while facing rack right tie-rods into the rack ends.
teeth toward pinion.
On condition
CAUTION: L: Approximately 40 mm (1.57 in)
Be sure to use a new gasket.
Tightening torque:
NOTE: 78 N-m (8.0 kgf-m, 58 ft-16)
Do not allow packing to be caught when installing
valve assembly.

S4M01.508

. S4M0155 (1) Tie-rod

19) Tighten the bolts alternately to secure the valve 22) Bend the lock washer using a chisel.
assembly.
CAUTION:
Tightening torque: Be careful not to scratch rack when bending
25 N.m (2.5 kgf-m, 18.1 ft-16) lock washer.
CAUTION:
Be sure to alternately tighten bolts.
20) Apply grease to the sliding surface of sleeve
and spring seat, then insert the sleeve into the pin-
ion housing. Fit the spring into the sleeve screw,
pack grease inside of screw, then install the screw. r

' S4M0384A

(1) Lock washer

B4M1129B

(1) Adjusting screw

(2) Spring
(3) Sleeve

PS-35
 STEERING GEARBOX
POWER ASSISTED SYSTEM (POWER STEERING)

23) Rack and pinion backlash adjustment (7) Install the lock nut. While holding adjusting
(1) Loosen the adjusting screw. screw with a wrench, tighten the lock nut using
(2) Rotate the input shaft so that the rack is in ST.
the straight ahead direction. ST 926230000 SPANNER
(3) Apply grease to the sleeve. Tightening torque (Lock nut):
39 N-m (4.0 kgf-m, 29 f?-lb)
I I NOTE:
P- Hold the adjusting screw with a wrench to pre-
vent it from turning while tightening lock nut.
Make adjustment so that the steering wheel can
be rotated fully from lock to lock without binding.
24) Check for service limit as per article of “Service
limit”.cRef. to PS-42, INSPECTION, Steering
Gearbox.> Make replacement and adjustment if
I B4M1130B necessary.
25) Install the boot to the housing.
(1) Adjusting screw NOTE:
(2) Lock nut Before installing boot, be sure to apply grease to
(3) Spring the groove of tie-rod.
(4) Sleeve Install fitting portions of boots to the following
portions in both sides of assembled steering gear-
(4) Tighten the adjusting screw by two threads. box.
I I The groove on gearbox
The groove on the rod
Make sure that the boot is installed without un-
usual inflation or deflation.

G4M0121

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

perimeter of adjusting screw thread.
Liquid packing:
S4M0151A
THREE BOND 1141

I S4M0385A

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

perimeter.

(6) Tighten the adjusting screw to 7.4 N.m (0.75

kgf-m, 5.4 ft-lb) and back off 25”.

PS-36
 STEERING GEARBOX
il
POWER ASSISTED SYSTEM (POWER STEERING)

26) Using a screwdriver, tighten the screw until the 28) If the tie-rod end was removed, screw in lock
ends “ A and “6”of the band come into contact with nut and tie-rod end to the screwed portion of tie-
each other. rod, and tighten the lock nut temporarily in a posi-
CAUTION: tion as shown in figure.
Use a new band. Installed tie-rod length: L
NOTE: 15 mm (0.59 in)
Always tighten the band from the underside of the NOTE:
gear box. Pay attention to difference between right and left
tie-rod ends.

A L
r-

S4M0152A
G4M0126
27) Fix the boot end with clip (small).
CAUTION: 29) Install the tie-rod end plate.
After installing, check boot end is positioned Tightening torque:
into groove on tie-rod. 13 N.m (1.3 kgf-m, 9.4 ft-lb)
30) Inspect the gearbox as follows:
“ A Holding tie-rod end, repeat lock to lock two or
three times as quickly as possible.
“ B Holding tie-rod end, turn it slowly at a radius one
or two times as large as possible.
After all, make sure that the boot is installed in the
specified position without deflation.

S4M0144B

(1) Clip

G4M0127

31) Remove gearbox from ST.

ST 926200000 STAND
32) Install the four pipes on gearbox.
(1) Connect the pipe A and B to the four pipe
joints of gearbox.
Tightening torque:
13 N-m (1.3 kgf-m, 9.4 ft-lb)
(2) Connect the pipe E and F to the gearbox.
Tightening torque:
Pipe E: 15 N.m (1.5 kgf-m, 10.8 ft-lb)
Pipe F: 25 N.m (2.5 kgf-m, 18.1 ft-lb)

PS-37
I
STEERING GEARBOX
POWER ASSISTED SYSTEM (POWER STEERING)

2. CONTROL VALVE ASSEMBLY 4) Using ST and press, install the special bearing in
valve housing.
Specified steering grease: ST 34099FA120 INSTALLER & REMOVER
VALIANT GREASE M2 (Part No. 003608001) SEAL
1) Clean all parts and tools before reassembling.
2) Apply a coat of specified power steering fluid to NOTE:
the inner wall of valve housing. To facilitate installation, attach the ball bearing to
the remover and position in valve housing before
pressing it into place.

I Fluid I S4M0162A

3) Attach ST2 to STI , and press the oil seal into the S4M0161B
place using a press.
STI 34099FA120 INSTALLER & REMOVER (1) Special bearing
SEAL (2) Oil seal
ST2 34099FA130 INSTALLER SEAL
(1) Face oil seal in the direction shown in figure 5 ) Put vinyl tape around pinion shaft splines to pro-
when installing. tect oil seal from damage.
(2) To avoid scratching oil seal, apply a coat of 6) Fit pinion and valve assembly into valve housing.
grease to the contact surface of installer and oil 7) Secure valve assembly to ST1 and ST2.
seal.
(3) To facilitate installation, attach oil seal to the
installer and position in valve housing before
pressing into place.

I S4M0160A

PS-38
 II
STEERING GEARBOX
POWER ASSISTED SYSTEM (POWER STEERING)

8 ) Put ST3 over pinion, and insert oil seal, then 10) Force-fit ball bearing using ST3.
force-fit oil seal into housing using ST4. ST1 926370000 INSTALLER A
ST1 926370000 INSTALLER A ST2 34099FA100 STAND BASE
ST2 34099FA100 STAND BASE ST3 927640000 INSTALLER B
ST3 926360000 INSTALLER A
ST4 927620000 INSTALLER B
I .

S4M04051

(1) Ball bearing

(2) Backing washer

NOTE:
Be careful not to tilt ball bearing during installation.
11) Install the snap ring using snap ring pliers.
NOTE:
Rotate the snap ring to check for proper installa-
tion.
12) Apply the specified grease to the dust cover.

S4M0404A

(1) Oil seal

NOTE:
Apply the specified power steering fluid to the oil
seal and ST3, being careful not to damage oil seal
lip.
Push the oil seal until ST3 contacts housing end
face. I S4M01566
9) Remove ST3, and fit backing washer.
(1) Dust cover

13) Install the dust cover on the valve assembly.

14) Apply genuine grease to the pinion gear and
bearing of valve assembly.

G4M0150

PS-39
 STEERING GEARBOX
POWER ASSISTED SYSTEM (POWER STEERING)

15) Install the gasket on the valve assembly. Insert 20) Rack and pinion backlash adjustment
the valve assembly into the place while facing rack (1) Loosen the adjusting screw.
teeth toward pinion. (2) Rotate the input shaft so that the rack is in
CAUTION: the straight ahead direction.
Be sure to use a new gasket. (3) Apply grease to the sleeve.
NOTE:
Do not allow packing to be caught when installing
valve assembly.

_I
r I

B4M1130E

(1) Adjusting screw

(2) Locknut
(3) Spring
16) Tighten the bolts alternately to secure the valve (4) Sleeve
assembly.
(4) Tighten the adjusting screw by two threads.
Tightening torque:
25 N-m (2.5 kgf-m, 18.1 ff-lb)
CAUTION:
m I
Be sure to alternately tighten bolts.
17) Apply grease to the sleeve insertion hole.
18) Apply grease to the dust seal insertion hole.
CAUTION:
Apply clean grease with clean hands. If material
having a sharp edge is used for applying
grease, oil seal at the inside might be damaged. G4M0121
19) Apply grease to the sliding surface of sleeve
(5) Apply liquid packing to at least 1/3 of entire
and spring seat, then insert the sleeve into the pin- perimeter of adjusting screw thread.
ion housing. Fit the spring into the sleeve the
screw, pack grease inside of screw, then install the Liquid packing:
screw. THREE BOND 1141

(1) Adjusting screw

(2) Spring
(3) Sleeve
1 B4M1129B
'(1)

S4M03851

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

perimeter.

(6) Tighten the adjusting screw to 7.4 N-m(0.75

kgf-m, 5.4 ft-lb) and back off 25".

PS-40
 1
STEERING GEARBOX
POWER ASSISTED SYSTEM [POWER STEERING)

(7) Install the lock nut. While holding adjusting

screw with a wrench, tighten the lock nut using
ST.
ST 926230000 SPANNER
Tightening torque (Lock nut):
39 N-m (4.0 kgf-m, 29 ff-lb)
NOTE:
Hold the adjusting screw with a wrench to pre-
vent it from turning while tightening lock nut.
Make adjustment so that the steering wheel can
be rotated fully from lock to lock without binding.
21) Check for service limit as per article of “Service
limit”.<Ref. to PS-42, INSPECTION, Steering
Gearbox.> Make replacement and adjustment if
necessary.
22) Take off the gearbox from ST.
23) Install the four pipes on the gearbox.
(1) Connect the pipe A and 6 to the gearbox.
Tightening torque:
13 N-m (1.3 kgf-m, 9.4 ft-lb)
(2) Connect the pipe E and F to the gearbox.
Tightening torque:
Pipe E: 15 Nom(1.5 kgf-m, 10.8 ft-lb)
Pipe F: 25 N.m (2.5 kgf-m, 18.1 ft-lb)

PS-41
 STEERING GEARBOX
POWER ASSISTED SYSTEM (POWER STEERING)

E: INSPECTION
1. BASIC INSPECTION
1) Clean all disassembled parts, and check for wear, damage, or any other faults, then repair or replace as
necessary.
2) When disassembling, check inside of gearbox for water. If any water is found, carefully check boot for
damage, input shaft dust seal, adjusting screw and boot clips for poor sealing. If faulty, replace with new
parts.

No. Parts Inspection Corrective action

(1) Bend of input shaft
1 Input shaft
(2) Damage on serration
(1) Crack or damage
2 Dust seal
(2) Wear
If the bend or damage is excessive, replace the entire
gearbox.
If the outer wall slips, the lip is worn out or damage is
found. redace it with new one.
~~

(1) Adjust the backlash properly.

3 Rack and pinion Poor mating of rack with pinion
(1) Bend of rack shaft
(2) Bend of cylinder portion
(3) Crack or damage on cast iron
portion
4 Gearbox unit
(4) Wear or damage on rack bush
( 5 ) Wear on input shaft bearing
5 Boot Crack, damaae or deterioration
(1) Looseness of ball joint
6 Tie-rod
(2) Bend of tie-rod
Damage or deterioration on dust
7 Tie-rod end
seal
Adjusting screw
8 Deterioration
swing
9 Boot clip Deterioration
10 Sleeve Damage
(1) Damage to flared surface
11 Pipes (2) Damage to flare nut
(3) Damage to pipe
By measuring turning torque of gearbox and sliding resis-
tance of rack, check if rack and pinion engage uniformly
and smoothly with each other. (Refer to “Service limit”.)
(2) Keeping rack pulled out all the way so that all teeth
emerge, check teeth for damage.
Even if abnormality is found in either (1) or (2), replace
the entire aearbox.
Replace the gearbox with new one.
If the free play of rack shaft in radial direction is out of the
specified range, replace the gearbox with new one. (Refer
to “Service limit”.)
If the free plays of input shaft in radial and axial directions
are out of the specified ranges, replace the gearbox with
new one. (Refer to “Service limit”.)
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.

PS-42
 a
STEERING GEARBOX
POWER ASSISTED SYSTEM (POWER STEERING)

2. SERVICE LIMIT 3. RACK SHAFT PLAY IN RADIAL DIREC-

TION
Make a measurement as follows. If it exceeds
the specified service limit, adjust or replace. Right-turn steering:
NOTE: Service limit
When making a measurement, vise gearbox by us- 0.19 mm (0.0075 in) or less
ing ST. Never vise gearbox by inserting aluminum
plates, etc. between vise and gearbox. On condition
L: 5 mm (0.20 in)
ST 926200000 STAND
P: 122.6 N (12.5 kgf, 27.6 lb)
Sliding resistance of rack shaft:
Service limit
340 N (35 kgf, 76 lb) or less

Left-turn steering:
Service limit
Direction
0.3 mm (0.012 in) or less
Direction +I)
0.15 mm (0.0059 in) or less

G4M0110

G4M0112

PS-43
 STEERING GEARBOX
POWER ASSISTED SYSTEM (POWER STEERING)

4. INPUT SHAFT PLAY 5. TURNING RESISTANCE OF GEARBOX

In radial direction: Using ST, measure gearbox turning resistance.
Service limit ST 34099PA100 SPANNER
0.18 mm (0.0071 in) or less Service limit
On condition Maximum allowable resistance
P: 98 N (10 kg< 22 lb) Less than 12 N (1.2 kgf, 2.7 lb)

In axial direction:
Service limit
0.5 mm (0.020 in) or less
On condition
P:20-49N(2-5kgf,4- 11 lb)

PS-44
 STEERING GEARBOX
1
POWER ASSISTED SYSTEM (POWER STEERING)

6. OIL LEAKING

S4M0153A

(1) Power cylinder (3) Rack piston (5) Input shaft

(2) Cylinder (4) Rackaxle (6) Valve housing
NOTE: 2) Inspect leakage from “a”
If the gearbox is dismounted without confirming The oil seal is damaged. Replace the valve assem-
where the leak is, it must be mounted again to lo- bly with a new one.
cate the leak point. 3) Inspect leakage from “ b
1) Even if the location of the leak can be easily The torsion bar O-ring is damaged. Replace the
found by observing the leaking condition, it is nec- valve assembly with a new one.
essary to thoroughly remove the oil from the sus- 4) Inspect leakage from “c”
pected portion and turn the steering wheel from The oil seal is damaged. Replace the valve assem-
lock to lock about 30 to 40 times with engine run- bly or oil seal with a new one.
ning, then make comparison of the suspected por- 5 ) Inspect leakage from “d”
tion between immediately after and several hours The pipe is damaged. Replace the faulty pipe or 0-
after this operation. ring.

PS-45
I
STEERING GEARBOX
POWER ASSISTED SYSTEM (POWER STEERING)

6) If leak is other than a, b, c, or d, and if oil is leak- 2) Adjust the steering angle of wheels.
ing from the gearbox, move the right and left boots
Standard of steering angle:
toward tie-rod end side, respectively,with the gear-
box mounted to the vehicle, and remove oil from TURBO, Sedan,
Model Others
the surrounding portions. Then, turn the steering OUTBACK
wheel from lock to lock 30 to 40 times with the en-
gine running, then make comparison of the leaked
Inner wheel I 34'05' f 1.5" I 36'55' k 1.5"
Outer wheel I 29'35' f 1.5" I 31"35' f 1.5"
portion immediately after and several hours after
this operation. 3) If the steering wheel spokes are not horizontal
(1) Leakage from "e" when wheels are set in the straight ahead position,
The cylinder seal is damaged. Replace the rack and error is more than 5" on the periphery of steer-
bush with a new one. ing wheel, correctly re-install the steering wheel.
(2) Leakage from "f"
There are two possible causes. Take the follow- I -0 - 17 mm I
in)
ing step first. Remove the pipe assembly B from
the valve housing, and close the circuit with ST.
ST 926420000 PLUG
Turn the steering wheel from lock to lock 30 to
40 times with the engine running, then make
comparison of the leaked portion between im-
mediately after and several hours after this op-
eration.
SAhlni R 8 A
CAUTION:
If leakage from "f" is noted again: 4) If the steering wheel spokes are not horizontal
The oil seal of pinion and valve assembly is with vehicle set in the straight ahead position after
damaged. Replace pinion and valve assembly this adjustment, correct it by turning the right and
with a new one. Or replace the oil seal and the left tie-rods in the same direction by the same
parts that are damaged during disassembly turns.
with new ones.
If oil stops leaking from "f":
The oil seal of rack housing is damaged. Re-
place the oil seal and the parts that are dam-
aged during disassembly with new ones.
F: ADJUSTMENT
1) Adjust the front toe.
Standard of front toe:
IN 3 - OUT 1 mm (IN 0.12 - OUT 0.039 in)
G4M0135

(1) Locknut

PS-46
 PIPE ASSEMBLY 1
POWER ASSISTED SYSTEM (POWER STEERING)

6. Pipe Assembly 4) Remove the clamp E from pipes C and D.

A: REMOVAL
1) Disconnect the battery ground terminal.
2) Lift the vehicle and remove the jack-up plate.
I

(1) Jack-up plate

3) Remove one pipe joint at the center of gearbox,

and connect a vinyl hose to the pipe and joint. Dis-
charge the fluid by turning steering wheel fully
clockwise and counterclockwise. Discharge the flu-
S4M0437F
id similarly from the other pipe.
CAUTION: (1) Return hose
Improper removal and installation of parts often (2) Pressure hose
causes fluid leak trouble. To prevent this, clean (3) Clamp E
the surrounding portions before disassembly (4) Pipe C
and reassembly, and pay special attention to
(5) Pipe D
keep dirt and other foreign matter from mating
surfaces. 5) Disconnect the pipe C.D from the pipe (on the
gearbox side).
CAUTION:
When disconnecting pipe C-D, use two
wrenches to prevent deformities.
Be careful to keep pipe connections free from
foreign matter.

(1) Pipe A
(2) Pipe B

(1) Pipe C
(2) Pipe D

PS-47
 PIPE ASSEMBLY
POWER ASSISTED SYSTEM (POWER STEERING)

6 ) Non-TURBO model: (3) Remove the coolant filler tank.

(1) Remove the air intake duct. <Ref. to IN(S0-
HC)-7, REMOVAL, Air Intake Duct.>
(2) Remove the bolt A.
(3) Disconnect the pipe C from the oil pump.
(4) Disconnect the pipe D from the return hose.
CAUTION:
Do not allow fluid from the hose end to come
into contact with pulley belt.
To prevent foreign matter from entering the
hose and pipe, cover the open ends of them
with a clean cloth.

(4) Disconnect the pipe C from oil pump.

(1) Bolt A
(5) Disconnect the pipe D from the return hose.
(2) Pipe C
(3) Pipe D CAUTION:
Do not allow fluid from the hose end to come
7) TURBO model: into contact with pulley belt.
(1) Remove the air intake duct, air cleaner up- To prevent foreign matter from entering the
per cover and air intake boot. hose and pipe, cover the open ends of them
<Ref. to IN(D0HC TURBO)-8, REMOVAL, Air with a clean cloth.
Intake Duct.> and <Ref. to IN(D0HC TURBO)-
7, REMOVAL, Air Cleaner.>
(2) Remove the two bolts fixing pipe C and D.

(1) Pipe C
(2) Pipe D

PS-48
 PIPE ASSEMBLY 3
POWER ASSISTED SYSTEM (POWER STEERING)

B: INSTALLATION 2) Install the coolant filler tank. (Turbo model)

1) Temporarily tighten the bolts fixing pipe C and D.
CAUTION:
Visually check that hose between tank and pipe
D is free from bending or twisting.
Non-TURBO model
Tightening torque:
T7: 79 N.m (7.9 kgf-m, 73.7 ff-lb)
T2: 27 N.m (2.7 kgf-m, 75.2 ff-lb)

(1) Bolt A
(2) Pipe C
(3) Pipe D

TURBOmodel

(1) Pipe C
(2) Pipe D

(1) Connect the pipe D to oil tank.

(2) Install the pipe C to oil pump.
CAUTION:
Use a new gasket.
Tightening torque:
39 N.m (4.0 kgf-m, 28.9 ff-lb)
(3) Tighten bolts fixing pipe C and D.
Tightening torque:
73 N.m (7.3 kgf-m, 9.4 ff-lb)

PS-49
 PIPE ASSEMBLY
POWER ASSISTED SYSTEM (POWER STEERING)

3) Temporarily connect the pipes C and D to the
pipes (on the gearbox side).
5) Tighten the clamp E firmly.
Tightening torque:
7.4 N-m (0.75 kgf-m, 5.4 ft-lb)
6) Tighten the joint nut.
Tightening torque:
15 N.m (1.5 kgf-m, 10.8 ft-lb)
7) Connect the pipes A and B to the four pipe joints
of gearbox. Connect the upper pipe B first, and low-
er pipe A second.
Tightening torque:
13 N-m (1.3 kgf-m, 9.4 ft-lb)

I S4M0430A

(1) Pipe A
(1) Return hose
(2) Pipe B
(2) Pressure hose
(3) Approx. 30 mm (1.18 in) 8) Install the jack-up plate.
(4) Clamp E 9) Install the air intake duct. (Non-TURBO model).
(5) Pipe C <Ref. to IN(S0HC)-7, INSTALLATION, Air Intake
(6) Pipe D Duct.>
(7) Pipe (on gearbox side) 10) Install the air intake duct, air intake boot and air
cleaner upper cover. (TURBO model)
4) Temporarily install the clamp E on the pipes C <Ref. to IN(D0HC TURBO)-7, INSTALLATION, Air
and D. Cleaner.> and <Ref. to IN(D0HC TURBO)-8, IN-
CAUTION: STALLATION, Air Intake Duct.>
Ensure that the letter “8” on each clamp are di- 11) Connect the battery ground terminal.
agonally opposite each other as shown in fig-
ure.

I I

(1) Clamp E
(2) Pipe C

PS-50
 PIPE ASSEMBLY 1
POWER ASSISTED SYSTEM (POWER STEERING)

12) Feed the specified fluid.

NOTE:
Never start the engine before feeding the fluid; otherwise vane pump might be seized up.

S4M02728

(1) High-pressure hose (3) Clearance between crossmember

(2) No interferenceis allowed and pipe: 3 - 8 mm (0.12 - 0.31
between hoses. in)
13) Finally check clearance between pipes and/or
hoses, as shown above.
If the clearance between cruise control pump and
power steering hose is less than 10 mm (0.39 in),
proceed as follows:
(1) Move the clamped section (A) (refer to fig-
ure above.) down to a point where the pipe is
close to crossmember.
Pipe-to-crossmember clearance:
10 mm (0.39 in), min.
(2) Check that clearance between cruise con-
trol pump and power steering hose is at least 10
mm (0.39 in). If it is not, bend section (B) down
until a clearance of at least 10 mm (0.39 in) is
obtained.

PS-51
I PIPE ASSEMBLY
POWER ASSISTED SYSTEM (POWER STEERING)

C: INSPECTION
Check all disassembled parts for wear, damage or other abnormalities. Repair or replace faulty parts as re-
qui red.
I Part name I Inspection I Remedv
O-ring fitting surface for
damage Replace with
Pipe
Nut for damage new one.
Pipe for damaae

Replace with
new one.

Flare nut for damage

Outer surface for cracks
Replace with
Outer surface for wear
new one.
Clip for damage

I End coupling or adapter for

degradation
CAUTION:

Excessive holding time of relief status Instruct customers.

Pressure hose burst
Forced out return hose
1 Wronu lavout, tensioned
Fluid bleeding out of hose
slightly
Malfunction of relief valve Replace oil pump.
Poor cold characteristic of fluid Replace fluid.
Poor connection Correct.
Poor holding of clip Retighten.
Poor cold characteristic of fluid Replace fluid.
1 Replace hose. I
Excessive play of engine due to deterioration of
Replace defective parts.
engine mounting rubber
Improper stop position of pitching stopper Replace defective parts.

I Excessive holding time of relief status

1 Excessive tightening torque for return hose clip I Replace. I

Crack on hose Power steering fluid, brake fluid, engine oil, electro- Replace.
lyte adhere on the hose surface Pay attention on service work.

I Too many times use in extremely cold weather

Replace.
Instruct customers.

PS-52
 I
PIPE ASSEMBLY
POWER ASSISTED SYSTEM (POWER STEERING)

CAUTION:
It is likely that although one judges fluid leakage, there is actually no leakage. This is because the flu-
id spilt during the last maintenance was not completely wiped off. Be sure to wipe off spilt fluid thor-
oughly after maintenance.

STOOl

PS-53
 PIPE ASSEMBLY
POWER ASSISTED SYSTEM (POWER STEERING)

Fluid leaking area I Possible cause I Corrective action

Insufficient tightening of flare nut, catching
Loosen and retighten, if ineffective,
dirt or the like, damage to flare or flare nut or
replace.
Leakage from connecting portions of eye bolt
pipes and hoses, numbered with (1) Poor insertion of hose, poor clamping Retighten or replace the clamp.
through (10) in figure Replace O-ring or gasket pipe or hose
Damaged O-ring or gasket with new one, if ineffective, replace the
gearbox also.
Leakage from hose (1 l ) , (12) and Crack or damage in hose I Replace with a new one.
(13) in figure Crack or damage in hose hardware I Replace with a new one.
Leakage from surrounding of cast iron Damaged O-ring Replace the oil pump.
portion of oil pump (14) and (15) in
fiaure Damaged gasket Replace the oil pump.
Leakage from oil tank (16) and (17) in
figure
Crack in oil tank I Replace the oil tank.

Damaged cap packing Replace the cap.

Leakage from filler neck (18) Crack in root of filler neck Replace the oil tank.
Hiah fluid level Adiust the fluid level.
Leakage from surrounding of power
cylinder of gearbox (19) in figure
I Damaged oil seal 1 Replace the oil seal.

Leakage from control valve of gear- Damaged packing or oil seal Replace the problem parts.
box (20) and (21) in figure Damage in control valve Replace the control valve.

PS-54

OIL PUMP
7. Oil Pump
A: REMOVAL
1. NON-TURBO MODEL
1) Remove the ground terminal from battery.
2) Remove the pulley belt cover.
3) Loosen the oil pump pulley nut, then remove the
bolts which secure alternator.
4) Loosen the lock bolt and slider bolt and remove
the power steering pump drive V-belt.
5) Disconnect the connector from the power steer-
ing pump switch.
PS-55
II
POWER ASSISTED SYSTEM (POWER STEERING)
6) Disconnect the pipe C and suction hose from the
oil pump.
CAUTION:
Do not allow fluid from the hose end to come
into contact with pulley belt.
To prevent foreign matter from entering the
hose, cover the open ends of them with a clean
cloth.
(1) Suction hose
(2) Pipe C
7) Remove the bolts, which install power steering
pump bracket.
8) Place the oil pump bracket in a vise, remove the
two bolts from the front side of oil pump.
CAUTION:
Do not place oil pump bracket directly in the
vise; use soft pads and hold oil pump lightly to
protect the pump.
STOOl6
I I
9) Remove the bolt from the rear side of oil pump.
 OIL PUMP
POWER ASSISTED SYSTEM (POWER STEERING)

10) Disassemble the oil pump and bracket by in- 6) Remove the bolts which install power steering
serting a screwdriver as shown in the figure. pump bracket.

2. TURBO MODEL
1) Remove the ground terminal from battery.
2) Remove the pulley belt cover.
3) Loosen the lock bolt and slider bolt and remove
the power steering pump drive V-belt.
7) Place the oil pump bracket in a vise, remove the
two bolts from the front side of oil pump.
CAUTION:
Do not place oil pump bracket directly in the
vise; use soft pads and hold oil pump lightly to
protect the pump.

w STOOl8
4) Disconnect the connector from the power steer-
ing pressure switch. 8) Remove the bolt from the rear side of oil pump.
5) Disconnect the pipe C and suction hose from the 9) Disassemble the oil pump and bracket by insert-
oil pump. ing a screwdriver as shown in the figure.
CAUTION:
Do not allow fluid from the hose end to come
into contact with pulley belt.
To prevent foreign matter from entering the
hose and pipe, cover the open ends of them
with a clean cloth.

(1) Suction hose

(2) Pipe C

PS-56
 OIL PUMP s
POWER ASSISTED SYSTEM (POWER STEERING)

B: INSTALLATION Tightening torque:

37.3 N.m (3.8 kgf-m, 27.5 ft-lb)
1. NON-TURBO MODEL
1) Install the oil pump to the bracket.
(1) Place the oil pump bracket in a vise. Tighten
the bushing using a 12.7 mm (1/2”) type 14 and
21-mm box wrench until it is in contact with oil
pump mounting surface.
CAUTION:
Do not place oil pump bracket directly in the
vise; use soft pads and hold oil pump lightly to
protect the pump. L
ST0019

2) Tighten the bolt which installs power steering

pump bracket.
Tightening torque:
22 N.m (2.2 kgf-m, 75.9 ft-lb)

B4M1670B I
(1) Bush
(2) Nut
(3) 21 mm
(4) 14 mm
(5) Bolt
3) Interconnect the pipe C and suction hose.
(2) Tighten the bolt which installs oil pump to Tightening torque:
the bracket. Joint nut
Tightening torque: 39.2 N.m (4 kgf-m, 28.9 ft-lb)
75.7 N.m (7.6 kgf-m, 7 1.6 ft-lb) CAUTION:
If a hose is twisted at this step, the hose may
come into contact with some other parts.

(1) Suction hose

(2) Pipe C

4) Connect the connector to the power steering

pump switch.
5) Install the pulley belt to the oil pump.

PS-57
 OIL PUMP
POWER ASSISTED SYSTEM (POWER STEERING)

6) Tighten the oil pump pulley nut to the specified (2) Tighten the bolt which installs oil pump to
torque. the bracket.
Tightening torque: Tightening torque:
52 N.m (5.3 kgf-m, 38 ft-lb) 37.3 N-m (3.8 kgf-m, 27.5 ft-lb)
7) Check the pulley belt tension.
<Ref. to ME(S0HC)-44, INSPECTION, V-belt.>
8) Tighten the bolt belt tension.
Tightening torque:
8 N.m (0.8 kgf-m, 5.8 ft-lb)
9)Install the pulley belt cover.
10) Connect the ground terminal of battery.
11) Feed the specified power steering fluid. <Ref.
to PS-72, Power Steering Fluid.>
CAUTION:
Never start the engine before feeding the fluid; Tightening torque:
otherwise vane pump might be seized up. 15.7 Nom(1.6 kgf-m, 11.6 ft-lb)
2. TURBO MODEL
1) Install the oil pump to the bracket.
(1) Place the oil pump bracket in a vise. Tighten
the bushing using a 12.7 mm (1/2”) type 14- and
21-mm box wrench until it is in contact with oil
pump mounting surface.
CAUTION:
Do not place oil pump bracket directly in the
vise; use soft pads and hold oil pump lightly to
protect the pump. mnni FI

2) Tighten the bolt which install power steering

pump bracket.
Tightening torque:
22 N-m (2.2 kgf-m, 15.9 ft-lb)

(1) Bush
(2) Nut
(3) 21 mm
(4) 14 mm
(5) Bolt

PS-58
 I
OIL PUMP
POWER ASSISTED SYSTEM (POWER STEERING)

3) Interconnect the pipes C and suction hose. C: DISASSEMBLY

Tightening torque: 1. NON-TURBO MODEL
Joint nut
39.2 N-m (4 kgf-m, 28.9 fi-lb) 1) Remove the nut and detach oil pump pulley.
2) Remove the stay from the oil pump.
CAUTION: 3) Remove the four bolts which secure rear cover.
If a hose is twisted at this step, the hose may
come into contact with some other parts.

v STOOBZ

(1) Rear cover

(1) Suction hose 4) Using a screwdriver, pry the retaining ring off.
(2) Pipe C

4) Connect the connector to the power steering oil

pressure switch.
5) Install the pulley belt to the oil pump.
6) Check the pulley belt tension. <Ref. to
ME(D0HC TURBO)-45, INSPECTION, V-belt.>
7) Tighten the bolt belt tension.
Tightening torque:
8 N m (0.8 kgf-m, 5.8 fi-lb)
8 ) Install the pulley belt cover.
9) Connect the ground terminal of battery. (1) Retaining ring
10) Feed the specified power steering fluid <Ref. to (2) Screwdriver
PS-72, Power Steering Fluid.>
CAUTION: 5) Extract the shaft from the front casing.
Never start the engine before feeding the fluid;
otherwise vane pump might be seized up.

PS-59
I OIL PUMP
POWER ASSISTED SYSTEM (POWER STEERING)

6) Remove the following parts from the front cas- 9) Slightly loosen the outlet connector, and remove
ing. the connector.
CAUTION:
Discard old seal washer; replace with a new
one.

ST0092

(1) Flow control spring

(2) Spool valve assembly
(3) O-ring
(1) O-ring (4) Connector
(2) Straight pin (2 ea.)
(3) Cam ring
2. TURBO MODEL
(4) Rotor 1) Using ST, place the oil pump in a vise and re-
(5) Vane (10 ea.) move the four bolts which secure rear cover.
(6) Pressure plate ST 34199AE020 MOUNT
(7) O-ring (2 ea.)

7) Pry the oil seal off using a screwdriver.

CAUTION:
Be careful not to scratch inner surface of cas-
ing.

2) Using a screwdriver, pry the retaining ring off.

CAUTION:
Do not remove cam ring, rotor, etc.

~~ ~
ST0091

(1) Oil seal

(2) Screwdriver

8) Remove the pressure switch.

3) Extract the oil pump pulley from the front casing.

PS-60
 a
OIL PUMP
POWER ASSISTED SYSTEM (POWER STEERING)

4) Remove the following parts from the front cas- D: ASSEMBLY

ing.
1. NON-TURBO MODEL
1) Reassembly precautions
(1) Whenever the O-rings, oil seals, and snap
rings are removed, they must be replaced with
new ones.
(2) Thoroughly wash the parts and allow to dry.
They must be kept free from cleaning oil and
dust.
(3) Reassembly procedure must be performed
in clean place. Ensure that the parts are kept
away from the waste threads or other dust parti-
cles.
(1) O-ring (4) Cleaning oil tends to stay inside the front
(2) Straight pin (2 ea.) casing. Remove it completely by blowing com-
(3) Cam ring pressed air.
(4) Rotor (5) Ensure that the parts are free from rust.
(5) Vane (10 ea.) (Use specified hydraulic oil for rust prevention
(6) Pressure plate after cleaning and drying.)
(7) O-ring (2 ea.) (6) Reverse the sequence of disassembly pro-
cedures.
5 ) Place the oil pump in a vise. 2) Apply the grease to the oil seal and inner surface
CAUTION: of front casing (at bearing location).
Do not place oil pump directly in the vise, use CAUTION:
soft pads and hold oil pump lightly to protect Make sure that the front body internal surfaces
the pump. are free from damage.
6) Pry the oil seal off using a screwdriver. 3) Attach ST to the front body. Using a press, install
CAUTION: the oil seal.
Be careful not to scratch inner surface of cas- ST 34199AE030
ing.

B4M1667A

4) Press-fit the shaft assembly into the front body.

5 ) Apply the specified hydraulic oil to the O-rings
and fit them into the front casing.

PS-61
 I
OIL PUMP
POWER ASSISTED SYSTEM (POWER STEERING)

6) Install the side plate to the front casing.
CAUTION:
Use care not to let side plate gall.
10) Install the cam ring to the front casing, securing
with knock pins.
CAUTION:
Do not use hammer to fit knock pins in position.
11) Mount the O-ring on the front casing.

ST0094

(1) Front casing

(2) O-ring
(3) Side plate (1) Rotor
(2) Vane
7) Install the cam ring to the front casing with align-
(3) Radius facing
ment mark facing forward.
(4) Cam ring
(5) O-ring

r3
(1) Front
(2) Alignment mark

8) Install the rotor to the front casing with groove

facing rearward.

(1) Rear
(2) Groove

9) Install the 10 vanes into the rotor with their nose

radius facing toward cam ring.

PS-62
 1
OIL PUMP
POWER ASSISTED SYSTEM (POWER STEERING)

12) Using STs, press the retaining ring into the CAUTION:
shaft groove. Make sure the retaining ring is fit in the second
CAUTION: groove of the shaft.
Discard retaining ring and replace with a new
one.
NOTE:
Use ST2, bending its top edge slightly toward the
inside.
ST1 34099AC030 INSTALLER RETAINING
RING CAP
ST2 34099AC040 INSTALLER RETAINING
RING PIPE
I ST009C
Press

0 (1) First groove

(2) Second groove
(3) Shaft
(4) Retaining ring
(5) Rotor

13) Mount on pressure switch on front casing.

14) With knock pin positions aligned, install the rear
cover.
CAUTION:
Loosely the tighten bolts in the sequence (A),
(B), (C), and (D) shown in figure. Then, tighten
in the same sequence.
Tightening torque:
21 N.m (2.14 kgf-m, 15.5 fi-lb)

I
ST009t

(1) Shaft
(2) Front casing
(3) 48 mm (1.89 in)
(4) Retaining ring
(5) Block
STOl OC

(1) Rear cover

15) Install the spring into the front casing. Then,

with spool valve dipped in specified hydraulic oil, in-
stall it into the front casing.
16) Using a 5-mm dia. round bar, ensure that the
valve moves smoothly.

PS-63
 OIL PUMP
POWER ASSISTED SYSTEM (POWER STEERING)
17) Set the O-ring, with grease applied to it, onto
the connector and secure connector to the front
casing.
CAUTION:
Use care to prevent damage to O-ring at in-
stallation.
When tightening the connector, ensure that
the O-ring does not protrude or get caught.
Tightening torque:
49 N-m (5.0 kgf-m, 36.2 ft-lb)
ST0092
(1) Flow control spring
(2) Spool valve assembly
(3) O-ring
(4) Connector
18) Fix the oil pump pulley temporarily.
19) When the reassembly procedures have been
completed, turn the shaft by hand to ensure it turns
smoothly. If it binds or other unusual conditions are
evident, disassemble again and check for foreign
matter trapped on sliding surfaces and improper in-
stallation. Eliminate the cause of trouble.
20) Check followings by referring to “CHECK arti-
cle.
Excessive play in pulley shaft
Ditch deflection of pulley
Resistance to rotation of pulley
Measurement of generated oil pressure
PS-64
2. TURBO MODEL
1) Reassembly precautions
(1) Whenever the O-rings, oil seals, and snap
rings are removed, they must be replaced with
new ones.
(2) Thoroughly wash the parts and allow to dry.
They must be kept free from cleaning oil and
dust.
(3) Reassembly procedure must be performed
in clean place. Ensure that the parts are kept
away from the waste threads or other dust parti-
cles.
(4) Cleaning oil tends to stay inside the front
casing. Remove it completely by blowing com-
pressed air.
(5) Ensure that the parts are free from rust.
(Use specified hydraulic oil for rust prevention
after cleaning and drying.)
(6) Reverse the sequence of disassembly pro-
cedures.
2) Apply grease to the oil seal and inner surface of
front casing (at bearing location).
CAUTION:
Make sure that the front body internal surfaces
are free from damage.
3) Attach ST to front body. Using a press, install the
oil seal.
ST 34199AE030 INSTALLER
4) Install the pump pulley to front body.
5) Using ST, place the oil pump in a vise.
ST 34199AE020 MOUNT
6) Remove the rear cover.
 OIL PUMP
POWER ASSISTED SYSTEM (POWER STEERING)

7) Install the following parts to casing.
9) Install the O-ring to the rear cover.
10) Install the rear cover.
Tightening torque:
27.5 N.m (2.8 kgf-m, 20.3 ff-lb)
CAUTION:
Loosely tighten the bolts in the sequence (A),
(B), (C), and (D) shown in figure. Then, tighten
in the same sequence.

ST007E

(1) O-ring
(2) Pressure plate
(3) Rotor
(4) Vane
(5) Cam ring
(6) Straight pin
I \ I ST0046
(7) O-ring
11) When the reassembly procedures have been
NOTE: completed, turn the shaft by hand to ensure it turns
Install the rotor with the mark facing the rear case smoothly. If it binds or other unusual conditions are
side. evident, disassemble again and check for foreign
matter trapped on sliding surfaces and improper in-
stallation. Eliminate the cause of trouble.
12) Check followings by referring to “CHECK arti-
cle.
Excessive play in pulley shaft
Ditch deflection of pulley
Resistance to rotation of pulley
Measurement of generated oil pressure

(1) Mark
(2) Rear

8) Using 8-mm box wrench, tap the retaining ring

into the shaft groove.

ST004L

PS-65
 OIL PUMP
POWER ASSISTED SYSTEM (POWER STEERING)

E: INSPECTION
1. BASIC INSPECTION
Perform the following inspection procedures and repair or replace defective parts.

Part name Description Remedy

1) Damage on body surfaces
2) Excessive wear on hole, into which spool
valve is inserted.
Replace with a new one together with spool
1. Front casing 3) Wear and damage on cartridge assembly
valve as selective fit is made.
mounting surface
4) Wear and damage on surfaces in contact with
shaft and oil seal
1) Damage on body surfaces
2. Rear cover Replace with a new one.
2) Wear and damage on sliding surfaces
1) Shaft bend
2) Wear and damage on surfaces in contact with
3. Shaft bushing and oil seal Replace with a new one.
3) Wear and damage on rotor mounting surfaces
4) Bearing damage
4. Pressure plate Wear and damage on sliding surfaces Replace with a new one.
5. Cam ring Ridge wear on sliding surfaces

6. Vane
I Excessive wear on nose radius and side sur-
faces
1) Wear and damage on sliding surfaces
If the damage is serious, replace with a new car-
tridge assembly.
2) Ridge wear on vane sliding grooves (If light
7. Rotor leaks with vane in slit aaainst liaht source)

I 3) Damage resulting from snap ring removal

Correct with oil stone. If the damage is serious,
replace with a new cartridge assembly.
8. Connector I Damage on threads Replace with a new one.
9. Spring Damage Replace with a new one.
10. Bolts and nuts Damage on threads Relslace with a new one.
In accordance with the following table, check all removed parts for wear and damage, and make repair or
replacement if necessary.

No. Parts Inspection Corrective action

(1) Crack. damaae or oil leakaae Replace the oil pump with a new one.
Measure the radial play and axial play.
1 Oil pump (Exterior)
(2) Play of pulley shaft If any of these exceeds the service limit, replace the
oil pump with a new one.
(1) Damage Replace it with a new one.
Measure the V ditch deflection.
2 Pulley
(2) Bend If it exceeds the service limit, replace the pulley with a
new one.
Check the resistance to the rotation of pulley.
(1) Defect or burning of vane pump If it is past the service limit, replace the oil pump with a
new one.
3 Oil pump (Interior) Oil pump emits a noise that is markedly different in
(2) Bend in the shaft or damage to tone and loudness from a sound of a new oil pump
bearing when turning with a string put around its pulley,
replace the oil pump with a new one.
4 0-rina Crack or deterioration Replace it with a new one.
5 Bracket Crack Replace it with a new one.

PS-66
 OIL PUMP 1
POWER ASSISTED SYSTEM (POWER STEERING)

2. SERVICE LIMIT 2) Ditch deflection of pulley

Make a measurement as follows. If it exceeds the Service limit:
specified service limit, replace the parts with new 1.0 mm (0.039 in) or less
ones. NOTE:
CAUTION: Read the value for one surface of V ditch, and then
Fix oil pump on a vise to make a measure- the value for another off the dial.
ment. At this time, hold oil pump with the least
possible force between two wood pieces.
Do not set outside of flow control valve or
pulley on a vise; otherwise outside or pulley
might be deformed. Select properly sized wood
pieces.
1) Play of pulley shaft
On condition:
P: 9.8 N (1.0 kgc 2.2 16)
Service limit: S4M0441
Radial play (Direction c))
0.4 mm (0.016 in) or less (1) Dial indicator

3) Resistance to rotation of pulley

Service limit:
Maximum load; 9.22 N (0.94 kgf, 2.07 16) or
less
NOTE:
A rather higher value may be indicated when pul-
ley starts turning.
Measure the load during rotation and make a
- 5
judgment.
S4M0439A

(1) Dial indicator

Axial play (Direction ) a

Non-TURBO model
0.4 mm (0.016 in) or less
TURBO model
0.8 mm (0.031 in) or less
G ' , I
S4M0442A

(1) Spring balance

(1) Dial indicator

PS-67
I OIL PUMP
POWER ASSISTED SYSTEM (POWER STEERING)

3. HYDRAULIC PRESSURE 2) Measure relief pressure.

(1) Using STs, measure the relief pressure.
CAUTION: (2) Close the valve.
Be sure to complete all items aforementioned
(3) Measure the relief pressure.
in “INSPECTION”, prior to measuring hydraulic
ST1 92571 1000 PRESSURE GAUGE
pressure. Otherwise, pressure can not be mea-
ST2 34099AC020 ADAPTER HOSE B
sured correctly. <Ref. to PS-74, INSPECTION,
General Diagnostic Table.> ST3 34099AC010 ADAPTER HOSE A
Do not leave the valve of pressure gauge
closed or hold the steering wheel at stop end
for 5 seconds or more in any case, as the oil
pump may be damaged due to long keep of
these conditions.
Put cotton cloth waste at a place where fluid
drops before pressure gauge is installed. Wipe
off spilt fluid thoroughly after the measure-
ment.
NOTE: I1676A
Keep engine idling during the measurement.
Service limit:
1) MEASURE REGULAR PRESSURE.
TURBO model
(1) Remove the two bolts securing power steer-
ing pipes to the engine. 7,350- 8,036kPa
(2) Install ST1,2 and 3 between power steering
(75- 82 k @ d , 1,067- 1,165psi)
pump and pipes using gasket (Part No. Non-TURBO model
34621AC021) and bolt (Part No. 34620AC010). 7,164- 7,840kPa
(3) Replenish the power steering fluid up to (73- 80 k & d , 1,040- 1,137psi)
specified level. (4) If it is not within the specified value, replace
(4) Open the valve, and start the engine. the oil pump.
(5) Measure the regular pressure. 3) Measure working pressure.
STI 92571 1000 PRESSURE GAUGE (1) Using STs, measure the working pressure.
ST2 34099AC020 ADAPTER HOSE B (2) Open the valve.
ST3 34099AC010 ADAPTER HOSE A (3) Measure the working pressure of control
valve by turning wheel from stop to stop.
ST1 925711000 PRESSURE GAUGE
ST2 34099AC020 ADAPTER HOSE B
ST3 34099AC010 ADAPTER HOSE A
-

l675A
~

Service limit:
981 kPa (IO kg/cd, 142 psi) or less
(6) If it is not within the specified value, replace 1 675A
the troubled part caused by the following symp-
toms; pipe or hose clogged, leaks from fluid line, Service limit:
and mix of foreign objects in fluid line. TURBO model
7,350- 8,036kPa
(75- 82 k g k d , 1,067- 1,165psi)
Non-TURBO model
7,164- 7,840kPa
(73- 80 kg/Cd, 1,040- 1,137psi)

PS-68
 OIL PUMP
POWER ASSISTED SYSTEM (POWER STEERING)

(4) If it is within the specified value, measure

the steering effort. <Ref. to PS-78, MEASURE-
MENT OF STEERING EFFORT, INSPECTION,
General Diagnostic Table.> If it is not within
specified value, replace the control valve itself or
control valve and pinion as a single unit with new
ones.

PS-69
 RESERVOIR TANK
POWER ASSISTED SYSTEM (POWER STEERING)

8. Reservoir Tank 3) Disconnect the return hose and suction hose

from the reservoir tank.
A: REMOVAL CAUTION:
Do not allow fluid from the hose end to come
1. NON-TURBO MODEL
into contact with pulley belt.
1) Remove the air intake duct. <Ref. to IN(S0HC)- To prevent foreign matter from entering the
7, REMOVAL, Air Intake Duct.> hose, cover the open ends of them with a clean
2) Drain the fluid from the reservoir tank. cloth.
3) Disconnect the pipe D from the return hose and
suction hose from the oil pump.
CAUTION:
Do not allow fluid from the hose end to come
into contact with pulley belt.
To prevent foreign matter from entering the
hose and pipe, cover the open ends of them
with a clean cloth.

(1) Suction hose

(2) Pipe D
(3) Return hose

4) Remove the reservoir tank from the bracket by

pulling it upwards.
B: INSTALLATION
(1) Suction hose 1. NON-TURBO MODEL
(2) Pipe D 1) Install the reservoir tank to the bracket.
(3) Return hose 2) Connect the pipes D to the return hose and suc-
tion hose to the oil pump.
4) Remove the reservoir tank from the bracket by
pulling it upwards.
2. TURBO MODEL
1) Remove the air intake duct. <Ref. to IN(D0HC
TURBO)-9, REMOVAL, Intake Duct.>
2) Drain the fluid from the reservoir tank.

(1) Suction hose

(2) Pipe D
(3) Return hose

3) Feed the specified power steering fluid. <Ref. to

PS-72, Power Steering Fluid.>

PS-70
 RESERVOIR TANK
m
POWER ASSISTED SYSTEM (POWER STEERING)

2. TURBO MODEL
1) Install the reservoir tank to the bracket.
2) Connect the pressure hose and suction hose to
the oil pump.

(1) Suction hose

(2) Pipe D
(3) Return hose

3) Feed the specified power steering fluid. <Ref. to

PS-72, Power Steering Fluid.>
C: INSPECTION
Check the reservoir tank for cracks, breakage, or
damage. If any cracks, breakage, or damage is
found, replace the reservoir tank.

PS-71
 POWER STEERING FLUID
POWER ASSISTED SYSTEM (POWER STEERING)
9. Power Steering Fluid
n
A: SPECIFICATION
I Recommended power steering- fluid [ Manufacturer
CALTEX
CASTROL
DEXRON Ill
MOBIL
SHELL
TEXACO
B: INSPECTION
1) Check the power steering fluid for deterioration
or contamination. If the fluid is highly deteriorated
or contaminated, drain it and refill with new fluid.
2) Check the joints and units for oil leakage. If any
oil leaks are found, repair or replace the applicable
part.
3) Inspect the fluid level on flat and level surface
with engine “OFF by indicator of reservoir tank.
If the level is at lower point or below, add fluid to
keep the level in the specified range of the indica-
tor. If at upper point or above, drain the fluid by us-
ing a syringe or the like.
(1) Check at temperature 20°C (68°F) on reser-
voir surface of oil pump; read the fluid level on
the “COLD” side.
(2) Check at temperature 80°C (176°F) on res-
ervoir surface of oil pump: read the fluid level on
the “HOT” side.
C: INSTALLATION
1) Set ST on the top of reservoir tank and fill it about
half way with the specified fluid.
I ST 34199AE040 OIL CHARGE
2) Continue to turn the steering wheel slowly from
lock to lock until the bubbles stop appearing in the
tank while keeping the fluid at that level.
3) In case air is absorbed to deliver bubbles into
piping because the fluid level is lower, leave it
about half an hour and then do the step 2) all over
again.
4) Start, and idle the engine.
5) Continue to turn the steering wheel slowly from
lock to lock again until the bubbles stop appearing
in the tank while keeping the fluid at that level.
It is normal that bubbles stop appearing after three
times turning of steering wheel.
6) In case bubbles do not stop appearing in the
tank, leave it about half an hour and then do the
step 5 ) all over again.
7) Stop the engine, and take out safety stands after
jacking up vehicle again.
Then lower the vehicle, and idle the engine.
8) Continue to turn the steering wheel from lock to
lock until the bubbles stop appearing and change of
the fluid level is within 3 mm (0.12 in).
9) In case the following happens, leave it about half
an hour and then do step 8) again.
(1) The fluid level changes over 3 mm (0.12 in).
(2) Bubbles remain on the upper surface of the
fluid.
(3) Grinding noise is generated from oil pump.
PS-72
 I
POWER STEERING FLUID
POWER ASSISTED SYSTEM (POWER STEERING)
~~ ~~ ~

IO) Check the fluid leakage at flare nuts after turn-

ing steering wheel from lock to lock with engine
running.
CAUTION:
Before checking, wipe off any fluid on flare
nuts and piping.
In case the fluid leaks from flare nut, it is
caused by dust (or the like) and/or damage be-
tween flare and tapered seat in piping.
So remove the flare nut, tighten again it to the
specified torque after cleaning flare and ta-
pered seat. If flare or tapered seat is damaged,
replace it with a new one.

PS-73
 GENERAL DIAGNOSTIC TABLE
POWER ASSISTED SYSTEM (POWER STEERING)

1O.General Diagnostic Table

A: INSPECTION
Trouble Possible cause Corrective action
1. Pulley belt
Unequal length of pulley belts
Adhesion of oil and grease
Loose or damage of pulley belt
Adjust or replace.
Poor uniformity of pulley belt cross section
Pulley belt touches to pulley bottom
Poor revolution of pulleys except oil pump pulley
Poor revolution of oil pump pulley
2. Tire and rim
Improper tires out of specification
Replace or reinflate.
ieavy steering effort in all Improper rims out of specification
Tires not properly inflated*l
ges
ieavy steering effort at 3. Fluid
nd still Low fluid level
steering wheel surges when Aeration Refill, bleed air, replace or
ling. Dust mix instruct customer.
Deteriorationof fluid
Poor warming-up of fluid *2
4. Idling speed
Lower idling speed
Adjust or instruct customer.
Excessive drop of idling speed at start or at turning steering
wheel *3
5. Measure hydraulic pressure.<Ref. to PS-66, INSPECTION,
Replace problem parts.
Oil Pump.>
6. Measure steering effort.<Ref. to PS-74, INSPECTION, Gen-
Adjust or replace.
eral Diagnostic Table.>
1. Fluid line
Folded hose Reform or replace.
Flattened pipe
2. Tire and rim
Flat tire
Mix use of different tires
Mix use of different rims Fix or replace.
/chicle leads to one side or Abnormal wear of tire
other. Unbalance of remained grooves
'oar return of steering wheel Unbalance of tire pressure
:enter 3. Front alignment
Steering wheel surges when Improper or unbalance caster
Adjust or retighten.
ning. Improper or unbalance toe-in
Loose connection of suspension
4. Others
Damaged joint assembly Replace, adjust or instruct cus.
Unbalanced height tomer.
One-sided weight ~~

5. Measure steering effort.<Ref. to PS-74, INSPECTION,Gen-

Adjust or replace.
eral Diaanostic Table.>
*1 If the tires and/or rims are wider, the load to power steering system is the more. Accordingly, in a condition, for example before
fluid warms-up, relief valve may work before maximum turning angle. In this case, steering effort may be heavy. When the mea-
sured hydraulic pressure is normal, there is no abnormal thing.
*2 In cold weather, steering effort may be heavy due to increased flow resistance of cold fluid. After warming-up engine, turn the
steering wheel from stop to stop several times to warm-up fluid. Then if steering effort reduces normally, there is no abnormal
thing.
*3 In cold weather or with insufficient warm-up of engine, steering effort may be heavy due to excessive drop of idling when turn-
ing steering wheel. In this case, it is recommended to start the vehicle with increasing engine speed than usual. Then if steering
effort reduces normally, there is no abnormal thing.

PS-74
 GENERAL DIAGNOSTIC TABLE
POWER ASSISTED SYSTEM (POWER STEERING)

1. NOISE AND VIBRATION

CAUTION:
Don’t keep the relief valve operated over 5 sec-
onds at any time or inner parts of the oil pump
may be damaged due to rapid increase of fluid
temperature.
NOTE:
Grinding noise may be heard immediately after
the engine start in extremely cold condition. In this
case, if the noise goes off during warm-up there is
no abnormal function in the system. This is due to
the fluid characteristic in extremely cold condition.
Oil pump makes whine or growl noise slightly
due to its mechanism. Even if the noise can be
heard when steering wheel is turned at stand still
there is no abnormal function in the system provid-
ed that the noise eliminates when the vehicle is
running.
When stopping with service brake and/or parking
brake applied, power steering can be operated
easily due to its light steering effort. If doing so, the
disk rotates slightly and makes creaking noise. The
noise is generated by creaking between the disk
and pads. If the noise goes off when the brake is re-
leased, there is no abnormal function in the system.
There may be a little vibration around the steer-
ing devices when turning steering wheel at stand-
still, even though the component parts are properly
adjusted and have no defects.
Hydraulic systems are likely to generate this kind of
vibration as well as working noise and fluid noise
because of combined conditions, Le., road surface
and tire surface, engine speed and turning speed of
steering wheel, fluid temperature and braking con-
dition.
This phenomena does not indicate there is some
abnormal function in the system.
The vibration can be known when steering wheel is
turned repeatedly at various speeds from slow to
rapid step by step with parking brake applied on
concrete road and in “D” range for automatic trans-
mission vehicle.

PS-75

POWER ASSISTED SYSTEM (POWER STEERING)
Trouble
Hiss noise (continuous)
While engine is running.
Rattling noise (intermittent)
While engine is running.
Knocking
When turning steering wheel in
both direction with small angle
repeatedly at engine ON or OFF.
Grinding noise (continuous)
While engine is running.
Squeal, squeak (intermittent or
continuous)
While engine is running.
Sizzling noise (continuous)
While engine is running.
Whistle (continuous)
While engine is running.
Whine or growl (continuous or
intermittent)
While engine is running with/
without steering turned.
Creaking noise (intermittent)
While engine is running with
steering turned.
GENERAL DIAGNOSTIC TABLE
Possible cause Corrective action I
Relief valve emits operating sound when steering wheel is
completely turned in either direction. (Don't keep this con- Normal
dition over 5 seconds.)
Relief valve emits operating sound when steering wheel is Defective
not turned. This means that the relief valve is faulty. Replace the oil pump.
Check the clearance.
Correct if necessary.
Interference with adjacent parts
<Ref. to PS-52, INSPECTION,
Pipe Assembly.>
Loosened installation of oil pump, oil tank, pump bracket,
Retighten.
gearbox or crossmember
Loosened installation of oil D u m Dullev or other DulleW
~~~
Retighten. I
Loosened linkage or play of steering or suspension Loos-
Retighten or replace.
ened tightening of joint or steering column
Replace the bad parts of the
Sound generates from the inside of gearbox or oil pump.
aearbox or oil wmu.
Excessive backlash
Adjust and retighten.
Loosened lock nut for adjusting backlash
Loosened tightening or play of tie-rod, tie-rod end Retighten or replace.
Inspect and retighten the fluid
Vane pump aeration line connection.
Vane pump seizing
Pulley bearing seizing of oil pump
Folded hose. flat DiDe Replace. I
Maladjustmentof pulley belt
Adjust or replace.
Damaged or charged pulley belt
(Replace two belts as a set.)
Unequal length of pulley belts
Run out or soilage of V-groove surface of oil pump pulley Clean or redace.
Fix the wrong part causing aera-
Fluid aeration tion.
Damaged pipe of gearbox Redace the DiDe.
~
Abnormal inside of hose or pipe
Rectify or replace.
Flat hose or DiDe
Abnormal inside of oil tank Replace. I
Removed oil tank cap
Abnormal pipe of gearbox or abnormal inside of hose
or hose.
Loosened installation of oil Duma oil Dump bracket RetiQhten. I
Replace the oil pump, hose, if the
Abnormal inside of oil pump, hose noise can be heard when running
Remove the power steering pul-
Torque converter growl, air conditioner compression growl
ley belt and confirm.
Replace the bad parts of gear-
Abnormal inside of gearbox
Abnormal bearing for steering shaft
Generates when turning steering wheel with brake (ser-
vice or Darkina) amlied. is released, it is normal.
PS-76
 GENERAL DIAGNOSTIC TABLE
POWER ASSISTED SYSTEM (POWER STEERING)

Trouble Possible cause Corrective action

Too low engine speed at start Adjust and instruct customers.

Vibration I Vane pump aeration

Fix the wrong part.
.- . .. -.air. .
Vent
While engine is running with/ Replace the oil pump, bad parts
without steering turned. Damaged valve in oil pump, gearbox
I
of aearbox.
-
Looseness of play of steering, suspension parts I Retighten.

PS-77
 GENERAL DIAGNOSTIC TABLE
POWER ASSISTED SYSTEM (POWER STEERING)

2. MEASUREMENT OF STEERING EFFORT

~~
~~

Step Check Yes No

CHECK STEERING EFFORT. Is the steering effort 31.4 N Go to step 2. 4djustment back-
1)Stop the vehicle on a concrete road. (3.2 kgf, 7.1 Ib) or less? ash.
2)Start the engine.
3)ldle the engine.
4)lnstall the spring scale on the steering wheel.
5)Pull the spring scale at an right angle to the
steering wheel, and measure both right and left
steering wheel effort.
NOTE:
When turning steering more quickly than nec-
essary from a direction to the other direction at
an engine speed over 2,000 rpm, steering effort
may be heavy. This is caused by flow charac-
teristic of oil pump and is not a problem.
! CHECK STEERING EFFORT. Is the steering effort 294.2 N Go to step 3. tdjustment.
1)Stop the engine. (30 kgf, 66.2 Ib) or less?
2)Pull the spring scale at an right angle to the
steering wheel, and measure both right and left
steering wheel effort.
I CHECK STEERING WHEEL EFFORT. Is the maximum force steering Go to step 4. Check, adjust and
1)Remove the universal joint. wheel effort 2.26 N (0.23 kgf, replace if neces-
2)Measure the steering wheel effort. 0.51 Ib) or less? sary.
I CHECK STEERING WHEEL EFFORT. Is the fluctuation width 1.08 N Go to step 5. Check, adjust and
Measure the steering wheel effort. (0.11 kgf, 0.24 Ib) or less? replace if neces-
sary.
CHECK UNIVERSAL JOINT. Is the folding torque 7.3 N Go to step 6. Replace with new
Measure the folding torque of the joint (yoke of (0.74 kgf, 1.64 Ib) or less? one.
steering column side). <Ref. to PS-22,
INSPECTION, Universal Joint.>
i CHECK UNIVERSAL JOINT. Is the folding torque 7.3 N Go to step 7. Replace with new
Measure the folding torque of the joint (yoke of (0.74 kgf, 1.64 Ib) or less? one.
gearbox side). <Ref. to PS-22, INSPECTION,
Universal Joint.>
I CHECK FRONT WHEEL. Are the front wheels for Inspect, readjust Go to step 8.
unsteady revolution or rattling and replace if nec.
and brake for dragging? essary.
5 CHECK TIE-ROD ENDS. Are the tie-rod ends of suspen Inspect and Go to step 9.
Remove the tie-rod ends. sion for unsteady revolution or replace if neces-
ratting? sary.
3 CHECK BALL JOINT. Are the ball joints of suspen- Inspect and Go to step 10.
sion for unsteady revolution or replace if neces-
ratting? sary.
IO CHECK GEARBOX. Is rotating resistance 12.7 N Go to step 11. Readjust back-
Measure the rotating of gearbox. (1.3 kgf, 2.9 Ib) or less in all lash, and if ineffec
<Ref. to PS-44, TURNING RESISTANCE OF positions within 20% difference tive, replace bad
GEARBOX, INSPECTION, Steering Gear- between clockwise and coun- parts.
box.> terclockwise?
I1 CHECK GEARBOX. Is sliding resistance 340 N (35 Steering effort is Readjust back-
Measure sliding of gearbox. kgf, 76 Ib) or less with 20% dif. normal. lash, and if ineffec
<Ref. to PS-43, SERVICE LIMIT, INSPEC- ference between left and right tive, replace bad
TION, Steering Gearbox.> direction? Darts.

PS-78
I
2002 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX

BODY SECTION

This service manual has been prepared

to provide SUBARU service personnel
with the necessary information and data
for the correct maintenance and repair
of SUBARU vehicles.
This manual includes the procedures
c- -
for maintenance, disassembling, reas-
sembling, inspection and adjustment of
components and diagnostics for guid-
ance of experienced mechanics.
Please peruse and utilize this manual
fully to ensure complete repair work for
satisfying our customers by keeping
their vehicle in optimum condition.
When replacement of parts during
repair work is needed, be sure to use
SUBARU genuine parts.

All information, illustration and specifi-

cations contained in this manual are
based on the latest product information
available at the time of publication
approval.

FUJI HEAVY INDUSTRIES LTD. Gl830BE6

HVAC SYSTEM
(HEATER. VENTILATOR AND A/C)

ACa
Page
1. General Description .................................................................................... 2
2. Refrigerant Pressure with Manifold Gauge Set ......................................... 15
3. Refrigerant Recovery Procedure............................................................... 16
4. Refrigerant Charging Procedure ............................................................... 17
5. Refrigerant Leak Check ............................................................................ 20
6. Compressor Oil ......................................................................................... 21
7. Blower Motor Unit Assembly ..................................................................... 22
8. Blower Resistor ......................................................................................... 23
9. Heater Core............................................................................................... 24
.. 10. Control Unit ............................................................................................... 25
11. Compressor............................................................................................... 26
12. Condenser................................................................................................. 27
13. Heater and Cooling Unit ............................................................................ 28
14. Evaporator................................................................................................. 29
15. Hose and Tube .......................................................................................... 30
16. Relay and Fuse ......................................................................................... 31
17. Pressure Switch (Dual Switch) .................................................................. 32
18. Air Vent Grille ............................................................................................ 33
19. Heater Duct ............................................................................................... 34
20. Heater Vent Duct....................................................................................... 35
21 . General Diagnostics.................................................................................. 36
 GENERAL DESCRIPTION
HVAC SYSTEM (HEATER, VENTILATOR AND N C )

1. General Description
A: SPECIFICATIONS
1. HEATER SYSTEM

Item SDecifications Condition

Mode selector switch: HEAT
Temperature control switch: FULL HOT
5.0 kW (4,300 kcal/h, 17,062 BTU/ Temperature difference between hot water
Heating capacity
h) or more and inlet air: 65°C (149°F)
Hot water flow rate: 360 Q (95.1 US gal,
79.2 Imp gal)/h
Air flow rate 280 m3 (9,888 cu ft)/h Heat mode (FRESH), FULL HOT at 12.5 V
Temperature control switch: FULL COLD
Max air flow rate 450 m3 (15,892 cu ft)/h Blower fan speed: 4th position
Mode selector lever: RECIRC
Heater core size 163.9 x 200 x 25.0 mm
(height x length x width) (6.45 x 7.87 x 0.984 in)
Type Maanet motor 200 W or less at 12 V
Blower
Fan type and size Sirocco fan type
motor
(diameter x width) 150 x 75 mm (5.91 x 2.95 in)

AC-2
I

Item Specifications

1 Cooling capacity
5.1 kW
(4.385 kcal/h. 17,402 BTU/h)
HFC-134a (CH,FCF,)
Refrigerant
[0.5f0.05 kg (0.99f0.11 Ib)]
Type Vane rotary, fix volume (CR-14)
Compressor Discharge 144 cm3 (8.79 cu in)/rev
Max. permissible speed 7,000 rpm
Tvpe Drv, single-disc type
Power consumption 47 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 (Sub cool type)
I c e alea 0.21 m2 (2.26 sq ft)
Condenser
I Core thickness I 16 mm (0.63 in)
c-
I Radiation area I
~

5.34 m2 157.5 sa ft)

Receiver drier Effective inner capacity 250 cm3 (15.26 cu in)
Expansion valve Type Internal equalizing
TvDe Sinale tank

I Evaporator
I Dimensions (W x H x T)
I 255 x 200 x 48 mm
(10 x 7.87 x 1.89 in)
Fan type Sirocco fan
Blower fan Outer diameter x width 150 x 75 mm (5.91 x 2.95 in)
Power consumption 200 W at 12 V
Motor t w e Magnet
1 Condenser fan (Sub fan) I Power consumption I 70 W at 12 V
I Fan outer diameter I 320 mm (12.6 in)
Motor type Magnet
Radiator fan (Main fan) Power consumption 70 W at 12 V
Fan outer diameter 320 mm (12.6 in)
ldlina SDeed 1NC ON)
. , I
I MPFI model 850f100 rpm
278f29 kPa
ON -+ OFF
Low-pressure switch (2.83+0.3 kg/cm2,40.3f4.2 psi)
operating pressure 287+39/L25kPa
OFF + ON
Dual switch kg/cm2,42+5.7
(2.9+0.4/-0.25 /-3.6Psi)
(Pressure switch) 2,800f100 kPa
ON -+ OFF
High-pressureswitch (29fl kg/cm2, 406+15 psi)
operating pressure 600f200kPa
DlFF
(6.12f2 kg/cm2, 87229 psi)
~

Diff. 2.5*0.5"C(36.5&0.9"F)
Thermo control amplifier working temperature
(Evaporator outlet air)
OFF ON
1.5zkO.5"C(35+0.9"F)
HV004!

AC-3
 GENERAL DESCRIPTION
HVAC SYSTEM (HEATER. VENTILATOR AND A/C)

B: COMPONENT
1. HEATER COOLING UNIT

~~

(1) Unit cover (10) Heater core (19) Expansion valve

(2) Side link (11) Drain hose (20) Evaporator
(3) Mode acutuator lever (12) Mix acutuator lever (21) Evaporator cover
(4) Foot lever (13) Unit assembly (22) Thermistor
(5) Spring (14) Foot duct
(6) Mode acutuator link (15) Clip Tightening torque: N.m (kgf-m, ft-lb)
(7) Defroster lever (16) Packing T: 7.35 (0.750, 5.421)
(8) Foot nozzle (17) Cooling unit block
(9) Unit duct cover (18) O-ring

AC-4
I GENERAL DESCRIPTION
HVAC SYSTEM (HEATER, VENTILATOR AND NC)

2. BLOWER MOTOR UNIT

(1) Upper case (6) Filter cover Tightening toque: N-m (kgf-m, ft-lb)
(2) Blower link (7) Filter T: 7.35 (0.750,5.421)
(3) Blower link lever A (8) Blower motor assembly
(4) Blower link lever B (9) Hose
(5) Clip (10) Blower resistor

AC-5
 GENERAL DESCRIPTION
HVAC SYSTEM (HEATER. VENTILATOR AND A/C)

3. CONTROL UNIT

HV0054

(1) Dial (6) Heater control panel (1 1) Mode cable

(2) Fan control plate (7) Air conditioner knob (12) Temperature cable
(3) Temperature control plate (8) Plug knob (13) Bulb
(4) Mode control plate (9) Heater control base (14) Fan switch ASSY
(5) Heater control knob (IO) Intake cable (15) Harness

AC-6
I GENERAL DESCRIPTION
HVAC SYSTEM (HEATER, VENTILATOR AND NC)

4. AIR CONDITIONING UNIT

(5)

HV0055

(1) Condenser (6) O-ring Tightening torque: N-m (kgf-m, ft-lb)

(2) Hose (High-pressure) (7) ClampA T1: 7.4 (0.75, 5.4)
(3) Hose (Low-pressure) (8) Clamp B T2: lS(1.5, 10.8)
(4) Bracket (9) Tube (To condenser)
(5) Compressor (IO) Tube (To evaporator)

AC-7
I GENERAL DESCRIPTION
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

5. COMPRESSOR

HV0051

(1) Idler pulley bracket (7) V-belt Tightening torque: N.m (Irgf-m, ft-lb)
(2) Idler pulley adjuster (8) Compressor belt cover TI: 7.4 (0.75, 5.4)
(3) Idler pulley T2: 22.6(2.3, 16.6)
(4) Compressor bracket upper T3: 23.0 (2.35, 17.0)
(5) Compressor T4: 28.9 (2.95, 21.3)
(6) Compressor bracket lower T5: 35 (3.6,26)

AC-8
I GENERAL DESCRIPTION
HVAC SYSTEM (HEATER, VENTILATOR AND NC)

6. HEATER DUCT

HV0056

(1) Front defroster nozzle (4) Side ventilation duct (LH) (7) Rear heater duct (RH)
(2) Side defroster duct (LH) (5) Side ventilation duct (RH)
(3) Side defroster duct (RH) (6) Rear heater duct (LH)

AC-9
I GENERAL DESCRIPTION
HVAC SYSTEM (HEATER. VENTILATOR AND N C )
C: CAUTION
1. HFC-134A A/C SYSTEM
Unlike the old conventional HFC-12 system com-
ponents, the cooling system components for the
HFC-134a system such as the refrigerant and com-
pressor oil are incompatible.
Vehicles with the HFC-134a system can be iden-
tified by the label “ A attached to the vehicle.
Before maintenance, check which A/C system is in-
stalled in the vehicle.
2. COMPRESSOR OIL
HFC-134a compressor oil has no compatibility
with that for R12 system.
Use only the manufacturer-authorized compres-
sor oil for the HFC-134a system; only use DH-PR.
Do not mix multiple compressor oils.
If HFC-12 compressor oil is used in a HFC-134a
A/C system, the compressor may become stuck
due to poor lubrication, or the refrigerant may leak
due to swelling of rubber parts.
On the other hand, if HFC-134a compressor oil is
used in a HFC-12 A/C system, the durability of the
A/C system will be lowered.
HFC-134a compressor oil is very hygroscopic.
When replacing or installing/removing A/C parts,
immediately isolate the oil from the atmosphere us-
ing a plug or tape. In order to avoid moisture, store
the oil in a container with its cap tightly closed.
3. REFRIGERANT
The HFC-12 refrigerant cannot be used in the
HFC-134a A/C system. The HFC-134a refrigerant,
also, cannot be used in the HFC-12 A/C system.
If an incorrect or no refrigerant is used, poor lu-
brication will result and the compressor itself may
be damaged.
AC-10
4. HANDLING OF REFRIGERANT
The refrigerant boils at approx. -30°C (-22°F).
When handling it, be sure to wear safety goggles
and protective gloves. Direct contact of the refriger-
ant with skin may cause frostbite.
If the refrigerant gets into your eye, avoid rubbing
your eyes with your hands. Wash your eye with
plenty of water, and receive medical treatment from
an eye doctor.
Do not heat a service can. If a service can is di-
rectly 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.
Do not drop or impact a service can. (Observe
the precautions and operation procedure described
on the refrigerant can.)
When the engine is running, do not open the
high-pressure valve of the manifold gauge. The
high-pressure gas will back-flow resulting in an ex-
plosion of the can.
The refrigerant is non-toxic and harmless under
normal operating circumstance, but it may change
to phosgene (a noxious fume) under open flames
or high temperatures (caused by a cigarette or
heater).
Provide good ventilation and do not work in a
closed area.
Never perform a gas leak test using a halide
torch-type leak tester.
In order to avoid destroying the ozone layer, pre-
vent HFC-134a from being released into the atmo-
sphere. Using a refrigerant recovery system,
discharge and reuse it.
Goggles Gloves
Avoid open No direct heat Do not
flame on container discharge
Loosen
G4M097S
 GENERAL DESCRIPTION a
HVAC SYSTEM (HEATER, VENTILATOR AND NC)

5. O-RING CONNECTIONS Use the oil specified in the service manual to Iu-
bricate the O-rings.
Use new O-rings.
Apply the oil to the top and sides of the O-rings be-
In order to keep the O-rings free of lint which will
fore 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.
Apply the compressor oil to the O-rings to avoid
sticking, then install them.
Use a torque wrench to tighten the O-ring fittings:
Over-tightening will damage the O-ring and tube
end distortion.
If the operation is interrupted before completing a
pipe connection, recap the tubes, components, and
fittings with a plug or tape to prevent contamination
from entering.

HV0062

Kea' After tightening, use a clean shop towel to re-

move excess oil from the connections and any oil
which may have run on the vehicle body or other
parts.
If any leakage is suspected after tightening, do
not retighten the connections, Disconnect the con-
nections, remove the O-rings, and check the 0-
G4M050'i rings, threads, and connections.
Visually check the surfaces and mating surfaces
of O-rings, threads, and connecting points. If a fail-
ure is found, replace the applicable parts.
Install the O-rings at right angle to the tube
beads.
,-O-ring

O.K. Bead

Not O.K.

Not O.K.
HV0046

AC-11
 GENERAL DESCRIPTION
HVAC SYSTEM (HEATER, VENTILATOR AND N C )

D: PREPARATION TOOL
CAUTION:
When working on vehicles with the HFC-134a
system, only use HFC-134a specified tools and
parts. Do not mix with CFC-12 tools and parts. If
HFC-134a and CFC-12 refrigerant or compres-
sor oil is mixed, poor lubrication will result and HFC-134a CFC-12
the compressor itself may be destroyed. Tool & screw type Millimeter size Inch size
Valve type Quick joint type Screw-in type

Tools and Equipment Description

Wench
Various WRENCHES will be required to service any A/Csystem. A 7 to
40 N.m (0.7 to 4.1 kg-m, 5 to 30 ft-lb) torque wrench with various crow-
loot wrenches will be needed. Open end or flare nut wrenches will be
ieeded for back-up on the tube and hose fittings.

G4M0571
Applicator bottle
A small APPLICATOR BOlTLE is recommended to apply refrigerant
3il 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
sommercial refrigerationsupply house or from an auto shop equipment
suppIier.

AC-12
 GENERAL DESCRIPTION
HVAC SYSTEM (HEATER, VENTILATOR AND N C )

Tools and Equipment Description

Refrigerant recovery system
A REFRIGERANTRECOVERY 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.

G4MQ576
Can tap
A CAN TAP for the 397 g (14 02) can is available from an auto supply
store.

A
G4M0577

AC-13
 GENERAL DESCRIPTION
HVAC SYSTEM (HEATER, VENTILATOR AND N C )

Tools and Equipment Description

Thermometer
Pocket THERMOMETERS are available from either industrial hard-
ware store or commercial refrigeration supply houses.

G4M0570
Electronic leak detector
An ELECTRONIC LEAK DETECTOR can be obtained from either a

G4M0579
Weight scale
A WEIGHT SCALE such as an electronic charging scale or a bath-
room scale with-digitaldisplay will be needed if a 13.6.kg (30 Ib) refrig-
erant container is used.

AC-14
 REFRIGERANT PRESSURE WITH MANIFOLD GAUGE SET
HVAC SYSTEM (HEATER, VENTILATOR AND NC)

2. Refrigerant Pressure with Manifold Gauge Set

A: OPERATION
1) Place the vehicle in the shade and draftless condition.
2) Connect the manifold gauge set.
3) Open the front windows and close all doors.
4) Open the hood.
5) Increase the engine to 1,500 rpm.
6) Turn ON the A/C switch.
7) Turn the temperature control switch to MAX COOL.
8) Put in RECIRC position.
9) Turn the blower control switch to HI.
10) Read the gauge.
Standard:
-
Low pressure: 127 196 kPa (1.3 - 2.0 kg/cn?, 18 - 28 psi)
High pressure: 1,471 - 1,667 kPa (15 - 17 kg/cn?, 213 - 242 psi)
Ambient temperature: 30 - 35 OC (86 95 OF) -
B: INSPECTION
-.
r Svmntnm I Probable cause
I I Defective condenser fan motor Replace the fan motor.
Clogged condenser fan Clean the condenser fin.
High-pressureside is unusually high. Too much refrigerant Discharge refrigerant.
Air inside the system Replace the receiver dryer.
Defective receiver dryer
Defective compressor Replace the compressor.
Not enough refrigerant Check for leaks.
High-pressureside is unusually low. Clogged expansion valve Replace the expansion valve.
Expansion valve frozen temporarily by
moisture
Defective compressor Replace the compressor.
Low-pressure side is unusually high. Defective expansion valve Replace the expansion valve.
Too much refrigerant Discharge refigerant.
Not enough refrigerant Check for leaks.
Clogged expansion valve Replace the expansion valve
Low-pressure side is unusually low. Expansion valve frozen temporarily by Replace the receiver dryer.
moisture
Saturated receiver dryer

AC-15
I REFRIGERANT RECOVERY PROCEDURE
HVAC SYSTEM (HEATER, VENTILATOR AND N C )

3. Refrigerant Recovery Proce-

dure
A: OPERATION
CAUTION:
During operation, be sure to wear safety gog-
gles and protective gloves.
Connect the refrigerant recovery system with
the manifold gauge set to discharge the refrig-
erant from the A/C system and reuse it.
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.
Follow the detailed operation procedure de-
scribed in the operation manual attached to the
refrigerant recovery system.
1) Perform the compressor oil return opera-
tion.cRef. to AC-21, OPERATION, Compressor
"Oi I.>
2) Stop the engine.
3) Close the valves on the low-/high-pressuresides
of the manifold gauge set.

Low-pressure gauge
(Compound pressure gauge)

Close Close

I G4M0585

4) Install the low-/high-pressure hoses to the ser-

vice ports on the low-/high-pressure sides of the
vehicle respectively.

Low-pressure gauge
(Compound pressure gauge)

5) Connect the center hose to the refrigerant recov-

ery system.
6) Follow the operation manual to activate the re-
frigerant recovery system.

AC-16
 REFRIGERANT CHARGING PROCEDURE
HVAC SYSTEM (HEATER, VENTILATOR AND N C )

4. Refrigerant Charging Proce- 4) Carefully open the valves on the low-/high-pres-

sure sides to activate the vacuum pump.
dure
A: OPERATION I Low-pressure gauge
(Compound pressure High-pressure gauge
CAUTION: gauge)
During operation, be sure to wear safety gog-
gles and protective gloves. Slowly Slowly
Before charging the refrigerant, evacuate the open G o p e n
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 4M0597
level. The minimum vacuum level affects the
temperature in the system. 5) After the low-pressure gauge reaches 100.0 kPa
The list below shows the vacuum values nec- (750 mmHg, 29.5 inHg) or higher, evacuate the
essary to boil water in various temperature. In system for approx. 15 minutes.
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.
-.
I Vacuum level required to boil water (at sea level) I
I TemDerature I Vacuum I
I 1.7"C (35°F)
I
1I 100.9 kPa (757 "Ha. -. 29.8 inHal I
I I
"I

7.2"C (45°F) I 100.5 kPa (754 mmHa 29.7 inHa)

I 12.8"C (55°F) I 99.8 kPa (749 mmHa 29.5 inHq) I
18.3"C (65°F) I 99.2 kPa (744 mmHg, 29.3 inHg)
I G4M0598

23.9"C (75°F) 1 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 higher,
35°C (95°F) 95.8 kPa (719 mmHg, 28.3 inHg) close the valves on the both sides to stop the vac-
uum pump.
1) Close the valves on low-/high-pressure sides of
the manifold gauge. Low-pressure gauge
(Compound pressure High-pressure gauge
gauge)
Low-pressure gauge
(Compound pressure gauge)

Close Close

Close Close
Vacuu
Turn OFF G4M0599
u l d u
G4M0596
7) Note the low-pressure gauge reading.

2) Install the low-/high-pressure hoses to the corre-

sponding service ports on the vehicle respectively.
3) Connect the center hose of the manifold gauge
set with the vacuum pump.

AC-17
I REFRIGERANT CHARGING PROCEDURE
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

8) Leave it at least 5 minutes, and then check the 15) Carefully open the high-pressure valve with the
low-pressure gauge reading for any changes. engine stopping.
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.
Low-pressure gauge
9) Following the can tap operation manual instruc-
tions, install it to the refrigerant can.
(Compound pressure 6 High-pressure

I Center
Tap valve

Close
manifold
hose

\
G4M0601

CAUTION:
Never run the engine during charging from the
G4M0980 high-pressure side.
10) Disconnect the center manifold hose from the 16) Close the high-pressure valve when the low-
,.vacuum pump, and connect the hose to the tap pressure gauge reaches 98 kPa (1 kg/cm2, 14 psi).
valve. Using a leak tester, check the system for leaks.
11) When a 13.6 kg (30 Ib) refrigerant container is If any leakage is found after the refrigerant recov-
used, measure the refrigerant amount in use using ery is completed, repair the applicable area.
a weight scale. 17) After confirming that there are no leaks with the
leak test, charge the required amount of refrigerant.
CAUTION:
Refrigerant Never run the engine during charging from the
container high-pressure side.
(HFC-I34a)
18) Close the high-pressure valve when;
the readings of low- / high-pressure gauges be-
come almost equal, after the charging speed is re-
duced,
Weight
scale
the HFC-134a source becomes empty, or
c the system is filled with the gas.
G4M0981

12) Confirm that all the 3 hoses are tightly connect-

ed to the manifold gauge set.

Low-pressure gauge
(Compound pressure gauge)

Close Close
G4M060E

I G4M0603 I
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 es-
cape by the refrigerant.

AC-18
 REFRIGERANT CHARGING PROCEDURE
a
HVAC SYSTEM (HEATER, VENTILATOR AND N C )

19) If the HFC-134a source is empty, close the 27) Disconnect the hose from the service port, and
high-pressure valve, close the valve on the can tap, install the service port cap.
and replace the HFC-134a source with a new one
to restart the operation.

Low-pressure gauge
(Compound pressure High-pressure gauge

I G4M0606

20) Confirm that both the low- / high-pressure

valves can be closed. Start the engine with the A/C
switch OFF.
21) Quickly repeat ON-OFF cycles a few times to
prevent initial compressor damage.
22).Set up the vehicle to the following status:
A/C switch ON
Engine running at 1,500 rpm
Blower speed setting to “HI”
Temperature setting to “MAX COOL”
Air inlet setting to “RECIRC”
Windows open
23) While reading the low-pressure gauge, careful-
ly open the low-pressure valve with the refrigerant
source connected and the service hose purged.
CAUTION:
Never open the high-pressure valve with the en-
gine is running.

G4M0608

24) Adjust the refrigerant flow to maintain the pres-

sure 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.
I Refrigerant amount I
Refrigerant Minimum Maximum
HFC-134a 0.6 kg (1.3 Ib) 0.7 kg (1.5 Ib)

AC-19
I REFRIGERANT LEAK CHECK
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

5. Refrigerant Leak Check
A: INSPECTION
1) Operate the A/C system for approx. 10 minutes,
and confirm that the high-side pressure shows at
least 690 kPa (7.03 kg/cm2, 100 psi). Then stop the
engine to start the leak test.
2) Starting from the connection between the high-
pressure tube and evaporator, check the system
for leaks along the high-pressure side through the
compressor. The following items must be checked
IO) 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
and tubes at approx. 25 mm (0.98 in) per sec-
ond.
Flexible hose

thoroughly.
3) Check the joint and seam between the pressure
switch (dual switch) and receiver dryer.
4) Check the connections between the condenser
and tubes, and welded joints on the condenser.
The leak tester may detect the oil on the condenser
fins as a leak.
5) Check the joint between the compressor and G4M0617
hoses.
6). Check the machined area of compressor and
c
11) Disconnect the drain hose from the evaporator
other joints on the compressor. case, and check the hose end for at least 10 sec-
7) Check the thermal limiter (if equipped) on the onds.
compressor housing. After the test is finished, reconnect the drain hose.
8) Check the compressor shaft seal at the area 12) Turn the ignition key to ON position, and run the
near the center of compressor clutch pulley. blower at high speed for 1 minute. Stop the blower
Some shaft seals show a slight amount of leakage to check the ventilation grille on the instrument pan-
about 28 g (1.O oz) per year. This is not a problem. el. While moving the tester closer to the grille, run
9) Starting from the connection between the low- the blower for 1 or 2 seconds, then stop it. Check
pressure tube and evaporator, check the system the grille at that point for at least 10 seconds.
for leakage along the high-pressure side through
the compressor. The following items must be
checked thoroughly.
Connection between the tube and tube fitting
Connection between 2 parts
Connection between the tube and nut

13) Check the valve in the service port.

14) Visually check the rubber seal in the service
port cap.

AC-20
 COMPRESSOR OIL
HVAC SYSTEM (HEATER. VENTILATOR AND A/Cl

6. Compressor Oil B: REPLACEMENT

A: OPERATION NOTE:
If a component is replaced, add an appropriate
NOTE: amount of compressor oil.
Before making repairs, conduct the oil return oper- When replacing the compressor, the new com-
ation to return the compressor oil in circulation with pressor will already have the specified amount of
the refrigerant to the compressor. oil in it. Install the new compressor after removing
1) Increase the engine to 1,500 rpm. the same amount of oil that is remaining in the com-
2) Turn ON the A/C switch. pressor removed.
3) Turn the temperature control switch to MAX
COOL. I Replacement parts I Amount of oil replenishment I
4) Put in RECIRC position. I Evaporator I 114 m 8 (3.9 US fl 02,4.0 Imp fl 02) I
5) Turn the blower control switch to HI. I Condenser I 7 m 8 (0.24 US fl 02, 0.25 Imp fl 02) I
6) Leave in this condition for 10 minutes. I Hose I 1 m 8 (0.03 US fl 02. 0.04 ImD fl 02) I

AC-21
 BLOWER MOTOR UNIT ASSEMBLY
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

7. Blower Motor Unit Assembly B: INSTALLATION

A: REMOVAL
1) Disconnect the ground terminal from battery.
2) Remove the glove box. <Ref. to EI-39, REMOV-
AL, Glove Box.>
3) Loosen the nut to remove support beam stay.
Install in the reverse order of removal.
C: INSPECTION
Connect the motor connector terminal 1 from the
battery to the positive (+) lead and terminal 2 to the
negative (-) lead. Make sure the motor runs
smoothly.

I
404
4) Disconnect the blower motor connector.
--

5 ) Disconnect the blower resistor connector

6) Loosen the bolt and nut to remove blower motor

unit assembly.

HV0013

AC-22
 BLOWER RESISTOR
HVAC SYSTEM (HEATER, VENTILATOR AND N C )

8. Blower Resistor
A: REMOVAL
1) Remove the glove box. <Ref. to El-39, REMOV-
AL, Glove Box.>
2) Disconnect the blower resistor connector.
3) Loosen two screws to remove the blower resis-
tor.

B: INSTALLATION
IKstall in the reverse order of removal.
C: INSPECTION

HVO0.57

I 3 and 1 I Approx. 0.51 0 I

I 3 and 2 I Approx. 2.70 0 I
I 3 and 4 I Approx. 1.43 0 I
If NG, replace the blower resistor

AC-23
 HEATER CORE
HVAC SYSTEM (HEATER, VENTILATOR AND N C )

9. Heater Core
A: REMOVAL
1) Remove the heater and cooling unit. <Ref. to
AC-28, REMOVAL, Heater and Cooling Unit.>
2) Loosen the screws to remove heater core cover.

HVOOOl

3) Remove the heater core.

--

HV0002

B: INSTALLATION
Install in the reverse order of removal.

AC-24
 CONTROL UNIT
HVAC SYSTEM (HEATER, VENTILATOR AND NC)

1O.Control Unit 2) Remove the glove box. <Ref. to El-39, REMOV-

AL, Glove Box.>
A: REMOVAL 3) Remove the lower panel. <Ref. to El-42, Instru-
1) Disconnect the ground terminal from battery. ment Panel Assembly.>
4) Remove the control wires.

5 ) Remove the center console panel. 7) Pull out the control unit and disconnect connec-
tors.
B: INSTALLATION

x Install in the reverse order of removal.

=J1 r Clip

6) Remove four screws.

-1-
BOO1 1 i

AC-25
 COMPRESSOR
HVAC SYSTEM (HEATER, VENTILATOR AND NC)

11.Compressor 7) Remove the low-pressure hose and high-pres-

sure hose.
A: INSPECTION
1. MAGNETIC CLUTCH CLEARANCE
1) Check the clearance of the entire circumference
around the drive plate and pulley.
Standard:
0.45-M.15 mm (0.0177-M.0059 in)
2. MAGNETIC CLUTCH OPERATION
1) Disconnect the compressor connector.
2) Connect the battery positive terminal to the No.3
terminal of the compressor connector. 8) Disconnect the compressor harness from body
Ground the negative terminal to the body. harness.
9) Loosen the bolts to remove compressor bracket.

84M2407

3) Make sure the magnet clutch engages.

If NG, replace the compressor. 10) Remove the bolts and then separate compres-
sor and bracket.
B: REMOVAL
1) Perform the compressor oil return operation.
<Ref. to AC-21, OPERATION, Compressor Oil.>
2) Turn A/C switch OFF and stop the engine.
3) Using refrigerant recovery system, discharge re-
frigerant. <Ref. to AC-16, OPERATION, Refriger-
ant Recovery Procedure.>
4) Disconnect the ground terminal from battery.
5) Remove the V-belt. <Ref. to ME(S0HC)-43, RE-
MOVAL, V-belt.> or <Ref. to ME(D0HC TURBO)-
44, REMOVAL, V-belt.> HVOOI 1

6) Remove the generator. <Ref. to SC-13, RE-

MOVAL, Generator.> C: INSTALLATION
1) Install in the reverse order of removal.
2) Replace the O-rings on low-/high-pressure hos-
es with new ones, then apply compressor oil.
3) When replacing the compressor, adjust amount
of compressor oil. <Ref. to AC-21, OPERATION,
Compressor Oil.>
4) Charge refrigerant. <Ref. to AC-17, OPERA-
TION, Refrigerant Charging Procedure.>

AC-26
I
CONDENSER
HVAC SYSTEM (HEATER, VENTILATOR AND N C )

12.Condenser B: INSTALLATION
1) Install in the reverse order of removal
A: REMOVAL
CAUTION:
1) Using the refrigerant recovery system, discharge
Replace the O-rings on hoses or pipes with new
refrigerant. <Ref. to AC-16, OPERATION, Refriger-
ones, and then apply compressor oil. Confirm
ant Recovery Procedure.>
that lower guide of condenser (A) has been fit-
2) Disconnect the ground terminal from battery.
ted into holes on radiator panel.
3) Disconnect the pressure hose and pipe from
condenser.

I Y
B4M1822A
I
2) Charge refrigerant. <Ref. to AC-17, OPERA-
TION, Refrigerant Charging Procedure.>
4rRemove the radiator bracket (A).
1 C: INSPECTION
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 fail-
ure is found, replace the condenser with a new one.

5 ) Remove two bolts. While lifting condenser, pull it

out through space between the radiator and the ra-
diator panel.

CAUTION:
Be careful not t o damage the condenser fins. If
a damaged fin is found, repair it using a thin
screwdriver.
If the condenser is replaced, add appropriate
amount of compressor oil t o the compressor.
<Ref. t o AC-21, REPLACEMENT, Compressor
Oil.>

AC-27
 HEATER AND COOLING UNIT
HVAC SYSTEM (HEATER, VENTILATOR AND N C )

13.Heater and Cooling Unit B: INSTALLATION

1) Install in the reverse order of removal.
A: REMOVAL 2) Charge refrigerant. <Ref. to AC-17, OPERA-
1) Disconnect the ground terminal from battery. TION, Refrigerant Charging Procedure.>
2) Using the refrigerant recovery system, discharge
refrigerant. <Ref. to AC-16, OPERATION, Refriger-
ant Recovery Procedure.>
3) Drain LLC from the radiator. <Ref. to CO-25, RE-
PLACEMENT, Engine Coolant.>
4) Remove the bolts securing expansion valve and
pipe in engine compartment. Release the heater
hose clamps in engine compartment to remove the
hoses.

C.

HVOOE

5) Remove the instrument panel. <Ref. to El-42,

REMOVAL, Instrument Panel Assembly.>
6) Remove the support beam.
7) Remove the blower motor unit assembly. <Ref.
to AC-22, REMOVAL, Blower Motor Unit Assem-
bly.>
8) Loosen the bolt and nuts to remove the heater
and cooling unit.

AC-28
I EVAPORATOR
HVAC SYSTEM (HEATER, VENTILATOR AND N C )

14.Evaporator
A: REMOVAL
1) Remove the heater and cooling unit. <Ref. to
AC-28, REMOVAL, Heater and Cooling Unit.>
2) Loosen the screws and clip to remove the evap-
orator cover.

HV0024

3) Remove the evaporator.

4) Loosen two bolts to remove the expansion valve.

HV0026

CAUTION:
If the evaporator is replaced, add appropriate
amount of compressor oil to evaporator. <Ref.
to AC-21, REPLACEMENT, Compressor Oil.>
B: INSTALLATION
Install in the reverse order of removal.

AC-29
 HOSE AND TUBE
HVAC SYSTEM (HEATER, VENTILATOR AND N C )

15.Hose and Tube 13) Remove the high-pressure tube from the vehi-
cle.
A: REMOVAL
CAUTION:
When disconnecting/connecting hoses, do
not apply excessive force to them. Confirm that
no torsion and excessive tension exists after
installing.
Seal the disconnected hose with a plug or vi-
nyl tape to prevent contamination from enter-
ing.
1) Disconnect the ground terminal from battery.
2) Using the refrigerant recovery system, discharge
refrigerant. <Ref. to AC-16, OPERATION, Refriger-
ant Recovery Procedure.>
3) Remove the evaporator unit mounting bolt (A).
4) Remove the low-pressure hose attaching bolts
(B).
5) Disconnect the low-pressure hose from evapora-
-. unit.
tor
6) Disconnect the low-pressure hose from com-
pressor.
7) Remove the low-pressure hose from the vehicle.
8) Remove the high-pressure hose attaching bolts
(C). B: iNSTALLATlON
9) Disconnect the high-pressure hose from com-
pressor. CAUTION:
10) Disconnect the high-pressure hose from con- When disconnectingkonnecting hoses, do
denser. not apply an excessive force to them. Confirm
11) Remove the high-pressure hose from the vehi- that no torsion and excessive tension exists af-
cle. ter installing.
12) Remove the high-pressure tube attaching bolt
Seal the disconnected hose with a plug or vi-
nyl tape to prevent contamination from enter-
0 . ing.
1) Install in the reverse order of removal.
2) Charge refrigerant. <Ref. to AC-17, OPERA-
TION, Refrigerant Charging Procedure.>
C: INSPECTION
NOTE:
If cracking, damage, or swelling is found on a hose,
replace it with a new one.

AC-30
I RELAY AND FUSE
HVAC SYSTEM (HEATER, VENTILATOR AND N C )

16.Relay and Fuse B: INSPECTION

A: LOCATION

-Joint box

HV006
Main fuse box
HV0022 (3) - (4): Continuity exists.
(1) - (2): No continuity
Main Fan Relay 1 A While applying battery voltage to the cable be-
Main Fan Relay 2 B tween (3) and (4),check continuity between (1) and
Sub Fan Relay 1 C (2).
If no continuity exists, replace the relay with a new
Sub Fan Relay 2
one.
A/C Relay
Main Fan Fuse
Sub Fan Fuse G
N C Fuse H

AC-31
 PRESSURE SWITCH (DUAL SWITCH)
HVAC SYSTEM (HEATER, VENTILATOR AND NC)

17.Pressure Switch (Dual

Switch)
A: INSPECTION
1) Connect the manifold gauge to the service valve
on the high-pressure side.
2) Remove the pressure switch harness connector.
Using a circuit tester, inspect the ON-OFF opera-
tion of the pressure switch.
1

Terminal
No.
1 Operation
Standard
kPa (kg/cm2, psi)
Increasing to
2,800flOO(29fl14O6k15)
Turns OFF.
Decreasingto
278+29 (2.83k0.3,
40.3M.2)
High and low pressure switch 1 and2

Turns ON.
Decreasing to
I
2,20M200(22.4+2,31%29)

AC-32
 AIR VENT GRILLE
HVAC SYSTEM (HEATER, VENTILATOR AND NC)

18.Air Vent Grille

A: REMOVAL
1. CENTER GRILLE
1) Disconnect the ground terminal from battery.
2) Remove the center console panel (A).
3) Loosen two screws to remove the center air vent
grille (B).

2:-SIDE GRILLE
1) Disconnect the ground terminal from battery.
2) Remove the heater vent duct. <Ref. to AC-35,
REMOVAL, Heater Vent Duct.>
3) Loosen the screws to remove the side air vent
grille.

B: INSTALLATION
Install in the reverse order of removal.
C: INSPECTION
The direction and amount of air should be adjusted
smoothly.
The adjustment should be kept in each position.

AC-33
I HEATER DUCT
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

19.Heater Duct
A: REMOVAL
1) Remove the heater unit. <Ref. to AC-28, Remov-
al.>
2) Remove the front seat. <Ref. to SE-6, REMOV-
AL, Front Seat.>
3) Remove the front side sill cover.
4) Pull off the floor mat to remove the heater duct.

IB: INSTALLATION
Install in the reverse order of removal.

AC-34
 c3
HEATERVENTDUCT
HVAC SYSTEM (HEATER, VENTILATOR AND N C )

20.Heater Vent Duct

A: REMOVAL
1) Remove the instrument panel. <Ref. to El-42,
REMOVAL, Instrument Panel Assembly.>
2) Remove the screws.
3) Remove the heater vent duct.

I HV0064 I
B: INSTALLATION
Install in the reverse order of removal.

AC-35
 GENERAL DIAGNOSTICS
HVAC SYSTEM (HEATER. VENTILATOR AND A/C)

21 .General Diagnostics
A: INSPECTION

I Fuse I
Blower motor relay
Blower motor
Doesn't move.
Blower motor Blower motor resistor
Blower switch
I Wire harness I
1 Blower motor
~

Stranqe noise. I
Refrigerant
Fuse
Air conditioning relay
Maanet clutch
Doesn't move. (Comoressor I
I Pressure switch I
I A/C switch I
Blower switch
Wire harness
V-Belt
Strange noise Magnet clutch
Compressor
I Refrigerant I
I V-Belt I
Magnet clutch
Compressor
Pressure switch
m w i t c h I
I Blower switch I
I Wire harness I
I Heater duct
Heater vent duct
~
Enaine coolant
~ ~~~

Warm air not emitted. Blower switch I

Heater core I
Engine coolant I
Temperature of air from vents does not change. Mode actuator
Wire harness
Mode actuator
Unable to switch blow vents. Air flow switch
Wire harness I
Air inlet select switch I
Unable to switch suction vents. FRESH/RECIRC actuator I
Wire harness

AC-36
AIRBAG SYSTEM

A5
1.
Page
General Description .................................................................................... 2
m
2. Airbag Connector ........................................................................................ 8
3. Inspection Locations After a Collision ....................................................... 10
4. Driver's Airbag Module.............................................................................. 12
5. Passenger'sAirbag Module ...................................................................... 13
6. Side Airbag Module................................................................................... 14
7. Airbag Control Module .............................................................................. 15
8. Side Airbag Sensor ................................................................................... 16
9. Roll Connector .......................................................................................... 17
10. Front Sub Sensor ...................................................................................... 18
I GENERAL DESCRIPTION
AI RBAG SYSTEM

1. General Description
A: COMPONENT

RE0031

(1) Combination switch ASSY with roll (7) Side airbag sensor Tightening torque: N.m (kgf-m, ft-lb)
connector (8) Side airbag harness T1: 7.4 (0.75, 5.4)
(2) TORX@bolt T30 (9) Side airbag module T2: l O ( 1 . 0 , 7.2)
(3) Airbag module ASSY (Driver) (10) Airbag main harness T3: 20 (2.0, 14.5)
(4) Airbag module ASSY (Passenger) (1 1) Front sub sensor harness T4: 25 (2.5, 18.1)
(5) Airbag control module (12) Front sub sensor
(6) T O R P bolt T40 (13) TORX@bolt T30

AB-2
 GENERAL DESCRIPTION
AIRBAG SYSTEM

B: CAUTION When checking, use a test harness. Do not di-

rectly apply the tester probe to any connector termi-
When servicing a vehicle, be sure to turn the ig-
nal of the airbag.
nition switch OFF, disconnect the ground terminal
from battery, and wait for more than 20 seconds
before starting work. NO GOOD GOOD
The airbag system is fitted with a backup power
source. If the airbag system is serviced within 20
seconds after the ground terminal is disconnected,
it may inflate.

G5M0293

NO GOOD

\ 1 G5M0292

c-If the sensors, airbag module, airbag control

module, pretensioner and harness are deformed or
damaged, replace them with new genuine parts.
I I
I NO GOOD I GOOD

Test harness

G5M0291

Do not use the airbag or pretensioner parts from G5M0294

other vehicles. Always replace the defective parts
with new parts. Do not check continuity of the driver, passenger,
Never re-use a deployed airbag or pretensioner. side airbag modules and pretensioner.
When checking the system, be sure to use a dig- I
ital circuit tester.
Use of an analog circuit tester may cause the air-
bag to activate erroneously.

NO GOOD G5M0302

AB-3
I GENERAL DESCRIPTION
AIRBAG SYSTEM

Do not allow water or oil to come in contact with Install the wire harness securely with the speci-
the connector terminals. Do not touch the connec- fied clips to avoid interference or tangled up with
tor terminals. other parts.

A
\ NO GOOD

G5M0298 G5M0297

The airbag module (driver, passenger and side)
and pretensioner must not be disassembled.
NO GOOD
When painting or performing sheet metal work
on the front part of the vehicle, including the front
wheel apron, front fender, and front side frame, re-
move the front sub sensors and wire harness of the
airbag system.
When painting or performing sheet metal work
on the side of the vehicle, including the side sill,
center pillar, and front and rear doors, remove the
side airbag sensors and wire harness of the airbag
system.

v
~’ G5M0299

If any damage, opening, or rust is found on the

airbag system wire harness, do not attempt to re-
pair using soldering equipment. Be sure to replace
the faulty harness with a new genuine part.

\\ NO GOOD
G5M0310

NO GOOD
G5M0296

AB-4
 GENERAL DESCRIPTION
AIRBAG SYSTEM

Do not drop the airbag modulator parts, subject

them to high temperature over 93°C (199"F), or let
water, oil, or grease get on them; otherwise, the in-
ternal parts may be damaged and reliability greatly
lowered.

NO GOOD
G5M0295

The removed front seat with the airbag module

must be kept at least 200 mm (8 in) away from walls
and other objects.
I I

When storing a removed airbag module, do not

place any objects on it or pile airbag modules on
top of each other. If the airbag inflates for some rea-
son when it is placed with its pad side facing down-
ward or under any object, a serious accident may
result.

AB-5
 GENERAL DESCRIPTION
AIRBAG SYSTEM

Driver side GOOD

Passenger side

L
NO GOOD

NO GOOD

G5M0604

AB-6
 GENERAL DESCRIPTION
AIRBAG SYSTEM

C: PREPARATION TOOL
1. GENERAL TOOL

TORP
T ~ O Used for removaVinstallation of drivers airbag module
T O R P T40 (Tamper resistant type) Used for removaVinstallation of airbag control module
TOR)(@T30 (TamDer resistant m e ) Used for removal of side airbag sensor.

AB-7
I AIRBAG CONNECTOR
AIRBAG SYSTEM

2. Airbag Connector 2. DRIVER'S AIRBAG, PASSENGER'S AIR-

BAG, SIDE AIRBAG
A: OPERATION 1) How to disconnect:
1. POWER SUPPLY (1) Push the lock arm (A).
(2) With the lock arm (A) pushed in, move the
1) How to disconnect: slide lock (6)in the direction of the arrow.
(1) Move the slide lock (A) in the direction of the
arrow.
(2) Pull the female connector in the direction of
the arrow with slide lock (A) moved.

(3) With the slide lock (6)pulled, remove the

lock arm (A) to its original position, and then pull
RE0012 in the direction of the arrow and separate the
connector.
CAUTION:
When pulling, be sure to hold onto the connec- CAUTION:
tor and not the wire. When pulling, be sure to hold onto the connec-
tor and not the wire.
2) How to connect:
Holding the connector (A), and push it in carefully
until a connecting sound is heard.

lY 1

B5M1154

/ RE0013
CAUTION:
Be sure to insert the connector in until it locks.
Then pull on it gently to make sure that it is
locked.
2) How to connect:
I Holding the connector, and push it in carefully until
a connecting sound is heard.
CAUTION:
Be sure to insert the connector in until it locks.
Then pull on it gently to make sure that it is
locked.

AB-8
I AIRBAG CONNECTOR
AIRBAG SYSTEM

3. FRONT SUB-SENSOR, SIDE AIRBAG 4. PRETENSIONER

SENSOR 1) How to disconnect:
1) How to disconnect: (1) Move the slide lock (A) in the direction of the
(1) Holding the outer part (A), pull it in the direc- arrow.
tion of the arrow. (2) Pull the connector (B)in the direction of the
arrow with slide lock (A) moved.
CAUTION:
When pulling, be sure to hold onto the connec-
tor and not the wire.

CAUTION:
When pulling, be sure to hold onto the connec-
2) How to connect: tor and not the wire.
Holding the connector, and push it in carefully until 2) How to connect:
a connecting sound is heard. Holding the connector (A), and push it in carefully
until a connecting sound is heard.
CA UTI0N:
Outer (A) moves back, and so do not put your
hand on the outer part.
Be sure to insert the connector in until it
locks. Then pull on it gently to make sure that it
is locked.

CAUTION:
Be sure to insert the connector in until it
locks.
Then pull on it gently to make sure that it is
locked.

AB-9
I INSPECTION LOCATIONS AFTER A COLLISION
AIRBAG SYSTEM
3. Inspection Locations After a
Collision
A: INSPECTION
If the vehicle is involved in a collision on any side,
even if it is a slight collision, be sure to check the
following system parts.
1. AIRBAG MODULE (DRIVER)
1) Check for the following, and replace the dam-
aged parts with new parts.
Airbag module is cracked or deformed.
Harness and/or connector is cracked, deformed
or open. Lead wire is exposed.
The module surface is fouled with grease, oil,
water or cleaning solvent.
2) When installing a new driver's airbag module,
check the following. If necessary, install a new air-
bag module and steering wheel.
The steering wheel is in the way, making it diffi-
p ~ ltot install the airbag module.
The clearance between the driver's airbag mod-
ule and steering wheel is not constant.
When steering wheel deformation in axial and ra-
dial directions exceed limits.
Specifications:
Axial direction play A
Less than 6 mm (0.24 in)
Radial direction play L
Less than 17 mm (0.67 in)
I I
I I
2. AIRBAG MODULE (PASSENGER)
Check for the following, and replace damaged
parts with new parts.
Airbag module is cracked or deformed.
Harness and/or connector is cracked, deformed
or open. Lead wire is exposed.
Mounting bracket is cracked or deformed.
AB-I 0
3. AIRBAG MODULE (SIDE)
Check for the following, and replace damaged
parts with new parts.
Front seat is damaged or deformed.
Harness and/or connector is cracked, deformed
or open.
Lead wire is exposed.
4. AIRBAG CONTROL MODULE
Check for the following, and replace the damaged
parts with new parts.
Control module is cracked or deformed.
Mounting bracket is cracked or deformed.
Connector is scratched or deformed.
Airbag is deployed.
Side airbag is deployed.
5. FRONT SUB SENSOR
If the front section of vehicle as shown in the figure
is damaged:
Check for the following, and replace the damaged
parts with new parts.
Front sub sensor is cracked or deformed.
Mounting bracket is cracked or deformed.
Connector is scratched or cracked.
Airbag is deployed.
6. FRONT SUB SENSOR HARNESS
Check for the following, and replace the damaged
parts with new parts.
Harness is open, lead wire is exposed, and cor-
rugated tube is noticeably cracked.
Connector is scratched or cracked.
 INSPECTION LOCATIONS AFTER A COLLISION
AIRBAG SYSTEM

7. SIDE AIRBAG SENSOR 8. SIDE AIRBAG SENSOR HARNESS

If the side section of vehicle as shown in the figure
is damaged:
05M0514
Check for the following, and replace the damaged
parts with new parts.
Side airbag sensor is cracked or deformed.
Mounting bracket is cracked or deformed.
Connector is scratched or cracked.
Side airbag is deployed. (operating side)
r.
Check for the following, and replace the damaged
parts with new parts.
Harness is open, lead wire is exposed, and cor-
rugated tube is noticeably cracked.
Connector is scratched or cracked.
9. MAIN HARNESS
Check for the following, and replace the damaged
parts with new parts.
Harness is open, lead wire is exposed, and cor-
rugated tube is noticeably cracked.
Connector is scratched or cracked.
10.ROLL CONNECTOR
Check for the following, and replace the damaged
parts with new parts.
Combination switch or steering roll connector is
cracked or deformed.

11.STEERING SHAFT
Check for the following, and replace the damaged parts with new parts.
Overall length of steering column should be within specifications.
Specifications:
Overall length L
825.751.5 mm (32.5H.06 in)

RE0032
If necessary, replace it with new part.

AB-1 1
I DRIVER’S AIRBAG MODULE
AIRBAG SYSTEM

4. Driver’s Airbag Module D: INSPECTION

Check for the following, and replace the damaged
A: CAUTION parts with new parts.
Refer to the “CAUTION” of General Description be- Airbag module, harness, connector, and mount-
fore handling the airbag module. <Ref. to AB-3, ing bracket are damaged.
CAUTION, General Description.>
B: REMOVAL
1) Position the front wheels straight ahead. (After
moving a vehicle more than 5 m (16 ft) with front
wheels positioned straight ahead, make sure that
the vehicle moves straight ahead).
2) Turn the ignition switch OFF.
3) Disconnect the ground terminal from battery,
and wait for at least 20 seconds before starting
work.
4) Using TORX@BIT T30, remove the two TOFIX@
bolts on the side of steering wheel.

H5M0662A

5) Disconnect the airbag connector on the back of

airbag module, and then remove the airbag mod-
ule.

6) Refer to the “CAUTION” for handling of a re-

moved airbag module. <Ref. to AB-3, CAUTION,
General Description.>
C: INSTALLATION
1) Install in the reverse order of removal.
CAUTION:
Do not allow harness and connectors to inter-
fere or get tangled up with other parts.

AB-I 2
 PASSENGER’S AIRBAG MODULE
AIRBAG SYSTEM

5. Passenger’s Airbag Module

A: CAUTION
Refer to the “CAUTION” of General Description be-
fore handling the airbag module. <Ref. to AB-3,
CAUTION, General Description.>
B: REMOVAL
1) Turn the ignition switch OFF.
2) Disconnect the ground terminal from battery,
and wait for at least 20 seconds before starting
work.
3) Remove the glove box. <Ref. to El-39, REMOV-
AL, Glove Box.>
4) Detach the airbag connector from the support
beam bracket, and then disconnect the airbag con-
nector.
5) Remove the three bolts, and then carefully re-
move the airbag module.

6) Refer to the “CAUTION” for handling of a re-

moved airbag module. <Ref. to AB-3, CAUTION,
General Description.>
C: INSTALLATION
Install in the reverse order of removal.
CAUTION:
Do not allow harness and connectors to inter-
fere or get tangled up with other parts.
D: INSPECTION
Check for the following, and replace the damaged
parts with new parts.
Airbag module, harness, connector, and mount-
ing bracket are damaged.

AB-I 3
I SIDE AIRBAG MODULE
AIRBAG SYSTEM

6. Side Airbag Module

A: CAUTION
Refer to the “CAUTION” of General Description be-
fore handling the airbag module. <Ref. to AB-3,
CAUTION, General Description.>
B: REMOVAL
CAUTION:
The side airbag module cannot be detached
from the front seat assembly.
When replacing side airbag module, replace
front seat assembly.
<Ref. to SE-6, REMOVAL, Front Seat.>
C: INSTALLATION
<Ref. to SE-6, INSTALLATION, Front Seat.>
D: INSPECTION
Check for the following, and replace the damaged
parts with new parts.
-* Front seat is deformed or damaged.
Harness and/or connector is cracked, deformed
or open.
Lead wire is exposed.

AB-14
 AIRBAG CONTROL MODULE
AIRBAG SYSTEM

7. Airbag Control Module

A: REMOVAL
CAUTION:
Do not disassemble the airbag control mod-
ule.
If the airbag control module is deformed or if
water damage is suspected, replace the airbag
control module with a new genuine part.
Do not drop the airbag control module.
After removal, keep the airbag control mod-
ule on a dry, clean surface away from moisture,
heat, and dust.
1) Turn the ignition switch OFF.
2) Disconnect the ground terminal from battery,
and wait for at least 20 seconds before starting
work.
3) Remove the console box. <Ref. to El-41, RE-
MOVAL, Console Box.>
4) Disconnect the connector from the airbag control
module.
5 ) Using T40@ TORX bit (Tamper resistant type),
remove the four TORX@bolts.

B: INSTALLATION
CAUTION:
Use new TORX@bolts during re-assembly.
Install in the reverse order of removal.
C: INSPECTION
Check for the following, and replace the damaged
parts with new parts.
Control module, connector, and mounting brack-
et are damaged.
Airbag is deployed.
Side airbag is deployed.

AB-I 5
I SIDE AIRBAG SENSOR
AIRBAG SYSTEM

8. Side Airbag Sensor

A: REMOVAL
1) Turn the ignition switch OFF.
2) Disconnect the ground terminal from battery,
and wait for at least 20 seconds before starting
work.
3) Remove the outer belt (FRONT). <Ref. to SB-8,
OUTER BELT (FRONT), REMOVAL, Front Seat
Belt.>
4) Using T30 TORX@bit (Tamper resistant type),
remove the two TORX@bolts.
5) Detach the side airbag sensor, and then discon-
nect the airbag connector.
I

c-

REO018

B: INSTALLATION
CAUTION:
Use new TORX@bolts during re-assembly.
Install in the reverse order of removal.
C: INSPECTION
Check for the following, and replace the damaged
parts with new parts.
Bracket connector for side airbag sensor is dam-
aged.

AB-I 6
 ROLL CONNECTOR
AIRBAG SYSTEM

9. Roll Connector D: ADJUSTMENT

1) Check that front wheels are positioned in straight
A: REMOVAL ahead direction.
1) Turn the ignition switch OFF. 2) Turn the roll connector pin (A) clockwise until it
2) Disconnect the ground terminal from battery, stops.
and wait for at least 20 seconds before starting 3) Turn the roll connector pin (A) counterclockwise
\ I ~~

work. approximately 2.65 turns until “A” marks are

3) Remove the driver’s airbag module. <Ref. to AB- aligned.
12, Driver’s Airbag Module.>
4) Remove the steering wheel. <Ref. to PS-19,
REMOVAL, Steering Wheel.>
5) Remove the steering column cover.
6 ) Remove the screws, and then remove the roll
connector.
I J

W H5M0663B

B: INSTALLATION
1) Install the roll connector and steering column
cover in the reverse order of removal.
2) Before installing steering wheel, be sure the di-
rection of roll connector is adjusted with steering.
<Ref. to AB-17, ADJUSTMENT, Roll Connector.>
3) Install the steering wheel and airbag module.
C: INSPECTION
Check for the following, and replace the damaged
parts with new parts.
Combination switch and roll connector is cracked
or deformed.

AB-I 7
 FRONT SUB SENSOR

1O.Front Sub Sensor

A: REMOVAL
1) Turn the ignition switch OFF.
2) Disconnect the ground cable from the battery,
and wait for at least 20 seconds before starting
work.
3) Remove the front bumper. <Ref. to El-23, RE-
MOVAL, Front Bumper.>
4) Loosen the two bolts to remove sensor cover.

5) Remove the bolt, and then detach the front sub

sensor.
6) Disconnect the connector from the front sub sen-
sor.

B: INSTALLATION
Install in the reverse order of removal.
C: INSPECTION
Check for the following, and replace the damaged
parts with new parts.
Front sub sensor, mounting bracket, and con-
nector are damaged.

AB-I 8
AIRBAG SYSTEM (DIAGNOSTICS)

A5
Page
1. Basic Diagnostic Procedure ........................................................................ 2
2. Check List for Interview............................................................................... 3
3. General Description .................................................................................... 4
4. Electrical Components Location................................................................ 18
5. A/B Control Module I/O Signal .................................................................. 20
6. Airbag Connector ...................................................................................... 21
7. Airbag Warning Light Illumination Pattern................................................. 23
8. Read Diagnostic Trouble Code ................................................................. 24
9. Inspection Mode ........................................................................................ 25
10. Clear Memory Mode.................................................................................. 26
11. Airbag Warning Light Failure..................................................................... 27
12. List of Diagnostic Trouble Code ................................................................ 32
13. Diagnostic Chart with Trouble Code ......................................................... 36
 BASIC DIAGNOSTIC PROCEDURE
AIRBAG SYSTEM (DIAGNOSTICS)

1. Basic Diagnostic Procedure

A: PROCEDURE
Step Check Yes No
Read Diagnostic Trouble Code. s the normal code being -inish the diagno- Go to step 2.
<Ref. to AB-24, Read Diagnostic Trouble
Code.>
letected?

s the trouble code being

;is.

30 to step 3.
IGo to “Airbag
! Read Diagnostic Trouble Code.
<Ref. to AB-24, Read Diagnostic Trouble jetected? Warning Light Fail,
Code.> ure”.<Ref. to AB-
27, Airbag Warn-
ing Light Failure.>
I Perform the diagnosis. s the trouble code being Perform the proce- Finish the diagno-
1)Judge the possible cause from “List of Diag- Jetected? jure 1) to 5)in sis.
nostic Trouble Code” <Ref. to AB-32, List of
Diagnostic Trouble Code.> .
2)lnspect using “Diagnostic Chart with Trouble
Code”. (DTC)
3)Repair the cause of the trouble.
4)Perform the clear memory mode. <Ref. to
AB-26, Clear Memory Mode.>
5)Perform the inspection mode. <Ref. to AB-
25, Inspection Mode.>
6)Read diagnostic trouble code.

AB-2
 CHECK LIST FOR INTERVIEW
AIRBAG SYSTEM (DIAGNOSTICS)

2. Check List for Interview

A: CHECK

Customer's Name Inspector's Name

Date Vehicle Brought In I I Registration No.

Odometer Reading Vin No.

Miles

Date
-. - Problem Occurred I I Registration Year I I

Weather D Fine D Cloudy D Rainy D Snowy I2 Other:

"C (OF)

I2 Level road D Uphill CI Downhill D Rough road CI Others:

CI Starting D Idling
0 Driving (El Constant Speed tl Acceleration D Deceleration
I2 Steering wheel turn CI Other: )

I2 Remains ON D Remains OFF

r-
Check DTC Ll Normal Code

AB-3
D Trouble Code: (Code: )
 GENERAL DESCRIPTION
AIRBAG SYSTEM (DIAGNOSTICS)

3. General Description When checking, use a test harness. Do not di-

rectly apply the tester probe to any connector termi-
A: CAUTION nal of the airbag.
When servicing a vehicle, be sure to turn the ig-
nition switch OFF, disconnect the ground terminal NO GOOD GOOD
from the battery, and wait for more than 20 seconds
before starting work.
The airbag system is fitted with a backup power
source. If the airbag system is serviced within 20
seconds after the ground terminal is disconnected,
it may inflate.

G5M029:

NO GOOD

c-

\ 1 G5M0292

If the sensors, airbag module, airbag control

module pretensioner and harness are deformed or
damaged, replace them with new genuine parts.

r NO GOOD
GOOD

G5M0291 I
Do not use the airbag system and pretensioners G5M0294
on other vehicles. When replacing parts, be sure to Do not check continuity of the driver, passenger,
replace them with new parts. side airbag modules and pretensioner.
Never re-use a deployed airbag and pretension-
er.
When checking the system, be sure to use a dig-
ital circuit tester.
Use of an analog circuit tester may cause the air-
bag to activate erroneously.

NO GOOD
\
G5M0302 I
 GENERAL DESCRIPTION
AIRBAG SYSTEM (DIAGNOSTICS)

Do not allow water or oil to come in contact with Install the wire harness securely with the speci-
the connector terminals. Do not touch the connec- fied clips to avoid interference or tangled up with
tor terminals. other parts.

NO GOOD

I G6M0298 I G5M0297

The airbag module (driver, passenger, side) and When painting or performing sheet metal work
pretensioner must not be disassembled. on the front part of the vehicle, including the front
wheel apron, front fender, and front side frame, re-
NO GOOD
move the front sub sensors and wire harness of the
airbag system.
When painting or performing sheet metal work
r
on the side of the vehicle, including the side sill,
center pillar, and front and rear doors, remove the
side airbag sensors and wire harness of the airbag
system.

G5M0299

If any damage, opening or rust is found on the

airbag system wire harness, do not attempt to re-
pair using soldering equipment. Be sure to replace
the faulty harness with a new genuine part.

\\ NO GOOD
G5M0310

NO GOOD
G5M0296

AB-5
 GENERAL DESCRIPTION
AIRBAG SYSTEM (DIAGNOSTICS)

Do not drop the airbag modulator parts, subject

them to high temperature over 93°C (199"F), or let
water, oil, or grease get on them; otherwise, the in-
ternal parts may be damaged and reliability greatly
lowered.

NO GOOD
G5M029C

The removed front seat with the airbag module

must be kept at least 200 mm (8 in) away from walls
and other objects.

When storing a removed airbag module, do not

place any objects on it or pile airbag modules on
top of each other. If the airbag inflates for some rea-
son when it is placed with its pad side facing down-
ward or under any object, a serious accident may
result.

AB-6
 GENERAL DESCRIPTION
AIRBAG SYSTEM (DIAGNOSTICS)

Driver side GOOD

NO GOOD

NO GOOD
A
G5M0604

AB-7
 GENERAL DESCRIPTION
AIRBAG SYSTEM (DIAGNOSTICS)

Do not discard undeployed airbag modules.

They could easily cause a serious accident if acci-
dentally deployed.
B: INSPECTION
Before diagnosing, check the following items that
might be related to the engine problem:
1. BATTERY
Measure the battery voltage and specific gravity of
electrolyte.
Standard voltage: 12V
Specific gravity: Above 1.260

AB-8
 GENERAL DESCRIPTION
AIRBAG SYSTEM (DIAGNOSTICS)

C: PREPARATION TOOL
1. SPECIAL TOOLS
TEST HARNESS M

ILLUSTRATION TOOLNUMBER I DESCRlPTlON REMARKS

98299FE020 I TEST HARNESS M Used when measuring voltage, resistance of air-
bag system.

RE0033

6 5 4 3
RE0034

AB-9
 GENERAL DESCRIPTION
AIRBAG SYSTEM (DIAGNOSTICS)

TEST HARNESS F

ILLUSTRATION I TOOLNUMBER 1 DESCRIPTION REMARKS

98299FC010 I TEST HARNESS F Used when measuring voltage, resistance of air-
bag module harnesses.

RE0035

I RE0036

AB-I 0
 GENERAL DESCRIPTION
AIRBAG SYSTEM (DIAGNOSTICS)

TEST HARNESS G

ILLUSTRATION TOOL NUMBER

98299FC020
side airbag sensor.

RE0037

G3

1'1 l-4

&,
4 5 6 7 8

RE0038

AB-11
 GENERAL DESCRIPTION
AIRBAG SYSTEM (DIAGNOSTICS)

TEST HARNESS H

DESCRIPTION REMARKS
TESTHARNESSH Used when measuring voltage, resistance of
front sub-sensor.

I RE0039 I

RE0040

AB-I 2
 GENERAL DESCRIPTION
AIRBAG SYSTEM (DIAGNOSTICS)

TEST HARNESS L

I seat belt pretensionei

RE0041 I

RE0042

AB-I 3
 GENERAL DESCRIPTION
AIRBAG SYSTEM (DIAGNOSTICS)

TEST HARNESS 12

ILLUSTRATION I TOOLNUMBER I DESCRIPTION 1 REMARKS

98299FC041 I TEST HARNESS 12 I Used when measuring voltage, resistance of air-

REO045
I

r5 II 1i3 I

It I I 1 1
I

RE0046
 GENERAL DESCRIPTION
AIRBAG SYSTEM (DIAGNOSTICS)

AIRBAG RESISTOR

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

98299PA040 AIRBAG RESISTOR Used in replacement of airbag module which
resistance value is same as airbag module.

RE0047 I

RE0048

AB-16
GENERAL DESCRIPTION a
AIRBAG SYSTEM (DIAGNOSTICS)
 ELECTRICAL COMPONENTS LOCATION
AIRBAG SYSTEM (DIAGNOSTICS)

4. Electrical Components Location

A: LOCATION

*@--

*@-

RE0049
r Male connector

AB-1 8
 ELECTRICAL COMPONENTS LOCATION
AI RBAG SYSTEM (DIAGNOSTICS)

(1) Driver’s airbag module (7) Seat belt pretensioner (LH) (13) Airbag main harness
(2) Roll connector (8) Seat belt pretensioner (RH) (14) Front sub-sensor harness (LH)
(3) Passenger’s airbag module (9) Front sub-sensor (LH) (15) Front sub-sensor harness (RH)
(4) Airbag control module (IO) Front sub-sensor (RH) (16) Side airbag harness (LH)
(5) Side airbag module (LH) (1 1) Side airbag sensor (LH) (17) Side airbag harness (RH)
(6) Side airbag module (RH) (12) Side airbag sensor (RH)

AB-19
I A/B CONTROL MODULE I/O SIGNAL
AIRBAG SYSTEM (DIAGNOSTICS)

5. A/B Control Module I/O Signal

A: SCHEMATIC
<Ref. to WI-31, Airbag System.>

AB-20
 AIRBAG CONNECTOR 91
AIRBAG SYSTEM (DIAGNOSTICS)

6. Airbag Connector 2. DRIVER'S AIRBAG, PASSENGER'S AIR-

BAG, AND SIDE AIRBAG
A: OPERATION 1) How to disconnect:
1. POWER SUPPLY (1) Push the lock arm (A).
(2) With lock arm (A) pushed in, move the slide
1) How to disconnect:
lock (B) in the direction of the arrow.
(1) Move the slide lock (A) in the direction of the
arrow.
(2) Pull the female connector in the direction of
the arrow with slide lock (A) moved.

I \ \ B5M1153AI

* RE0012
(3) With slide lock (B) pulled, remove the lock
arm (A) to its original position, and then pull in
the direction of the arrow and separate the con-
nector.
CAUTION:
When pulling, be sure to hold onto the connec- CAUTION:
tor and not the wire. When pulling, be sure t o hold onto the connec-
tor and not the wire.
2) How to connect:
Holding the connector (A), and push it in carefully
until a connecting sound is heard.

B5M1154

2) How to connect:
/ RE0015 Holding the connector, and push it in carefully until
a connecting sound is heard.
CAUTION:
Be sure to insert the connector in until it locks. CAUTION:
Then pull on it gently t o make sure that it is Be sure to insert the connector in until it locks.
locked. Then pull on it gently to make sure that it is
locked.

AB-21
I AIRBAG CONNECTOR
AIRBAG SYSTEM fDIAGNOSTICS)

3. FRONT SUB-SENSOR, SIDE AIRBAG 4. PRETENSIONER

SENSOR 1) How to disconnect:
1) How to disconnect: (1) Move the slide lock (A) in the direction of the
(1) Holding the outer part (A), pull it in the direc- arrow.
tion of the arrow. (2) Pull the connector (B) in the direction of the
CAUTION: arrow with slide lock (A) moved.
When pulling, be sure to hold onto the connec- / / -1
tor and not the wire.

(A)
CAUTION:
When pulling, be sure to hold onto the connec-
2) How to connect: tor and not the wire.
Holding the connector, and push it in carefully until 2) How to connect:
a connecting sound is heard. Holding the connector (A), and push it in carefully
CAUTION: until a connecting sound is heard.
Outer (A) moves back, and so do not put your
hand on the outer part.
Be sure to insert the connector in until it
locks. Then pull on it gently to make sure that it
is locked.

CAUTION:
Be sure to insert the connector in until it locks.
Then pull on it gently to make sure that it is
locked.

AB-22
 AIRBAG WARNING LIGHT ILLUMINATION PATTERN
AIRBAG SYSTEM (DIAGNOSTICS)

7. Airbag Warning Light Illumi-

nation Pattern
A: INSPECTION
Keep the ignition switch ON, and confirm that the
airbag warning light remains off approximately 6
seconds after being turned on.

Approx. 6 seconds

Airbag warning ON
light OFF
A-1m
igniiion
switch ON
I READ DIAGNOSTIC TROUBLE CODE
AIRBAG SYSTEM (DIAGNOSTICS)

8. Read Diagnostic Trouble 3) Read trouble code by identifying the way the air
bag warning light flashes.
Code The airbag warning light flashes a code corre-
A: OPERATION sponding to the faulty parts.
The long segment (1.2 sec on) indicates a “ten”,
1) Turn the ignition switch ON.
and the short segment (0.3 sec on) indicates a
2) Connect the diagnosis terminal (1) to the diagno- “0ne”.
sis connector (2) terminal No. 1 in the driver’s seat
lower cover area. NOTE:
“List of Diagnostic Trouble Code” <Ref. to AB-32,
List of Diagnostic Trouble Code.>
“Airbag Warning Light Failure” <Ref. to AB-27,
Airbag Warning Light Failure.>

Example:

Flashing
code 12:

Flashing
code21: OFF - 10

1.2
-
,. 0.3 _.
r
10

1.2 1. 0.3 1
.
0.3 1.2
(Set)
1 1’

Flashing
normal
code:

B5M0117A

4) Turn the ignition switch OFF, and disconnect the

diagnosis terminal from the diagnosis connector
terminal No 1.
5 ) Wind the tape around the diagnosis terminal and
return it to its original position.

AB-24
 INSPECTION MODE
AIRBAG SYSTEM (DIAGNOSTICS)

9. Inspection Mode
A: OPERATION
According to the contents of check list, reproduce
the condition which problem has occurred as much
as possible.

AB-25
I CLEAR MEMORY MODE
AIRBAG SYSTEM (DIAGNOSTICS)

1O.Clear Memory Mode

A: OPERATION
1) Turn the ignition switch ON.
2) Connect the diagnosis terminal (1) to the diagno-
sis connector (2) terminal No. 1 in the driver's seat
lower cover area.

3) While the warning light flashes, connect another

diagnosis terminal (3) to the diagnosis connector
Jerminal No.2.
4) Once the memory is erased, the warning light re-
turns to the normal flash rate (0.6 sec on). The fail-
ure to recover the normal flash rate indicates that
trouble parts still remain. Having repaired such
parts, erase the memory again and confirm that the
normal flash rate has returned.
5) When the memory has been cleared, disconnect
the diagnosis terminal from the diagnosis connec-
tor.
6) Wind the tape around the diagnosis terminal and
return it to its original position.

AB-26
 AIRBAG WARNING LIGHT FAILURE
AIRBAG SYSTEM (DIAGNOSTICS)

11.Airbag Warning Light Failure

A: AIRBAG WARNING LIGHT REMAINS ON.
DIAGNOSIS:
Airbag warning light unit is faulty.
Airbag control module to airbag warning light circuit is shorted or open.
Grounding circuit is faulty.
Airbag control module is faulty.
(AB1) and (831) are not connected properly.
(AB6) is not connected properly to airbag control module.
CAUTION:
Before diagnosing the airbag system, be sure to turn the ignition switch OFF, disconnect the
ground terminal from the battery, and wait more than 20 seconds before starting to work.
Before replacing the airbag module, seat belt pretensioner, roll connector, control module, and
sensor, reconnect each part and confirm that the warning light operates properly.
When inspecting the airbag main harness, disconnect the airbag module connector of the driver
and passenger seats for safety reasons.

AB-27
 AIRBAG WARNING LIGHT FAILURE
AIRBAG SYSTEM (DIAGNOSTICS)

WIRING DIAGRAM:

IG SW
N0.13

I
TJ"====
INDICATOR

CIRCUIT
UI

r
k
m

I @ AIRBAG CONTROL MODULE

RE0052

1
(ABl) AND (831).
Step I

1)Turn the ignition switch OFF, disconnect the

battery ground terminal, and wait more than 20
seconds.
2)Remove the side sill cover. (Driver'sside)
3)Confirmthat firm contact is secured between
connectors (AB1 and (831).
Check
CHECK POOR CONTACT IN CONNECTORS I Is the Door contact in connec-
tors (ABI) and (B31)? harness or replace
the body harness
with airbag main
harness.
r
I No
Go to step 2.

AB-28
I AIRBAG WARNING LIGHT FAILURE
a
AIRBAG SYSTEM (DIAGNOSTICS)

Step Check Yes No

2 CHECK AIRBAG WARNING LIGHT. s the airbag warning light Go to step 4. ;o to step 3.
1)Turn the ignition switch OFF, disconnect the
battery ground terminal, and wait more than 20
seconds.
2)Connect the connector (11\11)in the test har-
ness M to the body harness connector (831).
3)Connect the battery ground terminal and
turn the ignition switch ON.
4)Connect two connectors, (3M) and (4M) in
the test harness M.
3 CHECK BODY HARNESS. s the anything unusual to body Repair the body 3eplace combina-
Check the body harness. iarness? harness. ion meter printed
NOTE: :ircuit. <Ref. to
After problem has been eliminated, disconnect DI-11, Combina-
connectors (3M) and (4M). ion Meter Assem-
,lY.>

i
CHECK POOR CONTACT. s the poor contact in connec- Replace the body So to step 5.
Confirm that the firm contact is secured or (AB6)? harness with air-
between the airbag control module and the bag main harness
connector (AB6). <Ref. to AB-15, Airbag Con- or replace the air-
trol Module.> bag control mod-
ule. <Ref. to AB-
15, Airbag Control
Module.>
CHECK AIRBAG MAIN HARNESS. s the airbag warning light Go to step 6. 3eplace the body
1)Turn the ignition switch OFF, disconnect the urned off? iarness with air-
battery ground terminal, and wait more than 20 )ag main harness
seconds.
2)Connect the connector (ABI) to (831).
3)Disconnect the connectors (AB3) and (AB8).
4)Remove the glove box and disconnect the
connectors (AB10) and (AB9).
5)Disconnect the connector (AB6) from the air-
bag control module, and connect the connector
(1I) in the test harness I or 12. <Ref. to AB-15,
Airbag Control Module.>
6)Connect the battery ground terminal and
turn the ignition switch ON.
7)Connect the connectors (41) and (51) in the
test harness I or 12.
NOTE:
After problem has been eliminated, disconnecl
connectors (41) and (51).
CHECK GROUNDING CIRCUIT. 3epair body-
1)Turn the ignition switch OFF, disconnect the 2? control module. jrounding circuit.
battery ground terminal, and wait more than 20 <Ref. to AB-15,
seconds. Airbag Control
2)Disconnect the connector (AB6) from the air-
bag control module.
3)Connect the connector (1I) in the test har-
ness I or 12 to body harness connector (AB6).
4)Measure the resistance between connector
(21) in the test harness I or 12 and the chassis
ground.
Connector & terminal
(21) No. 9 - Chassis ground:
(211 No. 10 - Chassis wound:

AB-29
I AIRBAG WARNING LIGHT FAILURE
AIRBAG SYSTEM (DIAGNOSTICS)

B: AIRBAG WARNING LIGHT REMAINS OFF.

DIAGNOSIS:
Fuse No. 13 (in fuse box) is blown.
Body harness circuit is open.
Airbag warning light is faulty.
Airbag main harness is faulty.
Airbag control module is faulty.
CAUTION:
Before diagnosing the airbag system, be sure to turn the ignition switch OFF, disconnect the
ground terminal from the battery, and wait more than 20 seconds before starting to work.
Before replacing the airbag module, seat belt pretensioner, roll connector, control module, and
sensor, reconnect each part and confirm that the warning light operates properly.
When inspecting the airbag main harness, disconnect the airbag module connector of the driver
and passenger seats for safety reasons.
WIRING DIAGRAM:

1
F
I @ AIRBAG CONTROL MODULE

RE0052

AB-30
 AIRBAG WARNING LIGHT FAILURE
AIRBAG SYSTEM (DIAGNOSTICS)

Step Check Yes No

1 CHECK COMBINATION METER. Do warning lights not for the Go to step 2. Repair the combi-
Turn the ignition switch ON, and confirm that airbag turn on? nation meter
warning lights equipped in the combination power supply.
meter are turned on. <Ref. to 101-4,
Combination
Meter System.>
2 CHECK FUSE NO. 13 (IN MAIN FUSE BOX). Is the fuse No. 13 (in main fuse Replace the fuse Go to step 3.
Remove the fuse No. 13 and perform visual box) blown? No. 13. If the fuse
inspection. No. 13 blows
again, go to step
3.
3 CHECK AIRBAG WARNING LIGHT CIRCUIT Is the airbag warning light Go to step 4. Replace the airbag
(IN COMBINATION METER). warning light bulb
1)Turn the ignition switch OFF, disconnect the or combination
battery ground terminal, and wait more than 20 meter printed cir-
seconds. cuit. <Ref. to IDI-
2)Disconnect the connector (ABI) from (831). 11, Combination
3)Connect the battery ground terminal and Meter Assembly.>
turn the ignition switch ON.
4 CHECK AIRBAG MAIN HARNESS. Is the airbag warning light Replace the airbag Replace the body
1)Turnthe ignition switch OFF, disconnect the turned on? control module. harness with air-
r- -
battery ground terminal, and wait more than 20 <Ref. to AB-15, bag main harness.
seconds. Airbag Control
2)Connect the connector (ABI) to (831). Module.>
3)Disconnect the connector (AB6) from the air-
bag control module. <Ref. to AB-15, Airbag
Control Module.>
4)Connect the battery ground terminal and
turn the ignition switch ON.

AB-31
I LIST OF DIAGNOSTIC TROUBLE CODE
AIRBAG SYSTEM (DIAGNOSTICS)

12.List of Diagnostic Trouble Code

A: LIST
Memory Index No.
Contents of diagnosis
function
Airbag main harness circuit is open, shorted or
shorted to ground.
Airbag module harness (driver) circuit is open, <Ref. to AB-36, TROU-
shorted or shorted to ground. BLE CODE 11, Diag-
Provided. Roll connector circuit is open, shorted or shorted nostic Chart with
to ground. Trouble Code.>
Airbag control module is faulty.
Driver's airbag module is faulty.
Airbag main harness circuit is open, shorted or
shorted to ground. <Ref. to AB-38, TROU-
Airbag module harness (passenger) circuit is BLE CODE 12, Diag-
Provided.
open, shorted or shorted to ground. nostic Chart with
Airbag control module is faulty. Trouble Code.>
Passenger's airbag module is faulty.
Airbag main harness circuit (driver) is shorted to
power supply.
<Ref. to AB-40, TROU-
Airbag module harness (driver) is shorted to power
BLE CODE 15, Diag-
Provided. supply. nostic Chart with
Roll connector is shorted to power supply.
Trouble Code.>
Airbag control module is faulty.
Driver's airbag module is faulty.
Airbag main harness circuit (passenger) is shorted
to power supply. <Ref. to AB-42, TROU-
Airbag module harness (passenger) is shorted to BLE CODE 16, Diag-
Provided.
power supply. nostic Chart with
Airbag control module is faulty. Trouble Code.>
Passenger's airbag module is faulty.
<Ref. to AB-43, TROU-
BLE CODE 21, Diag-
Provided. Airbag control module is faulty.
nostic Chart with
Trouble Code.>
<Ref. to AB-44, TROU-
Front airbag module and seat belt pretensioner (LH/ BLE CODE 22, Diag-
Provided.
RH) are inflated. nostic Chart with
Trouble Code.>
<Ref. to AB-44, TROU-
(AB6), (AB17) and (AB18) are not connected prop- BLE CODE 23, Diag-
Not provided. nostic Chart with
erly to airbag control module.
Trouble Code.>
Airbag control module is faulty. <Ref. to AB-46, TROU-
Airbag main harness circuit is open. BLE CODE 24, Diag-
Not provided. Fuse No. 11 (in joint box) is blown. nostic Chart with
Body harness circuit is open. Trouble Code.>
Airbag control module is faulty. <Ref. to AB-48, TROU-
Airbag main harness circuit is open. BLE CODE 25, Diag-
Provided. Fuse No. 6 (in joint box) is blown. nostic Chart with
Body harness circuit is open. Trouble Code.>
Front sub-sensor harness (RH) circuit is shorted. <Ref. to AB-50, TROU-
Front sub-sensor harness (RH) circuit is open. BLE CODE 31, Diag-
Provided. Front sub-sensor (RH) is faulty. nostic Chart with
Airbaq control module is faulty. Trouble Code.>

AB-32
 LIST OF DIAGNOSTIC TROUBLE CODE
AIRBAG SYSTEM (DIAGNOSTICS)

Trouble code/ Memory Contents of diagnosis Index No.

Contents of troubles function
Front sub-sensor harness (LH) circuit is shorted. <Ref. to AB-54, TROU-
Front sub-sensor harness (LH) circuit is open. BLE CODE 32, Diag-
Front sub-sensor (LH) is faulty. nostic Chart with
Airbag control module is faulty. Trouble Code.>
Side airbag harness (RH) is faulty. <Ref. to AB-58, TROU-
Side airbag module (RH) is faulty. BLE CODE 41, Diag-
Airbag control module is faulty. nostic Chart with
_____
Trouble Code.>
Side airbag harness (LH) is faulty. <Ref. to AB-60, TROU-
Side airbag module (LH) is faulty. BLE CODE 42, Diag-
42 Provided. nostic Chart with
Airbag control module is faulty.
Trouble Code.>
Side airbag harness (RH) is shorted to power sup- <Ref. to AB-62, TROU-
Ply. BLE CODE 45, Diag-
45 Provided. nostic Chart with
Airbag control module is faulty.
Trouble Code.>
Side airbag harness (LH) is shorted to power sup- <Ref. to AB-64, TROU-
Ply. BLE CODE 46, Diag-
46 Provided. nostic Chart with
Airbag control module is faulty.
-.. Trouble Code.>
Side airbag sensor (RH) is faulty. <Ref. to AB-66, TROU-
Side airbag harness (RH) is faulty. BLE CODE 51, Diag-
51 Provided. nostic Chart with
Airbag control module is faulty.
Trouble Code.>
Side airbag sensor (LH) is faulty. <Ref. to AB-68, TROU-
Side airbag harness (LH) is faulty. BLE CODE 52, Diag-
52 Provided.
Airbag control module is faulty. nostic Chart with
Trouble Code.>
<Ref. to AB-69, TROU-
BLE CODE 53, Diag-
53 Provided. Side airbag sensor (RH) is faulty. nostic Chart with
Trouble Code.>
<Ref. to AB-69, TROU-
BLE CODE 54, Diag-
54 Provided. Side airbag sensor (LH) is faulty.
nostic Chart with
Trouble Code.>
<Ref. to AB-70, TROU-
BLE CODE 55, Diag-
55 Provided. Side airbag module is inflated. nostic Chart with
Trouble Code.>
Seat belt pretensioner (RH) circuit is open, shorted
<Ref. to AB-72, TROU-
or shorted to ground. BLE CODE 61, Diag-
61 Provided. Airbag control module is faulty.
nostic Chart with
Pretensioner is faulty. Trouble Code.>
Pretensioner harness is faulty.
Seat belt pretensioner (LH) circuit is open, shorted
<Ref. to AB-74, Trouble
or shorted to ground.
Code 62, Diagnostic
Airbag control module is faulty.
Chart with Trouble
Pretensioner is faulty. Code.>
Pretensioner harness is faulty.
Seat belt pretensioner (RH) circuit is shorted to
<Ref. to AB-76, TROU-
power supply. BLE CODE 65, Diag-
Pretensioner is faulty.
nostic Chart with
Pretensioner harness is faulty.
Trouble Code.>
Airbag control module is faulty.

AB-33
 Trouble codel Memory
Contents of diagnosis Index No.
Contents of troubles function
Seat belt pretensioner (LH) circuit is shorted to
<Ref. to AB-78, TROU-
power supply. BLE CODE 66, Diag-
66 Provided. Pretensioner is faulty. nostic Chart with
Pretensioner harness is faulty.
Trouble Code.>
Airbag control module is faulty.

AB-34
LIST OF DIAGNOSTIC TROUBLE CODE
AIRBAG SYSTEM (DIAGNOSTICS)

AB-35
 DIAGNOSTIC CHART WITH TROUBLE CODE
AI RBAG SYSTEM (DIAGNOSTICS)

13.Diagnostic Chart with Trouble Code

A: TROUBLE CODE 11
DIAGNOSIS:
Airbag main harness circuit is open, shorted or shorted to ground.
Airbag module harness (Driver) circuit is open, shorted or shorted to ground.
Roll connector circuit is open, shorted or shorted to ground.
Driver's airbag module is faulty.
Airbag control module is faulty.
CAUTION:
Before diagnosing the airbag system, be sure to turn the ignition switch OFF, disconnect the
ground terminal from the battery, and wait more than 20 seconds before starting to work.
Before replacing the airbag module, seat belt pretensioner, roll connector, control module, and
sensor, reconnect each part and confirm that the warning light operates properly.
When inspecting the airbag main harness, disconnect the driver's airbag module and passenger's
airbag module connectors for safety reasons.
WIRING DIAGRAM:

@(YELLOW) @(YELLOW)

B5M109f

AB-36
I DIAGNOSTIC CHART WITH TROUBLE CODE
AIRBAG SYSTEM (DIAGNOSTICS)

Step Check Yes No

CHECK DRIVER'S AIRBAG MODULE. )oes the airbag warning light 3eplace the 30 to step 2.
1)Turn the ignition switch OFF, disconnect the iperate properly? iriver's airbag
battery ground terminal, and wait more than 20 nodule. <Ref. to
seconds. 4B-12, Driver's
2)Remove the driver's airbag module. <Ref. to 4irbag Module.>
AB-12, Driver'sAirbag Module.>
3)Connect the connector (1F) in the test har-
ness F to connector (AB7).
4)Connect the airbag resistor to connector (3F)
in the test harness F.
5)Connect the battery ground terminal and
turn the ignition switch ON.
CHECK ROLL CONNECTOR. )oes the airbag warning light 3eplace the roll 30 to step 3.
1)Turn the ignition switch OFF, disconnect the iperate properly? :onnector. <Ref.
battery ground terminal, and wait more than 20 o AB-17, Roll
seconds. :onnector.>
2)Disconnect the test harness F from the con-
nector (AB7).
3)Remove the lower cover panel, disconnect
the connector (AB3) from (AB8) and connect
the connector (1F) in the test harness F to con.
nector (AB8).
4)Connect the airbag resistor to connector (3F)
in the test harness F.
5)Connect the battery ground terminal and
turn the ignition switch ON.
CHECK AIRBAG MAIN HARNESS. ;the resistance less than 10 ;o to step 4. 3eplace the body
1)Turn the ignition switch OFF, disconnect the 1? iarness with air-
battery ground terminal, and wait more than 20 lag main harness
seconds.
2)Disconnect the airbag resistor from the con-
nector (3F) in the test harness F.
3)Remove the glove box, <Ref. to AB-13, Pas-
senger's Airbag Module.> and disconnect the
connectors (ABIO) and (AB9).
4)Disconnect the connector (AB6) from the air-
bag control module, and connect the connector
(1I) in the test harness I or 12. <Ref. to AB-15,
Airbag Control Module.>
5)Measure the resistance between connector
(21) in the test harness I or 12 and the connec-
tor (3F) in the test harness F.
Connector & terminal
(2l) NO. 1 - (3F) NO. 4:
(21) NO. 4 - (3F) NO. 3:
CHECK AIRBAG MAIN HARNESS. ;the resistance more than 1 3eplace the airbag 3eplace the body
Measure the resistance of the connector (21) in 1R? :ontrol module. iarness with air-
the test harness I or 12. :Ref. to AB-15, )ag main harness
Connector & terminal \irbag Control
(21) NO. 1 -NO. 4: Aodule.>
(21) No. 4 - Chassis ground:
(21) No. 1 - Chassis ground:

AB-37
 DIAGNOSTIC CHART WITH TROUBLE CODE
AIRBAG SYSTEM (DIAGNOSTICS)
~

B: TROUBLE CODE 12
DIAGNOSIS:
Airbag main harness circuit is open, shorted or shorted to ground.
Airbag module harness (Passenger) circuit is open, shorted or shorted to ground.
Passenger's airbag module is faulty.
Airbag control module is faulty.
CAUTION:
Before diagnosing the airbag system, be sure to turn the ignition switch OFF, disconnect the
ground terminal from the battery, and wait more than 20 seconds before starting to work.
Before replacing the airbag module, seat belt pretensioner, roll connector, control module, and
sensor, reconnect each part and confirm that the warning light operates properly.
When inspecting the airbag main harness, disconnect the airbag module connector of the driver
and passenger seats for safety reasons.
WIRING DIAGRAM:

@ AIRBAG CONTROL MODULE

INFLATOR
(PASSENGER SIDE)

AB-38
 DIAGNOSTIC CHART WITH TROUBLE CODE
AIRBAG SYSTEM (DIAGNOSTICS)
~

Step No
I CHECK PASSENGER'SAIRBAG MODULE. ;o to step 2.
1)Turn the ignition switch OFF, disconnect the
battery ground terminal, and wait more than 20
seconds.
2)Remove the glove box.
3)Disconnect the connector (AB10) from
(AB9).
4)Connect the connector (1F) in the test har-
ness F to connector (AB9).
5)Connect the airbag resistor to connector (3F)
in the test harness F. I
6)Connect the battery ground terminal and
turn the ignition switch ON.
! CHECK AIRBAG MAIN HARNESS. s the resistance less than 10 Go to step 3. leplace the body
1)Turn the ignition switch OFF, disconnect the Z? iarness with air-
battery ground terminal, and wait more than 20 lag main harness.
seconds.
2)Disconnect the airbag resistor from the con-
nector (3F) in test harness F.
3)Remove lower cover and disconnect the con-
nector (AB3) from (AB8).
r- 4)Disconnect the connector (AB6) from the air-
bag control module, and connect the connector
(1I) in the test harness I or 12. <Ref. to AB-15,
Airbag Control Module.>
5)Measure the resistance between connector
(21) in the test harness I or 12 and the connec-
tor (3F) in the test harness F.
Connector & terminal
(21) NO. 2 - (3F) NO. 3:
(21) NO. 5 - (3F) NO. 4:
I CHECK AIRBAG MAIN HARNESS. s the resistance more than 1 eeplace airbag leplace the body
Measure the resistance of the connector (21) in An? control module. larness with air-
the test harness I or 12. <Ref. to AB-15, lag main harness.
Connector 81terminal Airbag Control
-
(21)NO. 2 NO. 5: Module.>
-
(21)No. 2 Chassis ground:
-
(21) No. 5 Chassis ground:

AB-39
I
DIAGNOSTIC CHART WITH TROUBLE CODE
AIRBAG SYSTEM (DIAGNOSTICS)

C: TROUBLE CODE 15
DIAGNOSIS:
Airbag main harness circuit (Driver) is shorted to the power supply.
Airbag module harness (Driver) is shorted to the power supply.
Roll connector is shorted to the power supply.
Driver's airbag module is faulty.
Airbag control module is faulty.
CAUTION:
Before diagnosing the airbag system, be sure to turn the ignition switch OFF, disconnect the
ground terminal from the battery, and wait more than 20 seconds before starting to work.
Before replacing the airbag module, seat belt pretensioner, roll connector, control module, and
sensor, reconnect each part and confirm that the warning light operates properly.
When inspecting the airbag main harness, disconnect the driver's airbag module and passenger's
airbag module connectors for safety reasons.
WIRING DIAGRAM:

AB6 AIRBAG CONTROL MODULE

r
IO
I

STEERING
ROLL CONNECTOR

U
INFLATOR

@(YELLOW) @(YELLOW)

@(YELLOW)

B5M109t

AB-40
 DIAGNOSTIC CHART WITH TROUBLE CODE
AIRBAG SYSTEM (DIAGNOSTICS)

Step Check Yes No

I CHECK DRIVER'SAIRBAG MODULE. Ioes the airbag warning light Replace the 20 to step 2.
1)Turn the ignition switch OFF, disconnect the )perate properly? driver's airbag
battery ground terminal, and wait more than 20 module. <Ref. to
seconds. AB-12, Driver's
2)Remove the driver's airbag module. <Ref. to Airbag Module.>
AB-12, Driver's Airbag Module.>
3)Connect the connector (AB7) to connector
(1F) in the test harness F.
4)Connect the airbag resistor to connector (3F)
in the test harness F.
5)Connect the battery ground terminal and
turn the ignition switch ON.
? CHECK ROLL CONNECTOR. Ioes the airbag warning light Replace the roll 20 to step 3.
1)Turn the ignition switch OFF, disconnect the )perate properly? connector. <Ref.
battery ground terminal, and wait more than 20 to AB-17 , Roll
seconds. Connector.>
2)Disconnect the test harness F from the con-
nector (AB7).
3)Remove the lower cover panel and discon-
nect the connector (AB3) from (AB8).
4)Connect the connector (1F) in the test har-
I
r- ness F to the connector (AB8).
5)Connect the airbag resistor to connector (3F)
in the test harness F.
6)Connect the battery ground terminal and
turn the ignition switch ON.
i CHECK AIRBAG MAIN HARNESS. 3eplace the body
1)Turnthe ignition switch OFF, disconnect the control module. iarness with air-
battery ground terminal, and wait more than 20 <Ref. to AB-15, )ag main harness.
seconds. Airbag Control
2)Disconnect the airbag resistor from the con- Module.>
nector (3F) in test harness F.
3)Remove the glove box, and disconnect the
connectors (AB10) and (AB9).
4)Disconnect the connector (AB6) from the air-
bag control module, and connect the connector
(1I) in the test harness I or 12. <Ref. to AB-1 5,
Airbag Control Module.>
5)Connect the battery ground terminal and
turn the ignition switch ON. (Engine OFF)
6)Measure the voltage between connector (21)
in the test harness I or 12 and the chassis
ground.
Connector & terminal
(21) No. 4 (+) - Chassis groundI)-(
(21) No. 1 (+) - Chassis ground (-):

AB-41
I DIAGNOSTIC CHART WITH TROUBLE CODE
AIRBAG SYSTEM (DIAGNOSTICS)

D: TROUBLE CODE 16
DIAGNOSIS:
Airbag main harness circuit (Passenger) is shorted to the power supply.
Airbag module harness (Passenger) is shorted to the power supply.
Passenger's airbag module is faulty.
Airbag control module is faulty.
CAUTION:
Before diagnosing the airbag system, be sure to turn the ignition switch OFF, disconnect the
ground terminal from the battery, and wait more than 20 seconds before starting to work.
Before replacing the airbag module, seat belt pretensioner, roll connector, control module, and
sensor, reconnect each part and confirm that the warning light operates properly.
When inspecting the airbag main harness, disconnect the airbag module connector of the driver
and passenger seats for safety reasons.
WIRING DIAGRAM:

r
INFLATOR
(PASSENGER SIDE)

1 RE0053

AB-42
 DIAGNOSTIC CHART WITH TROUBLE CODE
AIRBAG SYSTEM (DIAGNOSTICS)

Step Check
CHECK PASSENGER'S AIRBAG MODULE. )es the airbag warning light
1)Turn the ignition switch OFF, disconnect the 'erate properly? ;enger airbag
battery ground terminal, and wait more than 20 nodule. <Ref. to
seconds. 4B-I 3, Passen-
2)Remve the glove box. jerk Airbag Mod-
3)Disconnect the connector (AB10) from (AB9
4)Connect the connector (1F) in the test har-
ness F to the connector (AB9).
5)Connect the airbag resistor to connector (3F)
in the test harness F.
6)Connect the battery ground terminal and
turn the ignition switch ON.
! CHECK AIRBAG MAIN HARNESS. the voltage less than 1 V?
1)Turn the ignition switch OFF, disconnect the
battery ground terminal, and wait more than 20
seconds. 4irbag Control
2)Disconnect the airbag resistor from the con- vlodu1e.r
nector (3F) in the test harness F.
3)Remove the lower cover and disconnect the
connector (AB3) from (AB8).
r-
4)Disconnect the connector (AB6) from the air
bag control module, and connect the connector
(1I) in the test harness I or 12. <Ref. to AB-15,
Airbag Control Module.>
5)Measure the voltage between connector (21)
in the test harness I or 12 and the chassis
ground.
Connector & terminal
(21) No. 2 - Chassis ground:
(21) No. 5 - Chassis ground:

E: TROUBLE CODE 21
DIAGNOSIS:
Airbag control module is faulty.
CAUTION:
Before diagnosing the airbag system, be sure to turn the ignition switch OFF, disconnect the
ground terminal from the battery, and wait more than 20 seconds before starting to work.
Before replacing the airbag module, seat belt pretensioner, roll connector, control module, and
sensor, reconnect each part and confirm that the warning light operates properly.

Step Check Yes No

1 CHECK IF TROUBLE CODE 21 IS INDICAT- Is the airbag warning light trou- Replacethe airbag Perform clear
ED. ble code 21 indicated? control module. memory. <Ref. to
Read Diagnostic Trouble Code. <Ref. to AB- <Ref. to AB-15, AB-26, Clear
24, Read Diagnostic Trouble Code.> Airbag Control Memory Mode.>
Module.>

AB-43
I DIAGNOSTIC CHART WITH TROUBLE CODE
AIRBAG SYSTEM (DIAGNOSTICS)

F: TROUBLE CODE 22
This code is indicated when the front airbag and the
pretensioner are in operation.
Once this code is indicated, memory is not erasable; therefore replace the following parts.
Airbag control module. <Ref. to AB-15 , Airbag Control Module.>
Driver's airbag module. <Ref. to AB-12, Driver's Airbag Module.>
Passenger's airbag module. <Ref. to AB-13, Passenger's Airbag Module.>
Front sub-sensor of both sides. <Ref. to AB-18, Front Sub Sensor.>
Front seat belt outer with pretensioner of both sides. <Ref. to SB-8, Front Seat Belt.>
G: TROUBLE CODE 23
DIAGNOSIS:
(AB6), (AB17) and (AB18) are not connected properly to airbag control module.
CAUTION:
Before diagnosing the airbag system, be sure to turn the ignition switch OFF, disconnect the ground
terminal from the battery, and wait more than 20 seconds before starting to work.

Step Check Yes No

1 CHECK POOR CONTACT IN CONECTORS Check if the rust or damage Replace the airbag Go to step 2.
(Ass), (AB17) and (AB18). appear on the harness con- control module.
.. 1)Turn the ignition switch OFF, disconnect the nector and the control module <Ref. to AB-15,
battery ground terminal, and wait more than 20 connector. Airbag Control
seconds. Module.> Replace
2)Disconnect the connectors (AB6), (AB17) the body harness
and (AB18) from the airbag control module. with airbag main
<Ref. to AB-15, Airbag Control Module.> harness.
Replace the body
harness with side
airbag harness.
I
2 CHECKPOORCONTACTINCONECTORS Finish the diagno- I Replace the airbag
(Ass), (AB17) and (AB18). operate properly? sis. control module.
1)Ensure that the connectors are firmly recon- <Ref. to AB-15,
nected. Airbag Control
2)Connect the battery ground terminal and Module.>
turn the ignition switch ON.

AB-44
I DIAGNOSTIC CHART WITH TROUBLE CODE
AIRBAG SYSTEM (DIAGNOSTICS)

AB-45
 DIAGNOSTIC CHART WITH TROUBLE CODE
AIRBAG SYSTEM (DIAGNOSTICS)

H: TROUBLE CODE 24
DIAGNOSIS:
Airbag control module is faulty.
Airbag main harness circuit is open.
Fuse No, 11 (in joint box) is blown.
Body harness circuit is open.
CAUTION:
Before diagnosing the airbag system, be sure to turn the ignition switch OFF, disconnect the
ground terminal from the battery, and wait more than 20 seconds before starting to work.
Before replacing the airbag module, seat belt pretensioner, roll connector, control module, and
sensor, reconnect each part and confirm that the warning light operates properly.
When inspecting the airbag main harness, disconnect the driver's airbag module and passenger's
airbag module connectors for safety reasons.
WIRING DIAGRAM:

IG SW
N0.11

I W

I AIRBAG CONTROL MODULE I

RE0054

AB-46
 DIAGNOSTIC CHART WITH TROUBLE CODE
m
At RBAG SYSTEM (DIAGNOSTICS)

Step Check Yes No

CHECK AIRBAG CONTROL MODULE. 3 the voltage more than 10 V? 3eplace the airbag ) to step 2.

1)Turn the ignition switch OFF, disconnect the :ontrol module.

battery ground terminal, and wait more than 20 :Ref. to AB-15,
seconds. 4irbag Control
2)Disconnect the connector (AB6) from the air- vlodule.>
bag control module. <Ref. to AB-15, Airbag
Control Module.>
3)Connect the connector (1I) in the test har-
ness I or 12 to connector (AB6).
4)Connect the battery ground terminal and
turn the ignition switch ON.
5)Measure the voltage between connector (21)
in the test harness I or 12 and chassis ground.
Connector & terminal
(21) No. 3 (+) - Chassis ground (-):
CHECK AIRBAG MAIN HARNESS. s the resistance less than 10 30 to step 3. ?placethe body
1)While checking control module, turn the igni- 2? .messwith air-
tion switch OFF and disconnect the battery .g main harness.
ground terminal. Wait more than 20 seconds
before operation.
2)Disconnect the airbag connector (AB1) from
the body harness (B31).
3)Connect the connector (2M) in the test har-
ness M to connector (AB1).
4)Measure the resistance between connector
(5M) in the test harness M and the connector
(21) in the test harness I or 12.
Connector & terminal
(5M) NO. 2 - (21) NO. 3:
CHECK AIRBAG MAIN HARNESS. s the resistance more than 1 30 to step 4. ?placethe body
Measure the following resistance with the dfi? irness with air-
above-mentioned condition maintained. ig main harness
Connector & terminal
(5M) No. 2 - Chassis ground:
(21) No. 3 - Chassis ground:
CHECK FUSE No. 11 (IN JOINT BOX). s fuse No. 11 blown? 3eplace fuse No. ?pairthe body
1)Confirmthat the ignition switch is turned 11. Iffuse No. 11 irness.
OFF. lows again, repair
2)Remove the fuse No. 11 (in joint box) and :he body harness.
perform visual inspection.

AB-47
I DIAGNOSTIC CHART WITH TROUBLE CODE
AIRBAG SYSTEM (DIAGNOSTICS)

I: TROUBLE CODE 25
DIAGNOSIS:
Airbag control module is faulty.
Airbag main harness circuit is open.
Fuse No. 6 (in joint box) is blown.
Body harness circuit is open.
CAUTION:
Before diagnosing the airbag system, be sure to turn the ignition switch OFF, disconnect the
ground terminal from the battery, and wait more than 20 seconds before starting to work.
Before replacing the airbag module, seat belt pretensioner, roll connector, control module, and
sensor, reconnect each part and confirm that the warning light operates properly.
When inspecting the airbag main harness, disconnect the driver's airbag module and passenger's
airbag module connectors for safety reasons.
WIRING DIAGRAM:

r Y
AB6 AIRBAG CONTROL MODULE

RE0055

AB-48
 DIAGNOSTIC CHART WITH TROUBLE CODE
m
AIRBAG SYSTEM (DIAGNOSTICS)
~~ ~~ ~

Step Check Yes No

CHECK AIRBAG CONTROL MODULE. the voltage more than 10 V? Replace the airbag i o to step 2.
1)Turn the ignition switch OFF, disconnect the control module.
battery ground terminal, and wait more than 20 <Ref. to AB-15,
seconds. Airbag Control
2)Disconnect the connector (AB6) from airbag Module.>
control module. <Ref. to AB-15, Airbag Control
Module.>
3)Connect the connector (1 I ) in the test har-
ness I or 12 to the connector (AB6).
4)Connect the battery ground cable, and turn
the ignition switch ON.
5)Measure the voltage between the connector
(21) in the test harness I or 12 and the chassis
ground.
Connector & terminal
(21) No. 6 (+) - Chassis ground (-):
! CHECK AIRBAG MAIN HARNESS. the resistance less than 10 I Go to step 3. 3eplace the body
1) While checking control module, turn the igni iarness with air-
tion switch OFF and disconnect the battery )ag main harness
ground terminal. Wait more than 20 seconds
before operation.
-. . 2)Disconnect the airbag connector (ABI) from
the body harness (B31).
3)Connect the connector (2M) in the test har-
ness M to the airbag connector (AB1).
4)Measure the resistance between the con-
nector (5M) in the test harness M and the con-

01
nector (21) in the test harness I or 12.
Connector & terminal
(5M) NO. 2 - (20 NO. 6:
1 CHECK AIRBAG MAIN HARNESS. the resistance more than 1 Go to step 4. 3eplace the body
Measure the following resistance with the iarness with air-
above-mentionedcondition maintained. lag main harness
Connector & terminal
(5M) No. 2 - Chassis ground:
(21) No. 6 - Chassis ground:
I CHECK FUSE NO. 6 (IN JOINT BOX). 3epair the body
1)Confirm that the ignition switch is turned No. 6. If the fuse iarness.
OFF. No. 6 is blown
2)Remove the fuse No. 6 (in joint box) and per again, repair the
form visual inspection. bodv harness.

AB-49
I DIAGNOSTIC CHART WITH TROUBLE CODE
AIRBAG SYSTEM (DIAGNOSTICS)

J: TROUBLE CODE 31
DIAGNOSIS:
Front sub-sensor harness (RH) circuit is shorted.
Front sub-sensor harness (RH) circuit is open.
Front sub-sensor (RH) is faulty.
Airbag control module is faulty.
CAUTION:
Before diagnosing the airbag system, be sure to turn the ignition switch OFF, disconnect the
ground terminal from the battery, and wait more than 20 seconds before starting to work.
Before replacing the airbag module, seat belt pretensioner, roll connector, control module, and
sensor, reconnect each part and confirm that the warning light operates properly.
When inspecting the airbag main harness, disconnect the driver's airbag module and passenger's
airbag module connectors for safety reasons.
WIRING DIAGRAM:

7
E
AB6 AIRBAG CONTROL MODULE

m
FRONT SUB SENSOR RH

RE0029

AB-50
 DIAGNOSTIC CHART WITH TROUBLE CODE iim
AI RBAG SYSTEM (DIAG NOSTICS1

Step Check Yes No

CHECK FRONT SUB-SENSOR (RH) AND Is the resistance between 30 to step 2. I Go to step 3.
FRONT SUB-SENSOR HARNESS (RH). 7500 and 1 KQ?

Connector & terminal

(31) NO.2 - NO. 4:
CHECK FRONT SUB-SENSOR (RH) AND Is the resistance more than 1 3eplace the airbag Go to step 3.
FRONT SUB-SENSOR HARNESS (RH). MQ? :ontrol module.
Measure the resistance between connector :Ref. to AB-15,
(31) in the test harness I or 12 and the chassis 4irbag Control
ground. vlodule.>
Connector & terminal
-
(31) No. 2 Chassis ground:
(31) No. 4 - Chassis ground:
CHECK AIRBAG MAIN HARNESS AND Is the resistance less than 20 to step 4. Go to step 5.
FRONT SUB-SENSOR HARNESS (RH). 1on?
1)Disconnectthe connector (AB16) from the
front sub-sensor. <Ref. to AB-18, Front Sub
Sensor.>
2)Connect the connector (IH) in test harness H
to the connector (AB16).
3)Measure the resistance between connector
(31) in test harness I or 12 and connector (3H)
in the test harness H.
Connector & terminal
(31) NO. 2 - (3H) NO. 5:
(31) NO. 4 - (3H) NO. 6:
CHECK AIRBAG MAIN HARNESS AND Is the resistance more than 1 20 to step 10. Go to step 5.
FRONT SUB-SENSOR HARNESS (RH). MQ?
Measure the resistance between connector
(31) in the test harness I or 12 and the chassis
ground.
Connector & terminal
-
(3l) No. 2 Chassis ground:
-
(31) No. 4 Chassis ground:
CHECK AIRBAG MAIN HARNESS Is the resistance less than 10 20 to step 6. Replace the body
1)Disconnect the connector (AB15) from R? harness with air-
(AB14), and connect the connector (1F) in test bag main harness
harness F to the connector (AB14).
2)Measure the resistance between connector
(31) in the test harness I or 12 and connector
(3F) in the test harness F.
Connector & terminal
(31) NO. 2 - (3F) NO. 4:
(31) NO. 4 -(3F) NO. 3:
CHECK AIRBAG MAIN HARNESS Is the resistance more than 1 20 to step 7. Replace the body
Measure the resistance between connector MR? harness with air-
(31) in the test harness I or 12 and the chassis bag main harness
ground.
Connector & terminal
(31) No. 2 - Chassis ground:
(31) No. 4 - Chassis ground:

AB-51
I DIAGNOSTIC CHART WITH TROUBLE CODE
AIRBAG SYSTEM (DIAGNOSTICS)

Step Check Yes No

CHECK FRONT SUB-SENSOR HARNESS Is the resistance less than 10 30 to step 8. Replace the body
(RH). R? harness with front
1)Connect the connector (2F) in the test har- sub-sensor har-
ness F to the connector (AB1 5). ness (RH).
2)Measure the resistance between connector
(3H) in the test harness H and connector (3F)
in the test harness F.
Connector & terminal
(3F) NO.5 - (3H) NO. 5:
(3F) NO. 6 - (3H) NO. 6:
I CHECK FRONT SUB-SENSOR HARNESS Is the resistance more than 1M 20 to step 9. Replace the body
(RH). R? harness with front
Measure the resistance between connector sub-sensor har-
(3H) in the test harness H and connector (3F) ness.
in the test harness F.
Connector & terminal
(3F) NO. 6 - (3H) NO. 6:
(3F) NO. 5 - (3H) NO. 5:
I CHECK FRONT SUB-SENSOR HARNESS Is the resistance more than 1 20 to step 10. Replace the body
(RH). MR? harness with front
Measure the resistance between connector sub-sensor har-
(3F) in the test harness F and the chassis ness (RH).
ground.
Connector & terminal
(3F) No. 5 - Chassis ground:
(3F) No. 6 - Chassis ground:
0 CHECK FRONT SUB-SENSOR (RH). Is the resistance between i o to step 11. Replace the front
1)Connect the connector (2H) in test harness 750R and 1 KR? sub-sensor (RH).
H to the front sub-sensor (RH). <Ref. to AB-1 8,
2)Measure the resistance of the connector Front Sub Sen-
(3H) in the test harness H. sor.>
Connector & terminal
(3H) NO. 3 - NO. 4:
1 CHECK FRONT SUB-SENSOR (RH). Is the resistance more than 1 'inish the diagno- Replace the front
Measure the resistance between connector MR? ;is. sub-sensor (RH).
(3H) in the test harness H and the chassis <Ref. to AB-1 8,
ground. Front Sub Sen-
Connector & terminal so r.>
(3H) No. 3 - Chassis ground:
(3H) No. 4 - Chassis ground:

AB-52
I DIAGNOSTIC CHART WITH TROUBLE CODE
AIRBAG SYSTEM (DIAGNOSTICS)

AB-53
I DIAGNOSTIC CHART WITH TROUBLE CODE
AIRBAG SYSTEM (DIAGNOSTICS)

K: TROUBLE CODE 32
DIAGNOSIS:
Front sub-sensor harness (LH) circuit is shorted.
Front sub-sensor harness (LH) circuit is open.
Front sub-sensor (LH) is faulty.
Airbag control module is faulty.
CAUTION:
Before diagnosing the airbag system, be sure to turn the ignition switch OFF, disconnect the
ground terminal from the battery, and wait more than 20 seconds before starting to work.
Before replacing the airbag module, seat belt pretensioner, roll connector, control module, and
sensor, reconnect each part and confirm that the warning light operates properly.
When inspecting the airbag main harness, disconnect the driver's airbag module and passenger's
airbag module connectors for safety reasons.
WIRING DIAGRAM:

r AB6 AIRBAG CONTROL MODULE

rA
I I
FRONT SUB SENSOR LH

RE0056

AB-54
 DIAGNOSTIC CHART WITH TROUBLE CODE
a
AIRBAG SYSTEM (DIAGNOSTICS)

Step Check Yes No

1 CHECK FRONT SUB-SENSOR (LH) AND 5 the resistance between 30 to step 2. Go to step 3.
FRONT SUB-SENSOR HARNESS (RH). ‘50Q and 1 KR?
1)Turn the ignition switch OFF, disconnect the
battery ground terminal, and wait more than 20
seconds.
2)Disconnect the connector (AB6) from the air-
bag control module, and connect connector
(1I) in the test harness I or 12 to the connector
(AB6). <Ref. to AB-1 5, Airbag Control Mod-
ule.>
3)Measure the resistance of the connector (31)
in the test harness I or 12.
Connector & terminal
(31) NO. 1 -NO. 3:
2 CHECK FRONT SUB-SENSOR (LH) AND s the resistance more than 1 3eplace the airbag Go to step 3.
FRONT SUB-SENSOR HARNESS (RH). AQ? :ontrol module.
Measure the resistance between connector :Ref. to AB-15,
(31) in the test harness I or 12 and the chassis 4irbag Control
ground. vlodu1e.i
Connector & terminal
(34 No. 1 - Chassis ground:
-- (31) No. 3 - Chassis ground:
3 CHECK AIRBAG MAIN HARNESS AND s the resistance less than 10 30 to step 4. I Go to step 5.
FRONT SUB-SENSOR HARNESS (LH). 2?
1)Disconnectthe connector (AB13) from the
front sub-sensor. <Ref. to AB-18, Front Sub
Sensor.>
2)Connect the connector (1H) in the test har-
ness H to the connector (AB13).
3)Measure the resistance between connector
(31) in the test harness I or 12 and connector
(3H)in the test harness H.
Connector & terminal

4
(31) NO. 3 - (3H) NO. 6:
(31) NO. 1 -(3H) NO. 5:
CHECK AIRBAG MAIN HARNESS AND
FRONT SUB-SENSOR HARNESS (LH).
Measure the resistance between connector
s the resistance more than 1
AR?
3
30 to step 10. Go to step 5.

(31) in the test harness I or 12 and the chassis

ground.

r
Connector & terminal
(31) No. 3 - Chassis ground:
(31) No. 1 - Chassis ground:
5 CHECK AIRBAG MAIN HARNESS. s the resistance less than 10 30 to step 6. Replace the body
1)Disconnect the connector (AB11) from 2? harness with air-
(AB12), and connect the connector (IF) in the bag main harness
test harness F to (AB11).
2)Measure the resistance between connector
(31) in the test harness I or 12 and connector
(3F) in the test harness F.
Connector & terminal
(31) NO. 3 -(3F) NO. 3:
(31) NO. 1 - (3F) NO. 4:
6 CHECK AIRBAG MAIN HARNESS. s the resistance more than 1
Measure the resistance between connector AR? harness with air-
(31) in the test harness I or 12 and the chassis bag main harness
ground.
Connector & terminal
(31) No. 3 - Chassis ground:
(31) No. 1 - Chassis ground:
I DIAGNOSTIC CHART WITH TROUBLE CODE
AIRBAG SYSTEM (DIAGNOSTICS)

Step Check Yes No

, CHECK FRONT SUB-SENSOR HARNESS the resistance less than 10 30 to step 8. Replace the body
(LH). ? harness with front
1)Connect the connector (2F) in the test har- sub-sensor har-
ness F to the connector (AB12). ness (LH).
2)Measure the resistance between connector
(3H) in the test harness H and connector (3F)
in the test harness F.
Connector & terminal
(3F) NO. 5 - (3H) NO. 5:
(3F) NO. 6 - (3H) NO. 6:
1 CHECK FRONT SUB-SENSOR HARNESS the resistance more than 1M 30 to step 9. Replace the body
? harness with front
W).
Measure the resistance between connector sub-sensor har-
(3H) in the test harness H and connector (3F) ness (LH).
in the test harness F.
Connector & terminal
(3F) NO. 6 - (3H) NO. 6:
(3F) NO. 5 - (3H) NO. 5:
1 CHECK FRONT SUB-SENSOR HARNESS the resistance more than 1 30 to step 10. Replace the body
(LW n? harness with front
Measure the resistance between connector sub-sensor har-
(3F) in the test harness F and the chassis ness (LH).
ground.
Connector & terminal
(3F) No. 5 - Chassis ground:
(3F) No. 6 - Chassis ground:
0 CHECK FRONT SUB-SENSOR (LH). the resistance between 30 to step 11. Replace the front
1)Coonect connector (2H) in the test harness OR and 1 KR? sub-sensor (LH).
H to the front sub-sensor (LH). <Ref. to AB-18,
2)Measure the resistance of the connector Front Sub Sen-
(3H) in the test harness H. sor.>
Connector & terminal
(3H) NO. 3 -NO. 4:
1 CHECK FRONT SUB-SENSOR (LH). the resistance more than 1 -inish the diagno- Replace the front
Measure the resistance between connector n? ;is. sub-sensor (LH).
(3H) in the test harness H and the chassis <Ref. to AB-18,
ground. Front Sub Sen-
Connector & terminal sor.>
(3H) No. 3 - Chassis ground:
(3H) No. 4 - Chassis ground:

AB-56
 DIAGNOSTIC CHART WITH TROUBLE CODE
AIRBAG SYSTEM (DIAGNOSTICS)

--

AB-57
I DIAGNOSTIC CHART WITH TROUBLE CODE
AIRBAG SYSTEM (DIAGNOSTICS)

L: TROUBLE CODE 41
DIAGNOSIS:
Side airbag harness (RH) is faulty.
Side airbag module (RH) is faulty.
Airbag control module is faulty.
CAUTION:
Before diagnosing the airbag system, be sure to turn the ignition switch OFF, disconnect the
ground terminal from the battery, and wait more than 20 seconds before starting to work.
Before replacing the airbag module, seat belt pretensioner, roll connector, control module, and
sensor, reconnect each part and confirm that the warning light operates properly.
When inspecting the airbag main harness, disconnect the driver's airbag module and passenger's
airbag module connectors for safety reasons.
When inspecting the side airbag harness, disconnect the side airbag module connector and seat
belt pretensioner connector for the safety reasons.
WIRING DIAGRAM:

T 818 AIRBAG CONTROL MODULE

SIDE AIRBAG
SENSOR RH
Ih
(SIDE RH)

B5M1105

AB-58
 DIAGNOSTIC CHART WITH TROUBLE CODE
AIRBAG SYSTEM (DIAGNOSTICS)

Step Check Yes No

1 CHECK SIDE AIRBAG MODULE. )oes the airbag warning light 3eplace the front i o to step 2.
1)Turn the ignition switch OFF, disconnect the lperate properly? ;eat with side air-
battery ground terminal, and wait more than 20 lag module (RH).
seconds. :Ref. to SE-6,
2)Disconnect the connector (AB26) from the ?ant Seat.>
seat belt pretensioner (RH). <Ref. to SB-8,
Front Seat Belt.>
3)Disconnect the connector (AB25) from
(AB24), and connect the connector (1F) in the
test harness F to (AB24).
4)Connect the airbag resistor to the connector
(3F) in the test harness F.
5)Connect the battery ground terminal, and
turn the ignition switch ON.
2 CHECK SIDE AIRBAG HARNESS (RH). s the resistance less than 10 30 to step 3. leplace the body
1)Turn the ignition switch OFF, disconnect the 2? iarness with side
battery ground terminal, and wait more than 20 iirbag harness.
seconds.
2)Disconnect the airbag resistor from the test
harness F.
3)Disconnect the connector (AB18) from the
r.
air bag control module. <Ref. to AB-15, Airbag
Control Module.>
4)Connect the connector (1 I) in the test har-
ness I or 12 to the connector (AB18).
5)Measure the resistance between connector
(31) in the test harness I or 12 and connector
(3F) in the test harness F.
Connector & terminal
(31) NO. 7 - (3F) NO. 4:
(31) NO. 9 - (3F) NO. 3:
3 CHECK SIDE AIRBAG HARNESS (RH). s the resistance more than 1 30 to step 4. 3eplace the body
Measure the resistance of the connector (31) in dQ? iarness with side
the test harness I or 12. airbag harness.
Connector & terminal
(31) NO. 7 - NO. 9:
4 CHECK SIDE AIRBAG HARNESS (RH). s the resistance more 1MR? 30 to step 5. 3eplace the body
Measure the resistance of the connector (3F) iarness with side
in the test harness F. airbag harness.
Connector & terminal
(3F) NO. 3 -NO. 4:
5 CHECK SIDE AIRBAG HARNESS (RH). s the resistance more than 1 Go to step 6. 3eplace the body
Measure the resistance between connector \nQ? iarness with side
(3F) in the test harness F and the chassis iirbag harness.
ground.
Connector & terminal
(3F) No. 3 - Chassis ground:
(3F) No. 4 - Chassis ground:
6 CHECK SIDE AIRBAG HARNESS (RH). s the resistance more than 1 Replace the airbag 3eplace the body
Measure the resistance between connector VIR? control module. iarness with side
(31) in the test harness I or 12 and the chassis <Ref. to AB-15, 3irbag harness.
ground. Airbag Control
Connector & terminal Module.>
(31) No. 7 - Chassis ground:
(31) No. 9 - Chassis ground:

AB-59
I DIAGNOSTIC CHART WITH TROUBLE CODE
AIRBAG SYSTEM (DIAGNOSTICS)

M: TROUBLE CODE 42
DIAGNOSIS:
Side airbag harness (LH) is faulty.
Side airbag module (LH) is faulty.
Airbag control module is faulty.
CAUTION:
Before diagnosing the airbag system, be sure to turn the ignition switch OFF, disconnect the
ground terminal from the battery, and wait more than 20 seconds before starting to work.
Before replacing the airbag module, seat belt pretensioner, roll connector, control module, and
sensor, reconnect each part and confirm that the warning light operates properly.
When inspecting the airbag main harness, disconnect the driver's airbag module and passenger's
airbag module connectors for safety reasons.
When inspecting the side airbag harness, disconnect the side airbag module connector and seat
belt pretensioner connector for the safety reasons.
WIRING DIAGRAM:

AIRBAG CONTROL MODULE

I-
ll

INF
[
(SI1
R
1)
SIDE AIRBAG
SENSOR LH

[G]
B5M1106

AB-60
 DIAGNOSTIC CHART WITH TROUBLE CODE
m
AIRBAG SYSTEM (DIAGNOSTICS)

Step Check Yes No

CHECK SIDE AIRBAG MODULE. Ioes the airbag warning light 3eplace the front Go to step 2.
1)Turn the ignition switch OFF, disconnect the iperate properly? ;eat with side air-
battery ground terminal, and wait more than 20 lag module (LH).
seconds. :Ref. to SE-6,
2)Disconnect the connector (AB21) from the 3ont Seat.>
seat belt pretensioner (LH). <Ref. to SB-8,
Front Seat Belt.>
3)Disconnect the connector (AB20) from
(AB19), and connect the connector (1 F) in the
test harness F to (AB19).
4)Connect the airbag resistor to the connector
(3F) in the test harness F.
5)Connect the battery ground terminal, and
turn the ignition switch ON.
I
CHECK SIDE AIRBAG HARNESS (LH). s the resistance less than 10 20 to step 3. Replace the body
1)Turn the ignition switch OFF, disconnect the R? harness with side
battery ground terminal, and wait more than 20 airbag harness.
seconds.
2)Disconnect the airbag resistor from the test
harness F.
3)Disconnect the connector (AB17) from the
r. airbag control module. <Ref. to AB-15, Airbag
Control Module.>
4)Connect the connector (1I) in the test har-
ness I or 12 to the connector (AB17).
5)Measure the resistance between connector
(31) in the test harness I or 12 and connector
(3F) in the test harness F.
Connector & terminal
(31) NO. 10 - (3F) NO. 3:
(31) NO. 12 - (3F) NO. 4:
I CHECK SIDE AIRBAG HARNESS (LH). IS the resistance more than 1 30 to step 4. Replace the body
Measure the resistance of the connector (31) in MR? harness with side
the test harness I or 12. airbag harness.
Connector & terminal
(31) NO. 10 - NO. 12:
I CHECK SIDE AIRBAG HARNESS (LH). Is the resistance more than 1 20 to step 5. Replace the body
Measure the resistance of the connector (3F) MR? harness with side
in the test harness F. airbag harness.
Connector & terminal
(3F) NO. 3 - NO. 4:
1 CHECK SIDE AIRBAG HARNESS (LH). Is the resistance more than 1 30 to step 6. Replace the body
Measure the resistance between connector MR? harness with side
(3F) in the test harness F and the chassis airbag harness.
ground.
Connector & terminal
(3F) No. 3 - Chassis ground:
(3F) No. 4 - Chassis ground:
i CHECK SIDE AIRBAG HARNESS (LH). Is the resistance more than 1 3eplace the airbag Replace the body
Measure the resistance between connector MR? :ontrol module. harness with side
(31) in the test harness I or 12 and the chassis :Ref. to AB-1 5, airbag harness.
ground. 4irbag Control
Connector & terminal Module.>
(31) No. 10 - Chassis ground:
(31) No. 12 - Chassis ground:

AB-61
I DIAGNOSTIC CHART WITH TROUBLE CODE
At RBAG SYSTEM f DIAGNOSTlCSl
~

N: TROUBLE CODE 45
DIAGNOSIS:
Side airbag harness (RH) is shorted to power supply.
Airbag control module is faulty.
CAUTION:
Before diagnosing the airbag system, be sure to turn the ignition switch OFF, disconnect the
ground terminal from the battery, and wait more than 20 seconds before starting to work.
Before replacing the airbag module, seat belt pretensioner, roll connector, control module, and
sensor, reconnect each part and confirm that the warning light operates properly.
When inspecting the airbag main harness, disconnect the driver's airbag module and passenger's
airbag module connectors for safety reasons.
When inspecting the side airbag harness, disconnect the side airbag module connector and seat
belt pretensioner connector for the safety reasons.
WIRING DIAGRAM:

7
e
B18 AIRBAG CONTROL MODULE

L
SIDE AIR1

SENSOR J
INFLATOR
(SIDE RH)
I@

AB-62
 DIAGNOSTIC CHART WITH TROUBLE CODE
AIRBAG SYSTEM (DIAGNOSTICS)

Step Check Yes No

I CHECK SIDE AIRBAG MODULE. >oes the airbag warning light Replace the front i o to step 2.
1)Turn the ignition switch OFF, disconnect the )perate properly? seat with side air-
battery ground terminal, and wait more than 20 bag module (RH).
seconds. <Ref. to SE-6,
2)Disconnect the connector (AB26) from the Front Seat.>
seat belt pretensioner (RH). <Ref. to SB-8,
Front Seat Belt.>
3)Disconnect the connector (AB25) from
(AB24), and connect the connector (1F) in the
test harness F to (AB24 ).
4)Connect the airbag resistor to the connector
(3F) in the test harness F.
5)Connect the battery ground terminal, and
turn the ignition switch ON.
! CHECK SIDE AIRBAG HARNESS (RH). 3eplace the body
1)Turn the ignition switch OFF, disconnect the control module. iarness with side
battery ground terminal, and wait more than 20 <Ref. to AB-15, iirbag harness.
seconds. Airbag Control
2)Disconnect the airbag resistor from the test Module.>
harness F.
3)Disconnectthe connector (AB18) from the
r- - airbag control module. <Ref. to AB-15, Airbag
Control Module.>
4)Connect the connector (1I) in the test har-
ness I or 12 to the connector (AB18).
5)Connect the battery ground terminal, and
turn the ignition switch ON.
6)Measure the voltage between connector (31)
in the test harness I or 12 and the chassis
ground.
Connector & terminal
(31) No. 7 (+) - Chassis ground (-):
(31) No. 9 (+) - Chassis ground (-):

AB-63
I
DIAGNOSTIC CHART WITH TROUBLE CODE
AIRBAG SYSTEM (DIAGNOSTICS)

0: TROUBLE CODE 46
DIAGNOSIS:
Side airbag harness (LH) is shorted to power supply.
Airbag control module is faulty.
CAUTION:
Before diagnosing the airbag system, be sure to turn the ignition switch OFF, disconnect the
ground terminal from the battery, and wait more than 20 seconds before starting to work.
Before replacing the airbag module, seat belt pretensioner, roll connector, control module, and
sensor, reconnect each part and confirm that the warning light operates properly.
When inspecting the airbag main harness, disconnect the driver's airbag module and passenger's
airbag module connectors for safety reasons.
When inspecting the side airbag harness, disconnect the side airbag module connector and seat
belt pretensioner connector for the safety reasons.
WIRING DIAGRAM:

7 AB17 AIRBAG CONTROL MODULE

SIDE AIRBAG
SENSOR LH
R
1)

B5M1106

AB-64
 DIAGNOSTIC CHART WITH TROUBLE CODE
AIRBAG SYSTEM (DIAGNOSTICS)

Step Check No
I CHECK SIDE AIRBAG MODULE. 30 to step 2.
1)Turn the ignition switch OFF, disconnect the )perate properly? seat with side air-
battery ground terminal, and wait more than 20 bag module (LH).
seconds. <Ref. to SE-6,
2)Disconnect the connector (AB21) from the Front Seat.>
seat belt pretensioner (LH). <Ref. to SB-8,
Front Seat Belt.>
3)Disconnect the connector (AB20) from
(AB19), and connect the connector (1F) in the
test harness F to (AB19).
4)Connect the airbag resistor to the connector
(3F) in the test harness F.
5)Connect the battery ground terminal and
turn the ignition switch ON.

-l
? CHECK SIDE AIRBAG HARNESS (LH). s the voltage less than 1 V? Replace the airbag 3eplace the body
1)Turn the ignition switch OFF, disconnect the control module. iarness with side
battery ground terminal, and wait more than 20 <Ref. to AB-15, iirbag harness.
seconds. Airbag Control
2)Disconnect the airbag resistor from the test Module.>
harness F.
3)Disconnectthe connector (AB17) from the
r. airbag control module. <Ref. to AB-15, Airbag
Control Module.>
4)Connect the connector (1 I) in the test har-
ness I or 12 to the connector (AB17).
5)Connect the battery ground terminal, and
turn the ignition switch ON.
6)Measure the voltage between connector (31)
in the test harness I or 12 and the chassis
ground.
Connector & terminal
(31) No. 10 (+) - Chassis ground (-):
(31) No. 12 (+) - Chassis ground (-):

AB-65
I DIAGNOSTIC CHART WITH TROUBLE CODE
AIRBAG SYSTEM (DIAGNOSTICS)

P: TROUBLE CODE 51
DIAGNOSIS:
Side airbag sensor (RH) is faulty.
Side airbag harness (RH) is faulty.
Airbag control module is faulty.
CAUTION:
Before diagnosing the airbag system, be sure to turn the ignition switch OFF, disconnect the
ground terminal from the battery, and wait more than 20 seconds before starting to work.
Before replacing the airbag module, seat belt pretensioner, roll connector, control module, and
sensor, reconnect each part and confirm that the warning light operates properly.
When inspecting the airbag main harness, disconnect the driver's airbag module and passenger's
airbag module connectors for safety reasons.
When inspecting the side airbag harness, disconnect the side airbag module connector and seat
belt pretensioner connector for the safety reasons.
WIRING DIAGRAM:

r
t
AB18 AIRBAG CONTROL MODULE

I
SIDE AIRBAG
SENSOR RH
Ih
(SIDE RH)

@ @

B5MllOL

AB-66
 DIAGNOSTIC CHART WITH TROUBLE CODE
AIRBAG SYSTEM (DIAGNOSTICS)

Step Check Yes No

30 to step 2. Replace the body
1)Turnthe ignition switch OFF, disconnect the R? harness with side
battery ground terminal, and wait more than 20 airbag harness.
seconds.
2)Disconnect the connector (AB26) from the
seat belt pretensioner (RH). <Ref. to SB-8,
Front Seat Belt.>
3)Disconnect the connector (AB25) from
(AB24).
4)Disconnect the connector (AB18) from the
airbag control module. <Ref. to AB-15, Airbag
Control Module.>
5)Connect the connector (1I) in the test har-
ness I or 12 to the connector (AB18).
6)Disconnect the connector (AB28) from the
side airbag sensor (RH), and connect the con-
nector (1G) in the test harness G to the con-
nector (AB28).
7)Measure the resistance between connector
(31) in the test harness I or 12 and connector
(3G) in the test harness G.
Connector & terminal
(31) NO. 17 - (3G) NO. 2:
(31) NO. 18 - (3G) NO. 1:
(31) NO. 19 - (3G) NO. 5:
(31) NO. 20 - (3G) NO. 4:
CHECK SIDE AIRBAG HARNESS (RH). Is the resistance more than 1 3eplace the side Replace the body
Measure the resistance between connector MR? iirbag sensor harness with side
(31) in the test harness I or 12 and the chassis RH). <Ref. to AB. airbag harness.
ground. 16, Side Airbag
Connector & terminal Sensor.> When
(31) No. 17 - Chassis ground: he sensor
(31) No. 18 - Chassis ground: eplacement is not
(31) No. 19 - Chassis ground: I K , replace the
(31) No. 20 - Chassis ground: iirbag control
nodule. <Ref. to
4B-15, Airbag
2ontrol Module.>

AB-67
 DIAGNOSTIC CHART WITH TROUBLE CODE
AIRBAG SYSTEM (DIAGNOSTICS)

Q: TROUBLE CODE 52
DIAGNOSIS:
Side airbag sensor (LH) is faulty.
Side airbag harness (LH) is faulty.
Airbag control module is faulty.
CAUTION:
Before diagnosing the airbag system, be sure to turn the ignition switch OFF, disconnect the
ground terminal from the battery, and wait more than 20 seconds before starting to work.
Before replacing the airbag module, seat belt pretensioner, roll connector, control module, and
sensor, reconnect each part and confirm that the warning light operates properly.
When inspecting the airbag main harness, disconnect the driver's airbag module and passenger's
airbag module connectors for safety reasons.
When inspecting the side airbag harness, disconnect the side airbag module connector and seat
belt pretensioner connector for the safety reasons.
WIRING DIAGRAM:

r AB17 AIRBAG CONTROL MODULE

INF 'R
-
SIDE AIRBAG
SENSOR LH

(SIDE LH)

B5M1IO€

AB-68
 DIAGNOSTIC CHART WITH TROUBLE CODE
AIRBAG SYSTEM (DIAGNOSTICS)

Step Check Yes No

CHECK SIDE AIRBAG HARNESS (LH). 5 the resistance less than 10 30 to step 2. Replace the body
1)Turn the ignition switch OFF, disconnect the 2? harness with side
battery ground terminal, and wait more than 20 airbag harness.
seconds.
2)Disconnect the connector (AB21) from the
seat belt pretensioner (LH). <Ref. to SB-8,
Front Seat Belt.>
3)Disconnect the connector (AB20) from
(AB19).
4)Disconnect the connector (AB17) from the
airbag control module. <Ref. to AB-15, Airbag
Control Module.>
5)Connect the connector (1I) in the test har-
ness I or 12 to the connector (AB17).
6)Disconnect the connector (AB23) from the
side airbag sensor (LH), and connect the con-
nector (1G) in the test harness G to the con-
nector (AB23).
7)Measure the resistance between connector
(31) in the test harness I or 12 and connector
(3G) in the test harness G.
Connector & terminal
(31) NO.5 - (3G) NO. 4:
-
(31) NO. 14 (3G) NO. 5:
(31) NO. 15 - (3G) NO. 1:
.~ NO. 16 - (3G)
(31) . , NO. 2:
! CHECK SIDE AIRBAG HARNESS (RH). s the resistance more than 1 3eplace the side Replace the body
Measure the resistance between connector AR? iirbag sensor harness with side
(31) in the test harness I or 12 and the chassis LH). <Ref. to AB- airbag harness.
ground. 16, Side Airbag
Connector & terminal Sensor.> When
-
(31) No. 5 Chassis ground: he sensor
-
(31) No. 14 Chassis ground: .eplacement is not
-
(31) No. 15 Chassis ground: 3K, replace the
-
(31) No. 16 Chassis ground: airbag control
nodule. <Ref. to
4B-15, Airbag
Zontrol Module.>

R: TROUBLE CODE 53
DIAGNOSIS:
Side airbag sensor (RH) is faulty.
When Code 53 is displayed, the circuit within the side airbag sensor (RH) is faulty. Replace the side airbag
sensor (RH).
<Ref. to AB-16, Side Airbag Sensor.>

S: TROUBLE CODE 54
DIAGNOSIS:
Side airbag sensor (LH) is faulty.
When Code 54 is displayed, the circuit within the side airbag sensor (LH) is faulty. Replace the side airbag
sensor (LH).
<Ref. to AB-16, Side Airbag Sensor.>

AB-69
 DIAGNOSTIC CHART WITH TROUBLE CODE
AIRBAG SYSTEM (DIAGNOSTICS)

T: TROUBLE CODE 55
This code is displayed when the side airbag is deployed.
When this code is displayed, the memory cannot be erased. Replace the following parts.
Airbag control module. <Ref. to AB-15, Airbag Control Module.>
Front seat assembly with side airbag module. (Operating side) <Ref. to SE-6, Front Seat.>
Side airbag sensor. (Operating side) <Ref. to AB-16, Side Airbag Sensor.>

AB-70
I DIAGNOSTIC CHART WITH TROUBLE CODE
AIRBAG SYSTEM (DIAGNOSTICS)

AB-71
I DIAGNOSTIC CHART WITH TROUBLE CODE
AIRBAG SYSTEM (DIAGNOSTICS)

U: TROUBLE CODE 61
DIAGNOSIS:
Seat belt pretensioner (RH) circuit is open, shorted or shorted to ground.
Airbag control module is faulty.
Pretensioner is faulty.
Pretensioner harness is faulty.
CAUTION:
Before diagnosing the airbag system, be sure to turn the ignition switch OFF, disconnect the
ground terminal from the battery, and wait more than 20 seconds before starting to work.
Before replacing the airbag module, seat belt pretensioner, roll connector, control module, and
sensor, reconnect each part and confirm that the warning light operates properly.
When inspecting the side airbag harness, disconnect the side airbag module connector and seat
belt pretensioner connector for the safety reasons.
WIRING DIAGRAM:

AB18 AIRBAG CONTROL MODULE

1
0
c
r

-
PRETENSIONER RH

B5M11OE

AB-72
 DIAGNOSTIC CHART WITH TROUBLE CODE
31
AI RBAG SYSTEM (DIAGNOSTICS)
~~~

Step Check Yes No

CHECK SEAT BELT PRETENSIONER. Ies the airbag warning light Ieplace the seat 20 to step 2.
1)Turn the ignition switch OFF, disconnect the erate properly? )elt pretensioner
battery ground terminal, and wait more than 20 RH). <Ref. to SB-
seconds. i,Front Seat
2)Disconnect the connector (AB26) from the 3elt.r
seat belt pretensioner (RH). <Ref. to SB-8,
Front Seat Belt.>
3)Connect the connector (1 L) in the test har-
ness L to (AB26).
4)Connect the airbag resistor to the connector
(3L) in the test harness L.
5)Connect the battery ground terminal and
turn the ignition switch ON.
CHECK SIDE AIRBAG HARNESS (RH). the resistance less than 10 20 to step 3. 3eplace the body
1)Turn the ignition switch OFF, disconnect the > iarness with side
battery ground terminal, and wait more than 20 3irbag harness.
seconds.
2)Disconnect the airbag resistor from the test
harness L.
3)Disconnect the connector (AB25) from
(AB24).
4)Disconnect the connectors (AB17) and
(AB18) from the airbag control module. <Ref.
to AB-15, Airbag Control Module.>
5)Connect the connector (1I) in the test har-
ness I or 12 to the connector (AB18).
6)Measure the resistance between connector
(31) in the test harness I or 12 and connector
(3L) in the test harness L.
Connector & terminal
(31) NO. 8 - (3L)NO. 6:
.~ NO. 6 - (3L)
(31) . . NO. 5:
CHECK SIDE AIRBAG HARNESS (RH). the resistance more than 1 30 to step 4. 3eplace the body
Measure the resistance of the connector (31) in n? iarness with side
the test harness I or 12. 3irbag harness.
Connector & terminal
(31) NO. 6 - NO. 8:
CHECK SIDE AIRBAG HARNESS (RH). the resistance more than 1 3eplace the airbag 3eplace the body
Measure the resistance between connector n? :ontrol module. iarness with side
(31) in the test harness I or 12 and the chassis :Ref. to AB-15, 3irbag harness.
ground. Vrbag Control
Connector & terminal vlodule.>
(31) No. 6 - Chassis ground:
(31) No. 8 - Chassis ground:

AB-73
I DIAGNOSTIC CHART WITH TROUBLE CODE
AIRBAG SYSTEM (DIAGNOSTICS)

V: TROUBLE CODE 62
DIAGNOSIS:
Seat belt pretensioner (LH) circuit is open, shorted or shorted to ground.
Airbag control module is faulty.
Pretensioner is faulty.
Pretensioner harness is faulty.
CAUTION:
Before diagnosing the airbag system, be sure to turn the ignition switch OFF, disconnect the
ground terminal from the battery, and wait more than 20 seconds before starting to work.
Before replacing the airbag module, seat belt pretensioner, roll connector, control module, and
sensor, reconnect each part and confirm that the warning light operates properly.
When inspecting the side airbag harness, disconnect the side airbag module connector and seat
belt pretensioner connector for the safety reasons.
WIRING DIAGRAM:

T
I
I
017 AIRBAG CONTROL MODULE

1
PRETENSIONER LH

B5M1108

AB-74
 DIAGNOSTIC CHART WITH TROUBLE CODE
AIRBAG SYSTEM (DIAGNOSTICS)

Step Check Yes No

CHECK SEAT BELT PRETENSIONER. loes the airbag warning light Ieplace the seat 30 to step 2.
1)Turn the ignition switch OFF, disconnect the iperate properly? )elt pretensioner
battery ground terminal, and wait more than 20 LH). <Ref. to SB-
seconds. b, Front Seat
2)Disconnect the connector (AB21) from the 3elt.>
seat belt pretensioner (LH). <Ref. to SB-8,
Front Seat Belt.>
3)Connect the connector (1L) in the test har-
ness L to (AB21).
4)Connect the airbag resistor to the connector
(3L) in the test harness L.
5)Connect the battery ground terminal and
turn the ignition switch ON.
CHECK SIDE AIRBAG HARNESS (LH). s the resistance less than 10 ;o to step 3. 3eplace the body
1)Turn the ignition switch OFF, disconnect the n? iarness with side
battery ground terminal, and wait more than 20 3irbag harness.
seconds.
2)Disconnect the airbag resistor from the test
harness L.
3)Disconnect the connector (AB20) from
(AB19).
-_ 4)Disconnect the connectors (AB17) and
(AB18) from the airbag control module. <Ref.
to AB-15, Airbag Control Module.>
5)Connect the connector (1 I) in the test har-
ness I or 12 to the connector (AB17).
6)Measure the resistance between connector
(31) in the test harness I or 12 and the connec-
tor (3L) in the test harness L.
Connector & terminal
(31)NO. 11 - (3L)NO. 6:
(31)NO. 13 - (3L)NO. 5:
I CHECK SIDE AIRBAG HARNESS (LH). Is the resistance more than 1 30 to step 4. 3eplace the body
Measure the resistance of the connector (31) in MQ? iarness with side
the test harness I or 12. airbag harness.
Connector & terminal
(31)NO. 11 - NO. 13:
I CHECK SIDE AIRBAG HARNESS (LH). Is the resistance more than 1 3eplace the airbag 3eplace the body
Measure the resistance between the connector MQ? :ontrol module. iarness with side
(31) in the test harness I or 12 and the chassis :Ref. to AB-15, airbag harness.
ground. 4irbag Control
Connector & terminal vlodu1e.r
(31)No. 11 - Chassis ground:
-
(31)No. 13 Chassis around:

AB-75
I DIAGNOSTIC CHART WITH TROUBLE CODE
AIRBAG SYSTEM (DIAGNOSTICS)

W: TROUBLE CODE 65
DIAGNOSIS:
Seat belt pretensioner (RH) circuit is shorted to the power supply.
Pretensioner is faulty.
Pretensioner harness is faulty.
Airbag control module is faulty.
CAUTION:
Before diagnosing the airbag system, be sure to turn the ignition switch OFF, disconnect the
ground terminal from the battery, and wait more than 20 seconds before starting to work.
Before replacing the airbag module, seat belt pretensioner, roll connector, control module, and
sensor, reconnect each part and confirm that the warning light operates properly.
When inspecting the side airbag harness, disconnect the side airbag module connector and seat
belt pretensioner connector for the safety reasons.
WIRING DIAGRAM:

7
E
AB18 AIRBAG CONTROL MODULE

-
r

PRETENSIONER RH

B5M110!

AB-76
 DIAGNOSTIC CHART WITH TROUBLE CODE
m
AIRBAG SYSTEM (DIAGNOSTICS)

Step Check
I CHECK SEAT BELT PRETENSIONER.
1)Turn the ignition switch OFF, disconnect the iperate properly? belt pretensioner
battery ground terminal, and wait more than 20 (RH). <Ref. to SB-
seconds. 8, Front Seat
2)Disconnect the connector (AB26) from the Belt.>
seat belt pretensioner (RH). <Ref. to SB-8,
Front Seat Belt.>
3)Connect the connector (1L) in the test har-
ness L to (AB26).
4)Connect the airbag resistor to the connector
(3L) in the test harness L.
5)Connect the battery ground terminal, and
turn the ignition switch ON.
! CHECK SIDE AIRBAG HARNESS (RH). 3eplace the body
1)Turn the ignition switch OFF, disconnect the control module. iarness with side
battery ground terminal, and wait more than 20 <Ref. to AB-15, iirbag harness.
seconds. Airbag Control
2)Disconnect the airbag resistor from the test Module.>
harness L.
3)Disconnect the connector (AB25) from
(AB24).
e. - 4)Disconnect the connectors (AB17) and
(AB18) from the airbag control module. <Ref.
to AB-15, Airbag Control Module.>
5)Connect the connector (1I) in the test har-
ness I or 12 to the connector (AB18).
6)Connect the battery ground cable and turn
the ignition switch ON.
7)Measure the voltage between connector (31)
in the test harness I or 12 and the chassis
ground.
Connector 81terminal
(31) No. 6 (+) - Chassis ground (-):
(31) No. 8 (+) - Chassis ground (-):

AB-77
I DIAGNOSTIC CHART WITH TROUBLE CODE
AIRBAG SYSTEM (DIAGNOSTICS)

X: TROUBLE CODE 66
DIAGNOSIS:
Seat belt pretensioner (LH) circuit is shorted to the power supply.
Pretensioner is faulty.
Pretensioner harness is faulty.
Airbag control module is faulty.
CAUTION:
Before diagnosing the airbag system, be sure to turn the ignition switch OFF, disconnect the
ground terminal from the battery, and wait more than 20 seconds before starting to work.
Before replacing the airbag module, seat belt pretensioner, roll connector, control module and the
sensor, reconnect each part and confirm that the warning light operates properly.
When inspecting the side airbag harness, disconnect the side airbag module connector and seat
belt pretensioner connector for the safety reasons.
WIRING DIAGRAM:

T
I
I
817 AIRBAG CONTROL MODULE

-
PRETENSIONER LH

B5M11Ot

AB-78
 DIAGNOSTIC CHART WITH TROUBLE CODE
AIRBAG SYSTEM IDIAGNOSTICS)

Step Check Yes No

CHECK SEAT BELT PRETENSIONER. Does the airbag warning light Replace the seat Go to step 2.
1)Turn the ignition switch OFF, disconnect the operate properly? belt pre-tensioner
battery ground terminal, and wait more than 20 (LH). <Ref. to SB-
seconds. 8, Front Seat
2)Disconnect the connector (AB21) from the Belt.>
seat belt pretensioner (LH). <Ref. to SB-8,
Front Seat Belt.>
3)Connect the connector (1L) in the test har-
ness L to (AB21).
4)Connect the airbag resistor to the connector
(3L) in the test harness L.
5)Connect the battery ground terminal and
turn the ignition switch ON.
CHECK SIDE AIRBAG HARNESS (LH). s the voltage less than 1 V? Replacethe airbag Replace the body
1)Turnthe ignition switch OFF, disconnect the control module. harness with side
battery ground terminal, and wait more than 20 <Ref. to AB-15, airbag harness.
seconds. Airbag Control
2)Disconnect the airbag resistor from the test Module.>
harness L.
3)Disconnect the connector (AB20) from
(AB19).
4)Disconnect the connectors (AB17) and
(AB18) from the airbag control module. <Ref.
to AB-15, Airbag Control Module.>
5)Connect the connector (1I) in the test har-
ness I or 12 to the connector (AB17).
6)Connect the battery ground terminal and
turn the ignition switch ON.
7)Measure the voltage between connector (31)
in the test harness I or 12 and the chassis
ground.
Connector & terminal
(30 No. 11 (+) - Chassis ground (-):
(31) No. 13 (+) - Chassis ground (-):

AB979
 DIAGNOSTIC CHART WITH TROUBLE CODE
AIRBAG SYSTEM (DIAGNOSTICS)

--

AB-80
 SEAT BELT SYSTEM

~~ ~ ~ ~
SB ~ ~~ ~~

Page
1. General Description ................................................................................... .2
2. Pretensioner Connector ............................................................................. .6
3. Inspection Locations After a Collision ......................................................... 7
4. Front Seat Belt ............................................................................................ 8
5. Rear Seat Belt ........................................................................................... 10
 GENERAL DESCRIPTION
SEAT BELT SYSTEM

1. General Description
A: COMPONENT
1. FRONT SEAT BELT

000239

(1) Adjuster anchor ASSY Tightening torque: N.m (kgf-m, ff-lb)

(2) Anchor cover T l : 7.5 (0.76, 5.5)
(3) Outer belt ASSY T2: 30 (3.1,22)
(4) Inner belt ASSY T3: 53 (5.4,39)

SB-2
 GENERAL DESCRIPTION
SEAT BELT SYSTEM

2. REAR SEAT BELT (SEDAN)

(1) Outer seat belt RH (6) Inner seat belt LH Tightening torque: N.m (kgf-m, ff-lb)
(2) Outer seat belt CENTER (7) Case center ELR T: 30 (3.1,22)
(3) Outer seat belt LH (8) Anchor cover
(4) Inner seat belt RH (9) Adjustable anchor ASSY
(5) Inner seat belt CENTER

SB-3
I GENERAL DESCRIPTION
SEAT BELT SYSTEM

3. REAR SEAT BELT (WAGON)

(1) Outer seat belt RH (5) Inner seat belt LH Tightening torque: N.m (kgf-m, ff-lb)
(2) Outer seat belt CENTER (6) Anchor cover T: 30 (3.1,22)
(3) Outer seat belt LH (7) Adjustable anchor ASSY
(4) Inner seat belt RH

SB-4
 GENERAL DESCRIPTION
SEAT BELT SYSTEM

6: CAUTION
Before starting, turn the ignition switch OFF, dis-
connect the battery ground cable and wait for 20
seconds or more.
The pretension system has a backup power
source. The pretensioner might deploy if you do not
wait for 20 seconds or more before starting work.
Do not drop or apply any impact to the preten-
sioner.
If oil, grease, or water gets on the pretensioner,
wipe it off immediately with a dry cloth.
Do not expose the pretensioner to high tempera-
ture or flame.
Do not allow current to flow through or voltage to
reach the pretensioner. Do not use a circuit tester
to check resistance of the pretensioner.
Do not disassemble or attempt to repair the pre-
tensioner. If it is dented, cracked, or deformed, re-
place it with a new one.
Do not use the airbag or pretensioner parts from
other vehicles. Always replace the parts with new
parts.
When handling a seat belt with a deployed pre-
tensioner, wear gloves and goggles. Wash your
hands afterwards.
Do not re-use a seat belt with a deployed preten-
sioner again.
If the material gets in your eyes or on your skin
during deployment, wash it away with clean water,
and then consult a doctor.

SB-5
 PRETENSIONER CONNECTOR
SEAT BELT SYSTEM

2. Pretensioner Connector
A: OPERATION
1) How to disconnect:
(1) Move the slide lock (A) in the direction of the
arrow.
(2) Pull the connector (B) in the direction of the
arrow with slide lock (A) moved.

CA JTION:
When pulling, be sure to hold onto the connec-
tor and riot the wire.
2) How to connect:
Holding connector (A), and push it in carefully until
a connecting sound is heard.

CAUTION:
Be sure to insert the connector in until it
locks.
Then pull on it gently to make sure that it is
locked.

SB-6
 INSPECTION LOCATIONS AFTER A COLLISION
SEAT BELT SYSTEM

3. Inspection Locations After a

Collision
A: INSPECTION
Check for the following, and then replace with new
parts if necessary.
Center pillar lower garnish is discolored or
cracked.
Wire harness and/or connector is damaged.

SB-7
 FRONT SEAT BELT
SEAT BELT SYSTEM

4. Front Seat Belt 2. INNER BELT (FRONT)

1) Disconnect the connector.
A: REMOVAL 2) Remove the anchor bolt, and then detach the in-
1. OUTER BELT (FRONT) ner belt.
1) Fold backrest all the way forward, and then
move the front seat all the way forward.
2) Turn the ignition switch OFF, disconnect the
ground cable from battery, and wait for more than
20 seconds before starting work.
3) Remove the center pillar lower trim. <Ref. to El-
46, REMOVAL, Lower Inner Trim.>
4) Remove the anchor cover. Loosen the shoulder
anchor bolt, and then detach the shoulder anchor
from center pillar. S5M0234

L B5M1070

5 ) Turn over the floor mat to remove the bolts.

6) Disconnect the yellow connector of pretensioner

harness, and remove the outer belt (front).
CAUTION:
Do not drop or apply any impact to the pre-
tensioner.
Pretensioner and bracket should be treated
as an assembly. Do not attempt to disassemble
it.

SB-8
I
FRONT SEAT BELT
SEAT BELT SYSTEM

B: INSTALLATION C: INSPECTION
1. OUTER BELT (FRONT) 1. OUTER BELT (FRONT)
Install in the reverse order of removal. Check for the following, and replace with new parts
CAUTION: if necessary.
Pretensioner is cracked or deformed.
The parts on right and left are not identical.
Before installation, make sure that the correct Seat belt is slackened, bent, or frayed. Seat belt
part is used. is abnormally wound or extended.
Be careful not to twist the belts during instal- 2. INNER BELT (FRONT)
lation.
Check for the following, and replace with new parts
I 2. INNER BELT (FRONT) if necessary.
Install in the reverse order of removal. Inner belt is deformed or damaged.
Seat belt buckle is engaged improperly.

SB-9
 REAR SEAT BELT
SEAT BELT SYSTEM

5. Rear Seat Belt 7) Remove the two bolts and adjustable anchor AS-
SY.
A: REMOVAL
1. OUTER BELT SIDE (SEDAN)
1) Remove the rear seat. <Ref. to SE-I 1, REMOV-
AL, Rear Seat.>
2) Remove the side sill rear lower cover. <Ref. to
El-46, REMOVAL, Lower Inner Trim.>
3) Remove the seat belt lower anchor bolt.

2. OUTER BELT CENTER (SEDAN)

1) Remove the rear seat. <Ref. to SE-11, REMOV-
AL, Rear Seat.>
2) Remove the seat belt lower anchor bolt.

4) Remoce the anchor cover. Remove the bolt and

shoulder anchor from pillar.

3) Remove the quarter pillar trim. <Ref. to El-47,

Removal, Rear Quarter Trim.>
4) Remove the rear shelf trim. <Ref. to El-53, RE-
MOVAL, Rear Shelf Trim.>
I RE0059I 5) Remove the bolts, and then detach the seat belt.
5) Remove the quarter pillar trim. <Ref. to El-47,
REMOVAL, Rear Quarter Trim.>
6) Remove the bolts, and then detach the seat belt.

\ - \ \

RE0005

SB-I 0
 REAR SEAT BELT
SEAT BELT SYSTEM

3. INNER BELT (SEDAN) 7) Remove the bolts, and then detach the outer belt
side.
1) Remove the rear cushion. <Ref. to SE-11, RE-
MOVAL, Rear Seat.>
2) Remove the bolts, and then detach the inner
belt.

,.. .
RE0062 I
8) Remove the two bolts and adjustable anchor AS-
SY.
~

4. OUTER BELT SIDE (WAGON)

1) Remove the luggage floor mat. <Ref. to El-56,
REMOVAL, Luggage Floor Mat.>
2) Remove the rear seat. <Ref. to SE-11, REMOV-
AL, Rear Seat.>
3) Remove the side sill rear lower cover. <Ref. to
El-46, REMOVAL, Lower Inner Trim.>
4) Remove the seat belt lower anchor bolt.

5) Remove the anchor cover. Remove the bolt and

shoulder anchor from pillar.

6) Remove the rear quarter trim. <Ref. to El-47,

REMOVAL, Rear Quarter Trim.>

SB-11
 REAR SEAT BELT
SEAT BELT SYSTEM

5. OUTER BELT CENTER (WAGON) 6. INNER BELT (WAGON)

1) Loosen the shoulder anchor bolt, and then de- 1) Remove the rear cushion.
tach the shoulder anchor from quarter pillar. 2) Remove the bolt, and then detach the inner belt.

0008 B5MO919

2) Remove the quarter trim. <Ref. to El-47, RE-

MOVAL, Rear Quarter Trim.>
3) Remove the three bolts, and then detach the out-
er belt center.

/ ' RE0009

SB-I 2
 REAR SEAT BELT
B: INSTALLATION
1. OUTER BELT SIDE (SEDAN)
Install in the reverse order of removal.
CAUTION:
During installation, make sure that the seat
belts are not twisted.
After installation, make sure that the seat
belts can be smoothly extended and wound.
2. OUTER BELT CENTER (SEDAN)
Install in the reverse order of removal.
CAUTION:
During installation, make sure that the seat
belts are not twisted.
After installation, make sure that the seat
belts can be smoothly extended and wound.
3. INNER BELT (SEDAN)
Install in the reverse order of removal.
CAUTION:
During installation, make sure that the seat
belts are not twisted.
4. OUTER BELT SIDE (WAGON)
Install in the reverse order of removal.
CAUTION:
During installation, make sure that the seat
belts are not twisted.
After installation, make sure that the seat
belts can be smoothly extended and wound.
5. OUTER BELT CENTER (WAGON)
Install in the reverse order of removal.
CAUTION:
During installation, make sure that the seat
belts are not twisted.
After installation, make sure that the seat
belts are smoothly extended and wound.
6. INNER BELT (WAGON)
Install in the reverse order of removal.
CAUTION:
During installation, make sure that the seat
belts are not twisted.
SB-13
SEAT BELT SYSTEM
C: INSPECTION
1. OUTER BELT SIDE (SEDAN)
Check for the following, and replace with new parts
if necessary.
Seat belt is slackened, bent, or frayed. Seat belt
is abnormally wound or extended.
2. OUTER BELT CENTER (SEDAN)
Check for the following, and replace with new parts
if necessary.
Seat belt is slackened, bent, or frayed. Seat belt
is abnormally wound or extended.
3. INNER BELT (SEDAN)
Check for the following, and replace with new parts
if necessary.
Inner belt is deformed or damaged.
Seat belt buckle is engaged improperly.
4. OUTER BELT SIDE (WAGON)
Check for the following, and replace with new parts
if necessary.
Seat belt is slackened, bent, or frayed. Seat belt
is abnormally wound or extended.
5. OUTER BELT CENTER (WAGON)
Check for the following, and replace with new parts
if necessary.
Seat belt is slackened, bent, or frayed. Seat belt
is abnormally wound or extended.
6. INNER BELT (WAGON)
Check for the following, and replace with new parts
if necessary.
Inner belt is deformed or damaged.
Seat belt buckle is engaged improperly.
 REAR SEAT BELT
SEAT BELT SYSTEM

SB-14
LIGHTING SYSTEM

Page
1. General Description .................................................................................... 2
2. Headlight and Tail Light System ................................................................. 3
3. Front Fog Light System ............................................................................... 4
4. Turn Signal and Hazard Light System ........................................................ 5
5. Back-up Light System ................................................................................. 6
6. Stop Light System ....................................................................................... 7
7. Interior Light System ................................................................................... 8
8. Combination Switch (Light) ......................................................................... 9
9. Headlight Assembly .................................................................................. 10
10. Headlight Bulb ........................................................................................... 12
11. Front Turn Signal Light Bulb ..................................................................... 13
12. Clearance/Parking Light Bulb.................................................................... 14
13. Front Fog Light Assembly ......................................................................... 15
14. Front Fog Light Bulb.................................................................................. 16
15. Front Side Marker Light Assembly ............................................................ 17
16. Rear Combination Light Assembly ............................................................ 18
17. Stopnail Light Bulb ................................................................................... 19
18. Back-up Light Bulb .................................................................................... 20
19. Rear Turn Signal Light Bulb ...................................................................... 21
20. Rear Side Marker Light Bulb ..................................................................... 22
21. License Plate Light .................................................................................... 23
22 . High-mounted Stop Light .......................................................................... 24
23. Spot Light .................................................................................................. 25
24. Room Light ................................................................................................ 26
25. Luggage Room Light ................................................................................. 27
26 . Trunk Room Light...................................................................................... 28
27. Glove Box Light ......................................................................................... 29
 F
GENERAL DESCRIPTION
LIGHTING SYSTEM

1. General Description
A: SPECIFICATIONS
Headliaht 12 V - 55 W/65 W (Haloaen)
Front turn signal light 12v-21 w
Side marker light 12V-5W
Parking light 12V-5W
Front fog light 12 V - 55 W (Halogen)
I Tail/Stou liaht 12v-21 w / 5 w
I Tail liqht I 12v-21 wT5w 1
Sedan I Stop light I 12v-21 w I
1 Turn signal light I 12v-21 w I
Rear combination light Back-up light 12v-21 w
Tail/Stop light 12v-21 w / 5 w
Turn signal light 12v-21 w
Wagon
Back-uD liaht 12v-21 w
I Side marker liqht I 12V-5W I
License plate light I 12V-5W I
Sedan 12v-21 w
High-mounted stop light
I
Waaon
d
12V-13W
Room light 12V-8W
. liaht
Suot " 12V-8W
Luggage room light 12V-13W
Trunk room light 12V-5W
Glove box light 12V-1.4W

B: PRECAUTIONS After reassembly, make sure functional parts op-

Before disassembling or reassembling parts, al-
ways disconnect the battery ground cable. When
replacing the radio, control module, and other parts
provided with memory functions, record the memo-
ry contents before disconnecting the battery
ground cable. Otherwise, the memory will be
erased.
Reassemble in reverse order of disassembly, un-
less otherwise indicated.
Adjust parts to the given specifications.
Connect the connectors and hoses securely dur-
ing reassembly.
erate smoothly.
WARNING:
The air bag system wiring harness is routed
near electrical parts and switches. All air bag
system wiring harnesses and connectors are
yellow. Do not use an electric test equipment
on these circuits.
Be careful not to damage the air bag system
wiring harness when servicing electrical parts
and switches.

C: PREPARATION TOOL
1. GENERAL TOOLS
TOOL NAME REMARKS
Circuit Tester Used for measuring resistance and voltage.

I
i

LI-2
 HEADLIGHT AND TAIL LIGHT SYSTEM
LIGHTING SYSTEM
-
2. Headlight and Tail Light Sys- 2. TAIL AND ILLUMINATION RELAY
tem Measure the tail and illumination relay resistance
between terminals when connectina terminal No. 4
A: SCHEMATIC to battery positive terminal and teyminal No. 3 to
battery ground terminal.
1. HEADLIGHT
<Ref. to WI-98, SCHEMATIC, Headlight System.>
2. CLEARANCE LIGHT AND ILLUMINA-
TION LIGHT
<Ref. to WI-94, SCHEMATIC, Clearance Light and
Illumination Light System.>
6 : INSPECTION
1. HEADLIGHT RELAY B0030f
Measure the headlight relay resistance between
terminals when connecting terminal No. 4 to battery Current I Terminal No. 1 Standard I
positive terminal and terminal No. 3 to battery Flow Less than 1Q
ground terminal. 1 and 2
No flow More than 1MQ

800308

Current Terminal No. Standard

Flow Less than 1R
1 and2
No flow More than 1MR

LI-3
 FRONT FOG LIGHT SYSTEM
LIGHTING SYSTEM

3. Front Fog Light System

A: SCHEMATIC
1. FRONT FOG LIGHT
<Ref. to WI-97, SCHEMATIC, Front Fog Light Sys-
tem.>
B: INSPECTION
1. FRONT FOG LIGHT SWITCH
Measure the front fog light switch resistance.
I

I * B6M1482

I Switch position I Terminal No. I Standard I

2. FRONT FOG LIGHT RELAY

Measure the front fog light relay resistance be-
tween terminals when connectinq terminal No. 4 to
battery positive terminal and terminal No. 3 to bat-
tery ground terminal.

B0030e

Current Terminal No. Standard

Flow Less than la
1 and 2
No flow More than 1 MR
I I I I

LI-4
 TURN SIGNAL AND HAZARD LIGHT SYSTEM
LIGHTING SYSTEM

4. Turn Signal and Hazard Light

System
A: SCHEMATIC
1. TURN SIGNAL LIGHT AND HAZARD
LIGHT
<Ref. to WI-104, SCHEMATIC, Turn Signal Light
and Hazard Light System.>
B: INSPECTION
1. TURN SIGNAL SWITCH
<Ref. to LI-9, INSPECTION, Combination Switch
(Light).>
2. HAZARD SWITCH
Measure the hazard switch resistance.

0 7 6 5

B6M1 483

OFF 6 and 7 I Less than 1!2

1,3and4 Less than If2
ON
7 and 8 Less than IC2

3. TURN SIGNAL & HAZARD MODULE

Connect the battery and turn signal light bulb to the
module, as shown in the figure. The module is
properly functioning if it blinks when power is sup-
plied to the circuit.

LI-5
 BACK-UP LIGHT SYSTEM
LIGHTING SYSTEM

5. Back-up Light System 2. INHIBITOR SWITCH (A/T)

Measure the inhibitor switch resistance.
A: SCHEMATIC
1. BACK-UP LIGHT
<Ref. to WI-93, SCHEMATIC, Back-up Light Sys-
tem.>
B: INSPECTION
F
rmj
1. BACK-UP LIGHT SWITCH (M/T)
Measure the back-up light switch resistance.

I Switch Dosition I Terminal No. I Standard I

I When select lever I I I
I is set in “R” posi-
tion I 1 and2 I Less than 1 0
I
Other positions More than 1MSL

BO0344

(A) Non-turbo model

(B) Turbo model

Switch position Terminal No. Standard

When shift lever is Turbo model:

I set in reverse
position
Other Dositions
I 2 and 4
Non-t,urb;drydel:
Less than In

LI-6
 STOP LIGHT SYSTEM
LIGHTING SYSTEM

6. Stop Light System

A: SCHEMATIC
1. STOP LIGHT
<Ref. to WI-103, SCHEMATIC, Stop Light Sys-
tem.>
B: INSPECTION
1. STOP LIGHT SWITCH
Measure the stop light switch resistance.

Without cruise control

With cruise control

B6M1486A

Switch position I Terminal No. I Standard

I I
When brake pedal I and 2: Without 1 Less than ,* I
is deDressed
IWhenbrabpedalI
is released
cruise
-. -. - - control

2and3:With
-- .-

cruise control
7
1 More than 1 M n

L1-7
 INTERIOR LIGHT SYSTEM
LIGHTING SYSTEM

7. Interior Light System

A: SCHEMATIC
1. INTERIOR LIGHT
<Ref. to WI-101, SCHEMATIC, In Compartment
Light System.>
B: INSPECTION
1. DOOR SWITCH
Measure the door switch resistance.

000157

[- Switch position I Terminal No. I Standard

When door is
Less than l R
1 and3
More than 1MR
closed

2. REAR GATE LATCH SWITCH

Measure the rear gate latch switch resistance.
I I I I

kl
Switch Dosition Terminal No. Standard
When rear gate is
Less than 1R
When rear gate is land2
More than 1Mn

3. TRUNK ROOM LIGHT SWITCH

Measure the trunk room light switch resistance.
I Switch Dosition I Terminal No. I Standard 1
When trunk lid is
Less than In
opened
1 and2
When trunk lid is
More than 1Mi2
closed

LI-8
 COMBINATION SWITCH (LIGHT)
-
LIGHTING SYSTEM

8. Combination Switch (Light) C: INSPECTION

Measure the combination switch resistance.
A: REMOVAL
1) Remove the instrument panel lower cover. <Ref.
to El-42, REMOVAL, Instrument Panel Assembly.>
2) Remove the screws which secure upper column
cover to lower column cover.

1-r 17 16 1514131211 10 9
06M1184 Lighting and turn signal switch connector
3) Disconnect the connector from combination
switch.
4) Remove the screws which secure switch and re-
move the siitch. Parking switch connector

06M1488A

1. LIGHTING SWITCH
I Switch position I Terminal No. I Standard
I OFF I - I More than 1MR I
Tail 14 and 16 I Less than 1R

2. DIMMER AND PASSING SWITCH

B: INSTALLATION m w i t c h position I Terminal No. I Standard I
Install in the reverse order of removal. Passing 7,8and 16 Less than IR
Low beam 16 and 17 Less than 1R
High beam 7 and 16 Less than 1R

Switch position Terminal No. Standard

1 and 2 Less than 1R
Neutral More than 1MR
Right 2 and 3 Less than 1R

4. PARKING SWITCH
Switch position Terminal No. Standard
OFF 2 and 4 Less than 1R
ON 1 and 4 Less than I R

LI-9
 HEADLIGHT ASSEMBLY
LIGHTING SYSTEM
9. Headlight Assembly
A: REMOVAL
1) Disconnect the ground terminal from battery.
2) Remove the duct (A) (when right side headlight
is removed).
3) Remove the front grille and headlight side cover.
<Ref. to El-18, REMOVAL, Front Grille.> and <Ref.
to El-23, REMOVAL, Front Bumper.>
4) Disconnect the headlight bulb connector.
5) Remove three bolts and disconnect the connec-
tors, and then detach the headlight assembly.
LI-I 0
B: INSTALLATION
Install in the reverse order of removal.
C: ADJUSTMENT
1. HEADLIGHT AIMING
NOTE:
As this headlignt is the “VISUAL AIMING TYPE”, it
is possible to adjust aiming only in the vertical di-
rection. It cannot be adjusted in the horizontal di-
rection.
CAUTION:
Turn off the light before adjusting headlight
aiming. If the light is necessary to check aim-
ing, do not turn on for more than two minutes.
NOTE:
Before checking the headlight aiming, be sure of
the following:
The area around the headlight has not sustained
any accident, damage or other type of deformation.
Vehicle is parked on level ground.
The inflation pressure of tires is correct.
Vehicle’s fuel tank is fully filled.
Bounce the vehicle several times to normalize
the suspension.
Make certain that someone is seated in the driv-
er’s seat.
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 adjusting
screw (A).
 HEADLIGHT ASSEMBLY
LIGHTING SYSTEM

Bulb center marking

H

t- 3 m (10 ft)

BOO400

H mm (in)
Sedan Wagon h mm (in) at 3 m (10 ft)
RS, WRX TS, WRX Outback
620 (24.41) 620 (24.41) 630 (24.80) 21 (0.83)

LI-I 1
 HEADLIGHT BULB
LIGHTING SYSTEM

1O.Headlight Bulb B: INSTALLATION

Install in the reverse order of removal.
A: REMOVAL
C: INSPECTION
CAUTION:
1) Visually check the bulb for blow out.
Because the tungsten halogen bulb operates
2) Check the bulb specification. <Ref. to LI-2,
at a high temperature, dirt and oil on the bulb
SPECIFICATIONS, General Description.>
surface reduces the bulb's service life. Hold the
flange portion when replacing the bulb. Never 3) If NG, replace the bulb with a new one.
touch the glass portion.
Do not leave the headlight without a bulb for
a long time. Dust, moisture, etc. entering the
headlight may affect its the performance.
1) Disconnect the ground terminal from battery.
2) Remove the duct (A) (when right side headlight
is removed).

3) Disconnect the harness connector.

4) Remove the cap (A).

5 ) Remove the headlight bulb (A).

LI-I2
 FRONT TURN SIGNAL LIGHT BULB
LIGHTING SYSTEM
-
11.Front Turn Signal Light Bulb
A: REMOVAL
1) Remove the headlight assembly. <Ref. to LI-10,
REMOVAL, Headlight Assembly.>
2) Turn the socket (A) and remove the bulb.

u BO0031

B: INSTALLATION
Install in the reverse order of removal.
C: INSPECTION
1) Visually’check the bulb for blow out.
2) Check the bulb specification. <Ref. to LI-2,
SPECIFICATIONS, General Description.>
3) If NG, replace the bulb with a new one.

LI-I 3
 CLEARANCE/PARKlNG LIGHT BULB
LIGHTING SYSTEM

12.Clearance/Parking Light Bulb

A: REMOVAL
1) Remove the headlight assembly. <Ref. to LI-10,
REMOVAL, Headlight Assembly.>
2) Turn the socket (A) and remove the bulb.

I BOO032

B: INSTALLATION
Install in the reverse order of removal.
C: INSPECTION
1) Visually check the bulb for blow out.
2) Check the bulb specification. <Ref. to LI-2,
SPECIFICATIONS, General Description.>
3) If NG, replace the bulb with a new one.

LI-I 4
 FRONT FOG LIGHT ASSEMBLY
LIGHTING SYSTEM

13.Front Fog Light Assembly

A: REMOVAL
1) Disconnect the ground terminal from battery.
2) Remove the mounting bolts, and then detach the
fog light assembly.

3) Disconnect the harness connector.

B: INSTALLATION
Install in the reverse order of removal.

LI-15
 FRONT FOG LIGHT BULB
LIGHTING SYSTEM

14.Front Fog Light Bulb

A: REMOVAL
1) Remove the front fog light assembly. <Ref. to LI-
15, REMOVAL, Front Fog Light Assembly.>
2) Remove the back cover.

3) Remove the spring retainer then detach the fog

light bulb.
6: INSTALLATION
Install inthe reverse order of removal.
C: INSPECTION
1) Visually check the bulb for blow out.
2) Check the bulb specification. <Ref. to LI-2,
SPECIFICATIONS, General Description.>
3) If NG, replace the bulb with a new one.

LI-I 6
 FRONT SIDE MARKER LIGHT ASSEMBLY
LIGHTING SYSTEM

15.Front Side Marker Light As-

sembly
A: REMOVAL
1) Disconnect the ground terminal from battery.
2) Pull out the light from body while pushing it up.

3) Disconnect the harness connector and remove

the light.
4) Turn the socket and remove the bulb.

I B003X

B: INSTALLATION
Install in the reverse order of removal.
C: INSPECTION
1) Visually check the bulb for blow out.
2) Check the bulb specification. <Ref. to LI-2,
SPECIFICATIONS, General Description.>
3)If NG,replace the bulb with a new one.

LI-I 7
 REAR COMBINATION LIGHT ASSEMBLY
-
LIGHTING SYSTEM

16.Rear Combination Light As- 3) Remove two bolts.

sembly
A: REMOVAL
1. SEDAN
1) Disconnect the ground terminal from battery.
2) Remove the clips and then detach the trunk rear
trim.

4) Remove the rear quarter trim.

<Ref. to El-47, WAGON, REMOVAL, Rear Quarter
Trim.>
5) Disconnect the connector and then detach the
rear combination light assembly.

BOO0

3) Remove the trunk side trim of rear portion.

4) Remove four nuts and then detach the rear com-
bination light while disconnecting the connector.

B: INSTALLATION
Install in the reverse order of removal.

2. WAGON
1) Disconnect the ground terminal from battery.
2) Remove the clips and then detach the rear com-
bination light covers.

LI-I 8
 STOP/TAIL LIGHT BULB
LIGHTING SYSTEM

17.StoplTaiI Light Bulb

A: REMOVAL
1. SEDAN
1) Remove the trunk side trim of rear portion.
2) Turn the socket and remove the bulb.
I H
-

(C) BOO351

(A) Stop light

(B) Tail light
(C) ‘TaiVstop lignt

2. WAGON
1) Remove the rear combination light assembly.
<Ref. to LI-18, WAGON, REMOVAL, Rear Combi-
nation Light Assembly.>
2) Turn the socket and remove the bulb.
I

B: INSTALLATION
Install in the reverse order of removal.
C: INSPECTION
1) Visually check the bulb for blow out.
2) Check the bulb specification. <Ref. to LI-2,
SPECIFICATIONS, General Description.>
3) If NG, replace the bulb with a new one.

LI-I 9
 BACK-UP LIGHT BULB
LIGHTING SYSTEM

18.Back-up Light Bulb

A: REMOVAL
1. SEDAN
1) Remove the trunk side trim of rear portion.
2) Turn the socket and remove the bulb.

2. WAGON
1) Remove the rear combination light assembly.
<Ref. to LI-18, WAGON, REMOVAL, Rear Combi-
nation Light Assembly.>
2) Turn the socket and remove the bulb.

B: INSTALLATION
Install in the reverse order of removal.
C: INSPECTION
1) Visually check the bulb for blow out.
2) Check the bulb specification. <Ref. to LI-2,
SPECIFICATIONS, General Description.>
3) If NG, replace the bulb with a new one.

LI-20
 REAR TURN SIGNAL LIGHT BULB
LIGHTING SYSTEM

19.Rear Turn Signal Light Bulb

A: REMOVAL
1. SEDAN
1) Remove the trunk side trim of rear portion.
2) Turn the socket and remove the bulb.

042

2. WAGON
1) Remove the rear combination light assembly.
<Ref. to Ll-18, WAGON, REMOVAL, Rear Combi-
nation Light Assembly.>
2) Turn the socket and remove the bulb.

9: INSTALLATION
Install in the reverse order of removal.
C: INSPECTION
1) Visually check the bulb for blow out.
2) Check the bulb specification. <Ref. to LI-2,
SPECIFICATIONS, General Description.>
3) If NG, replace the bulb with a new one.

LI-21
 REAR SIDE MARKER LIGHT BULB
LIGHTING SYSTEM

20.Rear Side Marker Light Bulb

A: REMOVAL
1) Remove the rear combination light assembly.
<Ref. to LI-18, WAGON, REMOVAL, Rear Combi-
nation Light Assembly.>
2) Turn the socket and remove the bulb.

B: INSTALLATION
Install in the reverse order of removal.
C: INSPECTION
1) Visually check the bulb for blow out.
2) Check the bulb specification. <Ref. to LI-2,
SPECIFICATIONS, General Description.>
3) If NG, replace the bulb with a new one.

LI-22
 LICENSE PLATE LIGHT
LIGHTING SYSTEM

21 .License Plate Light

A: REMOVAL
1) Disconnect the ground terminal from battery.
2) Remove the license plate light mounting screw
(A) and then remove the lens (B)

BOO122 I
3) Remove the bulb.
B: INSTALLATION
Install in the reverse order of removal.
c: INSPECTION
1) Visually check the bulb for blow out.
2) Check the bulb specification. <Ref. to LI-2,
SPECIFICATIONS, General Description.>
3) If NG, replace the bulb with a new one.

LI-23
 HIGH-MOUNTED STOP LIGHT
LIGHTING SYSTEM

22.High-mounted Stop Light

A: REMOVAL
1. SEDAN
1) Disconnect the ground terminal from battery.
2) Disconnect the connector of high-mounted stop
light from body harness.
3) Remove the bolts, then detach the high-mounted
stop light assembly.

2. WAGON
1) Disconnect the ground terminal from battery.
2) Remove the screws (A) and then detach the cov-
er (B).
3) Remove the screws (C) and then detach the
high-mounted stop light while disconnecting the
connector.
I

I BO0401

B: INSTALLATION
Install in the reverse order of removal.
C: INSPECTION
1) Visually check the bulb for blow out.
2) Check the bulb specification. <Ref. to LI-2,
SPECIFICATIONS, General Description.>
3) If NG, replace the bulb with a new one.

LI-24
 i_
SPOT LIGHT
LIGHTING SYSTEM

23.Spot Light
A: REMOVAL
1) Disconnect the ground terminal from battery.
2) Remove the lens (A) and spot light mounting
screw (B).

I BOO046

ON 1 and 2 *
1.5 0.58

LI-25
 ROOM LIGHT
LIGHTING SYSTEM

24.Room Light
A: REMOVAL
1) Disconnect the ground terminal from battery.
2) Remove the lens (A) and room light mounting
screws (6).

B)

B6M1479P

3) Disconnect the harness connectors and remove

the light.
B: INSTALLATION
Install in the reverse order of removal.
C: INSPECTION
1. ROOM LIGHT BULB
1) Visually check the bulb for blow out.
2 ) Check the bulb specification. <Ref. to LI-2,
SPECIFICATIONS, General Description.>
3) If NG, replace the bulb with a new one.
2. ROOM LIGHT SWITCH
Measure the room light resistance.

(fig)

B6M1489A

Switch position Terminal No. Standard

OFF - More than 1MR
ON 1 and 3 1.5 f 0.5R
I DOOR I 1 and2 I 1.5f0.5R I

LI-26
 LUGGAGE ROOM LIGHT
LIGHTING SYSTEM

25.Luggage Room Light 2. LUGGAGE ROOM LIGHT SWITCH

Measure the luggage room light resistance.
A: REMOVAL
1) Disconnect the ground terminal from battery.
2) Remove the lens (A)and luggage room light
mounting screws (B).

Switch position Terminal No. Standard

More than 1MQ
1 and3 1.5 f 0.5R
DOOR 1 and2 1.5 k 0.5Q

3) Disconnect the harness connectors and remove

the luggage room light.
B: INSTALLATION
Install in the reverse order of removal.
C: INSPECTION
1. LUGGAGE ROOM LIGHT BULB
1) Visually check the bulb for blow out.
2) Check the bulb specification. <Ref. to LI-2,
SPECIFICATIONS, General Description.>
3) If NG, replace the bulb with a new one.

LI-27
 TRUNK ROOM LIGHT
LIGHTING SYSTEM

26.Trunk Room Light

A: REMOVAL
1) Disconnect the ground terminal from battery.
2) Disconnect the harness connectors and remove
the trunk room light.

B: INSTALLATION
Install in the reverse order of removal.
C: INSPECTION
1) Visually check the bulb for blow out.
2) Check the bulb specification. <Ref. to LI-2,
SPECIFICATIONS, General Description.>
3) If NG, replace the bulb with a new one.

LI-28
 GLOVE BOX LIGHT
LIGHTING SYSTEM

27.Glove Box Light

A: REMOVAL
1) Disconnect the ground terminal from battery.
2) Remove the glove box. <Ref. to El-39, REMOV-
AL, Glove Box.>
3) Disconnect the harness connector.
4) Remove the glove box light.

I\ / 800040
B: INSTALLATION
Install in the reverse order of removal.
C: INSPECTION
1) Visually check the bulb for blow out.
2) Check the bulb specification. <Ref. to LI-2,
SPECIFICATIONS, General Description.>
3) If NG, replace the bulb with a new one.

LI-29
 GLOVE BOX LIGHT
LIGHTING SYSTEM

LI-30
 .

WIPER AND WASHER SYSTEMS

ww Page
1. General Description .................................................................................... 2
2. Wiper and Washer System ......................................................................... 5
3. Combination Switch (Wiper)........................................................................ 7
4. Wiper Blade................................................................................................. 9
5. Washer Tank and Motor............................................................................ 11
6. Front Wiper Arm ........................................................................................ 12
7. Front Wiper Motor and Link....................................................................... 13
8. Front Washer Nozzle ................................................................................ 15
9. Rear Wiper Arm ........................................................................................ 16
10. Rear Wiper Motor...................................................................................... 17
11. Rear Washer Nozzle ................................................................................. 18
12. Wiper Control Relay .................................................................................. 19
 GENERAL DESCRIPTION
WIPER AND WASHER SYSTEMS

1. General Description
A: SPECIFICATIONS
Front wiper motor [ Input 12 V-72 W or less
Rear wiDer motor I Input 12 V - 42 W or less

1 Front washer motor

Pump type
lnout
Centrifugal
12 V - 36 W or less
I I PumDtvDe I Centrifuaal I
I Rear washer motor
B: COMPONENT
1. FRONT WIPER

. .

BOO272

(1) Wiper rubber (4) Wiper link Tightening torque: N.m (kgf-m, ft-lb)
(2) Wiper blade ASSY (5) Wiper motor T1: 6.0 (0.61, 4.4)
(3) Wiper arm T2: 20 (2.0, 14.5)

ww-2
 GENERAL DESCRIPTION
WIPER AND WASHER SYSTEMS

2. REARWIPER

(1) Wiper rubber (7) SpacerB Tightening toque: N.m (kgf-myft-lb)

(2) Wiper blade ASSY (8) Nut T1: 6.0 (0.61, 4.4)
(3) Wiper arm (9) Cap T2: 7.5 (0.76, 5.5)
(4) Wiper motor (10 ) Wiper arm cover T3: 8.0 (0.82, 5.9)
(5) SpacerA
(6) Cushion

ww-3
 GENERAL DESCRIPTION
WIPER AND WASHER SYSTEMS

3. WASHER TANK

BOO295

(1) Washer nozzle (5) Front washer motor Tightening torque: N-m (kgf-m, ft-lb)
(2) Washer hose (6) Rear washer motor T: 6.0 (0.61, 4.4)
(3) Washer tank (7) Grommet
(4) Washer tank cap

C: CAUTION
Reconnect the connectors and hoses securely.
After reconnecting, confirm that each function operates normally.
Be careful that the wire harnesses of airbag system pass near electrical parts and switches.
Care must be taken when installing the piping hose so that no bending, jamming, etc. are caused.
If even a little oil or grease such as silicon oil gets in the tank and washer passages, an oil film easily forms
on the glass, causing the wiper to chatter and judder. Therefore, be careful not to let this happen.

ww-4
 WIPER AND WASHER SYSTEM
WIPER AND WASHER SYSTEMS

2. Wiper and Washer System

A: SCHEMATIC
1. WIPER AND WASHER (FRONT)
<Ref. to WI-127, SCHEMATIC, Wiper and Washer
System (Front).>
2. WIPER AND WASHER (REAR)
<Ref. to WI-128, SCHEMATIC, Wiper and Washer
System (Rear).>

ww-5
 WIPER AND WASHER SYSTEM
WIPER AND WASHER SYSTEMS

B: INSPECTION
Svmotom Repair order
Wiper and washers do not operate. (1) Wiper fuse (FIB 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 sprav does not operate. (11 Washer hose and nozzle

WW-6
 COMBINATION SWITCH (WIPER)
WIPER AND WASHER SYSTEMS

3. Combination Switch (Wiper) C: INSPECTION

Measure the combination switch.
A: REMOVAL
1) Loosen the screw to remove a steering column

I B6M1184

2) Disconnect the connectors from combination

switches.
3) Loosen the screw to remove combination switch.

S6M0137

OFF I 7and16 I less than 1R

I INT I 7and16 I lessthan 1R
FRONT I LO I 7and17 I lessthan 1R
8 and 17 less than 1R
B: INSTALLATION
Install in the reverse order of removal. 2 and 10
Washer ON 2 and 12 less than 1R
10 and 12

I
more than 1MR
2 and 10 less than 1R
2 and 10
Washer ON 2 and 12 less than 1R
REAR 10 and 12

If continuity is not as specified, replace the switch.

ww-7
 COMBINATION SWITCH (WIPER)
WIPER AND WASHER SYSTEMS

Intermittent operation inspection

1) Turn the wiper switch to INT.
2) Adjust the intermittent control switch to MAX.
3) Apply battery voltage to switch terminals 16 and 2, and inspect the voltage of terminals 7 and 2. (Measure
the voltage from after the second time the wiper stops.)

Switch position Voltage

I I
ov
12v T11*5 sec.

Non variable type

1o2vv T3 i 1 sec.

B6M1465A I

If operation is not as specified, replace the switch.

WW-8
 WIPER BLADE
WIPER AND WASHER SYSTEMS

4. Wiper Blade D: ASSEMBLY

A: REMOVAL 1. METALTYPE
While pushing the locking clip (A) up, pull out the 1) Insert the wiper rubber onto the blade so that the
blade from arm to arrow direction. stopper is in the position shown.

I B6M1497

B: INSTALLATION 2) Make sure the wiper rubber is securely fastened

1) Install in the reverse order of removal. to the pull stopper (A).
2) Confirm that the clip is locked securely.
c: DISASSEMBLY
1. METALTYPE
Pull on side (A) of the wiper rubber stopper and re-
move the rubber from the blade assembly.

I
I I B6M1498A

I -I I
B6M1496A

2. RESINTYPE
Pull the wiper rubber top slightly from the stopper
and pull out fully.

I I
BOO196

ww-9
b
WIPER BLADE
WIPER AND WASHER SYSTEMS

2. RESINTYPE

B C

BOOl97

1) Insert the wiper rubber through the claw (B). 3) Insert the wiper rubber into the claw (A).

A N . \

2) Insert the wiper rubber top until it protrudes E: INSPECTION

about 20" (0.79 in) from the stopper (D). 1) When the wiper does not perform well, inspect
the following:
Make sure the movable part of the blade assem-
20mm ( 0.79in. ) bly moves smoothly.
Make sure the wiper rubber is not deformed or
damaged.
2) Replace with a new part if damage is found.

BOOl 95

ww-10
 WASHER TANK AND MOTOR
WIPER AND WASHER SYSTEMS

5. Washer Tank and Motor D: ASSEMBLY

1) Assemble in the reverse order of disassembly.
A: REMOVAL 2) Confirm that water does not leak from installation
1) Open the hood. area of motor.
2) Disconnect the ground terminal from battery.
3) Remove the two bolts, hose and connector and E: INSPECTION
then remove the tank. Apply battery voltage to the connector terminal of
the washer motor and make sure the motor oper-
ates.

I464
-
W
B: INSTALLATION B6M1567
Install in the reverse order of removal.
C: DISASSEMBLY
Pull out the washer motor from tank.

ww-11
 FRONT WIPER ARM
WIPER AND WASHER SYSTEMS

6. Front Wiper Arm C: ADJUSTMENT

Operate the wiper once. Align the wiper blade to
A: REMOVAL ceramic print point mark (A) of front window pane.
1) Open the hood.
2) Remove the cap.
3) Loosen the nut to remove arm.

B6M 1193L

B: INSTALLATION
1) Install in the reverse order of removal.
2) Operate the wiper once.
3) Align-the wiper blade to ceramic print point mark
(A) of front window pane.

I B6M1193A

ww-12
 FRONT WIPER MOTOR AND LINK
WIPER AND WASHER SYSTEMS

7. Front Wiper Motor and Link C: INSPECTION

1) When the battery is connected to the terminal of
A: REMOVAL connectors, confirm that motor operates at low
1) Disconnect the ground terminal from battery. speed.
2) Remove the cowl panel. <Ref. to El-33, RE-
MOVAL, Cowl Panel.>
3) Disconnect the connector of motor.
4) Loosen the bolts and nuts to remove wiper link.

I 60020'

2) When the battery is connected to the terminal of

connectors, confirm that motor operates at high
speed.

5 ) Loosen the bolts and nuts to remove motor.

BO0202

3) Connect the battery to terminals of connector,

I B5M1467 I and remove the terminal connection with motor ro-
B: INSTALLATION tated at low speed, and stop the wiper motor
1) Connect the battery ground terminal to battery. through operation.
2) To confirm that the motor is at auto stop position,
connect the harness to motor and turn the wiper
switch ON/OFF once.
3) Disconnect the ground terminal from battery.
4) Tighten the nut where rod (A) and link plate (B) is
aligned in a straight line.

80020:

5 ) Install in the reverse order of removal.

ww-13
 FRONT WIPER MOTOR AND LINK
WIPER AND WASHER SYSTEMS

4) Connect the battery and confirm that the motor

stops at automatic stop position after the motor op-
erates at low speed again.

BOO204

ww-14
 FRONT WASHER NOZZLE
WIPER AND WASHER SYSTEMS

8. Front Washer Nozzle B: INSTALLATION

A: REMOVAL
1) Remove the washer hose from the washer noz-
zle.
2) Open the clips on the underside of the hood with
a thin screwdriver or other tool, and remove the
washer nozzle.
1) Install in the reverse order of removal.
2) Adjust the position of the washer liquid sprayer.
<Ref. to WW-15, ADJUSTMENT, Front Washer
Nozzle.>
C: INSPECTION
Make sure the nozzle and hose are not clogged.
Make sure the hose is not bent.
D: ADJUSTMENT

-
I I
1) Turn the wiper switch to OFF position.
2) When the vehicle stops, adjust the washer injec-
tion position as shown in the figure.
lnjection position:
A: 257 mm (10.12 in)
B: 512 mm (20.16 in)
B6M1505

BO0362

ww-15
 REAR WIPER ARM
WIPER AND WASHER SYSTEMS

9. Rear Wiper Arm

A: REMOVAL
1) Raise the wiper arm cover (A).
2) Loosen the nut to remove wiper arm.

I B6M1201A

B: INSTALLATION
1) Install in the reverse order of removal.
2) Operate the rear wiper once.
3) Align the blade to rear defogger heat wire (A).

‘ \I
\\
F
BOO206

C: ADJUSTMENT
1) Operate the rear wiper once.
2) Align the blade to rear defogger heat wire (A).

WW-16
 REAR WIPER MOTOR
WIPER AND WASHER SYSTEMS

10.Rear Wiper Motor C: INSPECTION

1) Connect the battery to wiper motor connector
A: REMOVAL and confirm that wiper motor operates.
1 ) Disconnect the ground terminal from battery.
2) Remove the rear wiper arm.
3) Remove the cap (A), nut (B), and spacer (C)
from rear wiper shaft.

S6M0072

2) Connect the battery to terminal of connector and

remove the terminal connections with motor rotat-
ed, and stop the wiper motor through operation.
06M12021

4) Remove the rear gate lower trim. <Ref. to El-52,

REMOVAL, Rear Gate Trim.>
5) Unclip we clip of harness and disconnect con-
nector of wiper motor.
6) Loosen the bolts to remove wiper motor assem-
bly (A).

S6M0073

3) Connect the battery and confirm that the motor

stops at automatic stop position after the motor op-
erates at low speed again.
I

B: INSTALLATION
1) Install in the reverse order of removal.
2) Installthe rear wiper cushion with the arrow mark
facing up, as shown in the figure.

I 05M1463

ww-17
 REAR WASHER NOZZLE
WIPER AND WASHER SYSTEMS

11.Rear Washer Nozzle B: INSTALLATION

A: REMOVAL
1) Remove the high-mount stop light. <Ref. to LI-
24, REMOVAL, High-mounted Stop Light.>
2) Remove the washer hose from the washer noz-
zle.
3) Open the clips on the underside of the hood with
a thin screwdriver or other tool, and remove the
washer nozzle.
1) Install in the reverse order of removal.
2) Adjust the position of the washer liquid sprayer.
<Ref. to WW-18, ADJUSTMENT, Rear Washer
Nozzle.>
C: INSPECTION
Make sure the nozzle and hose are not clogged.
Make sure the hose is not bent.
D: ADJUSTMENT
1) Turn the wiper switch to OFF position.
2) When the vehicle stops, adjust the washer injec-
tion position as shown in the figure.
Injection position:
A: 39 mm (1.54 in)
B: 72"

B6M1200(

ww-I a
 WIPER CONTROL RELAY
WIPER AND WASHER SYSTEMS

12.Wiper Control Relay

A: REMOVAL
1) Disconnect the ground terminal from battery.
Remove the right quarter lower trim. <Ref. to El-47,
REMOVAL, Rear Quarter Trim.>
2) Loosen the nut to remove control unit.

B: INSTALLATION
Install in the reverse order of removal.
C: INSPECTION
1) Disconnect the connector from the wiper control
relay.
2) Connect the positive (+) lead from the battery to
terminal 8 and the negative (-) lead to terminal 6.
Connect the positive (+) lead from the voltmeter to
terminal 3 and negative lead to ground.

U BO0276

3) Measure the voltage when the wiper relay is op-

erated.

Switch position Voltage

B6M1523,

If operation is not as specified, replace the switch.

ww-19
 WIPER CONTROL RELAY
WIPER AND WASHER SYSTEMS

ww-20
 .

ENTERTAINMENT

Page
1. General Description .................................................................................... 2
2. Radio System .............................................................................................. 3
3. Cigarette Lighter System............................................................................. 5
4. Radio Body.................................................................................................. 6
5. Front Speaker ............................................................................................. 7
6. Tweeter ....................................................................................................... 8
7. Rear Speaker .............................................................................................. 9
8. Antenna ..................................................................................................... 10
9. Cigarette Lighter........................................................................................ 11
 GENERAL DESCRIPTION
ENTERTAINMENT

1. General Description
A: CAUTION
Before disassembling or reassembling parts, al-
ways disconnect the battery ground cable. When
replacing radio, control module, and other parts
provided with memory functions, record memory
contents before disconnecting the battery ground
cable. Otherwise, the memory will be erased.
Reassemble in reverse order of disassembly, un-
less otherwise indicated.
Adjust the parts to the given specifications.
Connect the connectors and hoses securely dur-
ing reassembly.
After reassembly, make sure functional parts op-
erate smoothly.
B: PREPARATION TOOL
1. GENERAL TOOLS
I TOOL NAME I REMARKS 1
Circuit Tester Used for measuring resis-
tance and voltage.

ET-2
 RADIO SYSTEM
ENTERTAINMENT
~~~ ~ ~~~

2. Radio System
A: SCHEMATIC
1. RADIO
<Ref. to WI-52, SCHEMATIC, Audio System.>

ET-3
 -
RADIO SYSTEM
ENTERTAINMENT

B: INSPECTION
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 between radio and speaker.
Radio generates noise with engine running (1) Check radio ground.
(2) Check generator.
(3) Check ignition coil.
(4) Remove radio for repair.
AM and FM modes are weak or noisy (1) Check antenna.
(2) Check radio ground.
(3) Remove radio for repair.

ET-4
 B

CIGARETTE LIGHTER SYSTEM

ENTERTAl NM ENT

3. Cigarette Lighter System

A: SCHEMATIC
1. CIGARETTE LIGHTER
<Ref. to WI-88, SCHEMATIC, Front Accessory
Power Supply System.>

ET-5
 RADIO BODY
ENTERTAINMENT

4. Radio Body
A: REMOVAL
1) Disconnect the battery ground cable.
2) Remove the center panel while disconnecting
connector.

\
0 : Hook pawl
3) Remove the fitting screws, and slightly pull radio
out from the center console.

4) Disconnect the electric connectors and antenna

feeder cord.
B: INSTALLATION
Install in the reverse order of removal.

ET-6
 FRONT SPEAKER
ENTERTAINMENT

5. Front Speaker
A: REMOVAL
1) Disconnect the battery ground cable.
2) Remove the front door trim. <Ref. to El-37, RE-
MOVAL, Front Door Trim.>
3) Remove the front speaker mounting screws.

600019

4) Disconnect the harness connector and remove

the front speaker.
B: INSTALLATION
Install in the reverse order of removal.

ET-7
 TWEETER
ENTERTAINMENT

6. Tweeter
A: REMOVAL
1) Disconnect the battery ground cable.
2 ) Remove the front door trim. <Ref. to El-37, RE-
MOVAL, Front Door Trim.>
3) Remove the tweeter mounting screws.

4) Disconnect the harness connector and remove

the tweeter.
B: INSTALLATION
Install in the reverse order of removal.

ET-8
 REAR SPEAKER
ENTERTAINMENT

7. Rear Speaker
A: REMOVAL
1) Disconnect the battery ground cable.
2) Remove the rear door trim. <Ref. to El-38, RE-
MOVAL, Rear Door Trim.>
3) Remove the rear speaker mounting screws.

S6M05

4) Disconnect the harness connector and remove

the rear speaker.
B: INSTALLATION
Install in the reverse order of removal.

ET-9
 ANTENNA
ENTERTAINMENT

8. Antenna
A: REMOVAL
1) Remove the mounting screws and detach anten-
na.
2) Disconnect the harness connector.

B: INSTALLATION
Install in the reverse order of removal.

ET-10
 CIGARETTE LIGHTER
ENTERTAINMENT

9. Cigarette Lighter
A: REMOVAL
1) Disconnect the battery ground cable.
2) Remove the center panel. <Ref. to ET-6, RE-
MOVAL, Radio Body.>
3) Disconnect the harness connectors and remove
the cigarette lighter.

BO0023

B: INSTALLATION
Install in the reverse order of removal.

ET-11
 CIGARETTE LIGHTER
ENTERTAINMENT

ET-I 2
COMMUNICATION SYSTEM

COM
Page
1. General Description .................................................................................... 2
2. Horn System ............................................................................................... 3
3. Horn ............................................................................................................ 4
4. Horn Switch ................................................................................................. 5
 GENERAL DESCRIPTION
COMMUNICATION SYSTEM

1. General Description
A: PREPARATION TOOL
1. GENERAL TOOLS
TOOL REMARKS
NAME
Circuit Used for measuring resistance and voltage.
Tester

COM-2
 HORN SYSTEM
COMMUNICATION SYSTEM

2. Horn System
A: SCHEMATIC
1. HORN
<Ref. to WI-89, SCHEMATIC, Horn System.>
B: INSPECTION
1. HORN RELAY
Measure the horn relay resistance between termi-
nals (indicated in table below) when connecting ter-
minal No. 4 to battery positive terminal and terminal
No. 3 to battery ground terminal.

I 800308

Flow Less than 1R

1 and2
No Flow More than 1MR

COM-3
 HORN
COM MUNCATION SYSTEM

3. Horn
A: REMOVAL
1) Disconnect the battery ground cable.
2) Remove the horn bracket mounting bolt (A).
3) Disconnect the harness connector and remove
the horn assembly (B).

B: INSTALLATION
Install in the reverse order of removal.
C: INSPECTION
With 12 V direct current supply between horn termi-
nal and case ground, check that the horn sounds
properly.

COM-4
 HORN SWITCH
COMMUNICATION SYSTEM

4. Horn Switch C: INSPECTION

Measure the horn switch resistance.
A: REMOVAL
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) Disconnect the battery ground cable.
2) Remove the driver's airbag module. <Ref. to
AB-12, Driver's Airbag Module.>
3) Remove the horn switch from the steering wheel B6M1493
as shown.
Switch position I Terminal No. 1 Resistance I
When horn switch
Less than 1R
is pushed.
When horn switch
More than 1 MR
is not Dushed.

B: INSTALLATION
Install in the reverse order of removal.

COM-5
 HORN SWITCH
COMMUNICATION SYSTEM

COM-6
GLASSNVlNDOWS/MIRRORS
W
Page
1. General Description .................................................................................... 2
2. Power Window System ............................................................................... 9
3. Rear Window Defogger System ................................................................ 11
4. Remote Control Mirror System.................................................................. 13
5. Front Door Glass ....................................................................................... 15
6. Front Regulator and Motor Assembly ....................................................... 19
7. Rear Door Glass ....................................................................................... 20
8. Rear Regulator and Motor Assembly ........................................................ 22
9. Windshield Glass ...................................................................................... 23
10. Rear Gate Glass ....................................................................................... 26
11. Rear Quarter Glass ................................................................................... 27
12. Rear Window Glass .................................................................................. 28
13. Inner Rearview Mirror................................................................................ 29
14. Power Window Control Switch .................................................................. 30
15. Rear Window Defogger ............................................................................. 32
16. Outer Mirror Assembly .............................................................................. 33
17. Outer Mirror............................................................................................... 35
18. Remote Control Mirror Switch ................................................................... 36
 GENERAL DESCRIPTION
GLASSNVINDOWS/MIRRORS

1. General Description
A: COMPONENT
1. FIXED GLASS (SEDAN)

BO0391

(1) Windshield glass (4) Rearview mirror mount (7) Spring

(2) Dam rubber (5) Locate pin
(3) Molding (6) Rear window glass

GW-2
 GENERAL DESCRIPTION
GLASSMI NDOWS/MIRRORS

2. FIXED GLASS (WAGON)

BOO392

(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
 GENERAL DESCRIPTION
GLASSNVINDOWS/MI RRORS

3. FRONT DOOR GLASS

(1) Glass (5) Motor ASSY Tightening torque: N.m (kgf-m, ft-lb)
(2) Door sash (Front) T1: 7.4 (0.75, 5.5)
(3) Door sash (Rear) T2: 13.7(1.4, 10.1)
(4) Regulator ASSY

GW-4
 GENERAL DESCRIPTION
G LASSNVlNDOWS/MIR RO RS
4. REAR DOOR GLASS

(1) Glass (5) Motor ASSY Tightening torque: N-m (kgf-m, ft-lb)
(2) Door sash (Front) T1: 7.4 (0.75, 5.5)
(3) Door sash (Rear) T2: 13.7(1.4, 10.1)
(4) Regulator ASSY

GW-5
 GENERAL DESCRIPTION
GLASSNVINDOWSIMIRRORS

5. MIRRORS

B O ~ E

(1) Outer mirror (3) Mount (5) Mirror

(2) Inner rearview mirror (4) Spring

GW-6
 GENERAL DESCRIPTION
GLASSNVINDOWS/MI R RORS

B: CAUTION
When electrical connectors are disconnected, al-
ways conduct an operational check after connect-
ing them again.
Avoid impact and damage to the glass.

GW-7
 GENERAL DESCRIPTION
GLASS/WINDOWS/MIRRORS

C: PREPARATION TOOL
TOOL NAME REMARKS
Circuit Tester Used for checking voltage and continuity.
Piano Wire Used for window alass removal.
IWindshield Knife I Used for window glass removal. I

GW-8
 POWER WINDOW SYSTEM
GLASSNVINDOWS/MIRRORS

2. Power Window System

A: SCHEMATIC
<Ref. to WI-109, Power Window System.>

GW-9
 POWER WINDOW SYSTEM
GLASSNVINDOWSIMIRRORS

B: INSPECTION
Symptom Repair order
(1) Fuse (SBFS)
(2) Power window circuit breaker
All power windows does not operate.
(3)Power window relay
I41 Wire harness
(1) Power window main switch
(2) Power window sub switch
One window does not operate.
(3) Power window motor
I41 Wire harness
“Window Lock does not operate. (11 Power window main switch

GW-10
 REAR WINDOW DEFOGGER SYSTEM
GLASS/WINDOWS/MIRRORS

3. Rear Window Defogger System

A: SCHEMATIC
I <Ref. to WI-117, Rear Window Defogger System.>

GW-11
 REAR WINDOW DEFOGGER SYSTEM
GLASSNVINDOWSIMIRRORS

B: INSPECTION
Symptom Repair order
(1) Fuse (M/B No. 1) (F/B No. 11)
(2) Rear defogger relay
(3) Rear defogger timer
Rear window defogger does not operate. (4) Defogger switch
(5) Rear defogger condenser
(6) Deffogger wire
(7)Wire harness

GW-12
 I
REMOTE CONTROL MIRROR SYSTEM
GLASSMIINDOWSIMIRRORS

4. Remote Control Mirror System

A: SCHEMATIC
<Ref. to WI-118, Remote Controlled Rearview Mir-
I
ror System.>

E
i
1
GW-13
I
 REMOTE CONTROL MIRROR SYSTEM
GLASSNVINDOWSIMIRRORS

B: INSPECTION
Symptom ReDair order
(1)Fuse (F/B No. 1) (F/B No. 4) (F/B No. 19)
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-14
 FRONT DOOR GLASS
GLASS/WINDOWS/MIRRORS

6) Remove the rear end of door weather strip and

5. Front Door Glass weather strip outer
A: REMOVAL
1) Remove the front door trim. <Ref. to El-37, RE-
MOVAL, Front Door Trim.>
2) Remove the sealing cover. <Ref. to EB-14, RE-
MOVAL, Front Sealing Cover.>
3) Remove the outer mirror assembly. <Ref. to
GW-33, REMOVAL, Outer Mirror Assembly.>
4) Remove the gusset.

7) Operate the power window switch to move glass

to position shown in the figure, and then remove
the two nuts from the service holes.

8) Remove the door glass.

5 ) Remove the stabilizers and trim hooks.

B5M 1
- -7
CAUTION:
Do not turn regulator in the closing direction
after removal of the glass. Otherwise gear may
be disengaged.
BO0086
Avoid impact and damage to the glass.

GW-15
 FRONT DOOR GLASS
-
GLASS/WINDOWS/MIRRORS

B: INSTALLATION
1) Install in the reverse order of removal.
CAUTION:
Make sure that glass stay is placed securely in
sash.
2) Adjust the front door glass. <Ref. to GW-17, AD-
JUSTMENT, Front Door Glass.>

GW-16
 FRONT DOOR GLASS
GLASSNVINDOWSIMIRRORS

C: ADJUSTMENT 5) For adjustment of upper and lower ends of cen-

ter pillar, loosen the adjusting nut (A) of B-channel
NOTE:
(B).
Before adjustment, ensure that all adjusting bolts of
stabilizer, upper stopper, and sash are loose and
door glass is raised so that it is in contact with
weatherstrip.
1) Temporarily tighten one adjusting bolt on one
side of rear sash at the midpoint of slotted hole in
the inner panel.
2) Temporarily tighten the regulator 8-channel in a
position at the top of slotted hole.
3)Lower the door glass 10 to 15 mm (0.39to 0.59
in) from fully closed position. While applying out-
ward pressure of 45.0k4.9N (4.6k0.5kg, 1 1 .&l .1
' B5M0729A

Ib) (F) to upper edge of glass above midpoint of two 6)Adjust so that the upper and lower ends of center
outer stabilizers, press the inner stabilizer at pres- pillar are the same size.
sure of 1 Of5 N (1.0k0.5 kg, 0.2k0.1Ib) to the glass,
then secure it.
Full close
10 - 15 mm
(0.39 - 0.59 in)
,

u G5M0421

4) For adjustment of clearance between front glass

and center pillar cover, loosen the nuts (A), and
move the glass sash back and forward until clear-
,,(-TE Lower B channel

Glass tilts too

far forward
Wide

Narrow

ance becomes the value shown.

Raise B channel BOO389

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 the upper stopper lightly touches

-
the glass holder.

2-3
\ (0.079-0.118)
12 (0.472) 12 (0.472)
-7

A-A
Unit: mm (in)
800388

GW-17
 FRONT DOOR GLASS
GLASSNVlNDOWS/M IRRORS

For preventing wind noise, adjust the glass at the 10) Make adjustment of front sash in the same
position where tip of gusset is raised up a little. 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 exces-
sive load to regulator.
11) After adjustments, tighten the nuts.
12) After adjustment of glass, if there is a gap be-
tween outer lip of gusset and glass surface, adjust
(A) 0-1.5 mm (0-0.059in)
the gap with adjusting bolt (A) in lower fitting part of
8) After stabilizer adjustment, carry out glass crimp gusset to prevent generation of wind noise.
adjustment. First, visually ensure positional rela- 13) During adjustments, loosen other three clamp-
tionship between retainer & molding and glass of ing bolts.
the roof side, and then begin with rear sash adjust-
ment. Adjust two adjusting bolts alternately step by
step to obtain dimensions shown below (cross-sec-
tion A).
NOTE:
If two nuts are loosened at the same time, the sash
moves back and forth. Therefore, when one nut is
adjusted, secure the other.
9) Make the same adjustment of two adjusting bolts
of rear sash.
I
2-3
\ (0.079-0.118)

Unit: mm (in)
BO0267

CAUTION:
Do not tilt sash bracket to inner panel during 14) After adjustment, tighten the bolts and nuts.
adjustment. Otherwise smooth regulator opera-
tion cannot be achieved.

GW-18
 FRONT REGULATOR AND MOTOR ASSEMBLY
GLASSMI NDOWS/M IRRORS

6. Front Regulator and Motor B: INSTALLATION

1) Install in the reverse order of removal.
Assembly 2) Adjust the front door glass. <Ref. to GW-17, AD-
A: REMOVAL JUSTMENT, Front Door Glass.>
1) Remove the door glass. <Ref. to GW-15, RE- C: INSPECTION
MOVAL, Front Door Glass.> 1) Make sure that the power window motor rotates
2) Loosen the nuts to remove the rear sash. properly when the battery voltage is applied to the
I terminals of motor connector.
2) Change the polarity of battery connectionsto ter-
minals to ensure that the motor rotates in reverse
direction.

00089 I
I

3) Disconnect the motor connector.

4) Loosen four bolts and two nuts to remove the
regulator assembly .

5) Loosen the screw to remove motor assembly.

800091

GW-19
 REAR DOOR GLASS
GLASSNVINDOWSIMIRRORS

7. Rear Door Glass 5 ) Loosen two screw to remove weather strip outer.

A: REMOVAL
1) Remove the rear door trim. <Ref. to El-38, RE-
MOVAL, Rear Door Trim.>
2) Remove the sealing cover. <Ref. to EB-17, RE-
MOVAL, Rear Sealing Cover.>
3) Remove the stabilizer.

I B5M1044

4) Remove the door weather strip.

\ /
BOO093

6) Operate the power window switch to remove

glass as shown in the figure, and remove two nuts.

7) Loosen two rear sash installation nuts, and move

the rear sash backward.
8) Remove the glass.
CAUTION:
\ BO0092
Avoid impact and damage to the glass.

GW-20
 B

REAR DOOR GLASS

GLASS/WINDOWS/MIRRORS
~~

9: INSTALLATION After adjustment, move glass up and down to

1) Install in the reverse order of removal. check whether it is caught.
CAUTION:
Make sure that glass stay is placed securely in
sash.
2) Adjust rear door glass. <Ref. to GW-21, AD-
JUSTMENT, Rear Door Glass.>
C: ADJUSTMENT
NOTE:
The rear door glass, as a rule, should be adjusted
in the same manner as front glass, although they
are different in dimension. Special notes for rear
glass are given below.
1) Adjust the glass position using the following di-
mensions as a guide line.

12 (0.472) 12 (0.472)

A-A
Unit: mm (in)
BOO394

CAUTION:
If dimensions are smaller than the given di-
mensions, glass may get caught in weather-
strip during liftinghowering operation. In the
worst case, it may cause glass not to be opened
fully.
After adjustment, move glass up and down to
check whether it is caught.
2) Adjust the crimp of glass using the following di-
mensions as a guide line.

g
2-3
2-
(0.079-0.1 18)

1% (41
6 (0.236)

Unit: mm (in)
BO0269

CAUTION:
If crimp of rear glass is higher than neces-
sary, glass may get caught in weatherstrip of
center pillar corner, resulting in early wear of
weatherstrip. Be careful when adjusting.

GW-21
 REAR REGULATOR AND MOTOR ASSEMBLY
GLASSNVINDOWSIMIRRORS

8. Rear Regulator and Motor As-

sembly
A: REMOVAL
1) Remove the door glass. <Ref. to GW-20, RE-
MOVAL, Rear Door Grass.>
2) Remove the front sash.
3) Disconnect the motor connector.
4) Loosen four bolts and two nuts to remove r
lator assembly.

5 ) Loosen' screws to remove motor assembly.

1
V
B0009E

B: INSTALLATION
1) Install in the reverse order of removal.
2) Adjust the rear door glass. <Ref. to GW-21, AD-
JUSTMENT, Rear Door Glass.>
C: INSPECTION
1) Make sure that the power window motor rotates
properly when the battery voltage is applied to the
terminals of motor connector.
2) Change the polarity of battery connections to the
terminals to ensure that the motor rotates in re-
verse direction.

GW-22
 I

WINDSHIELD GLASS
GLASSMINDOW S/M IRRORS

9. Windshield Glass NOTE:

A: REMOVAL
1. USING WINDSHIELD KNIFE
1) Remove the cowl panel. <Ref. to El-33, RE-
MOVAL, Cowl Panel.>
2) Remove the glass molding.
3) Tape the body side of the circumference of wind-
shield glass for protection.
4) Apply the sufficient amount of soapy water to the
adhesive layer.
5) Insert the windshield knife into the adhesive lay-
er.
6) While holding the knife edge and windshield
glass edge at a right angle, move the windshield
knife in parallel to the windshield glass edge along
face and edge of windshield glass to cut the adhe-
sive layer.
CAUTION:
Do not twist windshield knife.
Cutting'of adhesive layer shall be started with
wider gap between windshield glass and body.
Because the matching pins are bonded to the cor-
ners of glass, use piano wire to cut the pin.
Matching pin
A-A
G5M0412
2. USING PIANO WIRE
1) Remove the cowl panel. <Ref. to El-33, RE-
MOVAL, Cowl Panel.>
2) Remove the roof molding and upper front mold-
ing.
3) Tape the body side of the circumference of wind-
shield glass for protection.
4) Make a hole in the adhesive layer using drill or
knife.
5) Pass the piano wire through the hole, and attach
securely both the wire ends to pieces of wood.

A-A
/-
\ \ G5M0494

6) Pull the wire ends alternately to cut off the adhe-

sive layer.
CAUTION:
Do not tightly pull the piano wire against the
windshield glass edge.
Be careful not to damage interior and exterior
parts.
G5M041e When removal is made with area close to in-
strument panel, place a protection plate over it.
Pay particular attention to the removal.
Do not cross piano wires. Otherwise they
may be cut.

GW-23
 WINDSHIELD GLASS
GLASSNVINDOWS/MIRRORS

B: INSTALLATION 8) Fit the molding mark (B) to notch (A).

1) Clean the external circumference of windshield
glass with alcohol or white gasoline.
2) Remove the adhesive layer on the body using
cutter knife to obtain smooth face 2 mm (0.08 in)
thick.
CAUTION:
Be careful not to damage the body and paint
surface.

' 2mm
(0.08 in)

G5M0553

3) Clean l h e body with alcohol or white gasoline to

remove thoroughly chips, dusts, and dirts from the
body face.
4) Place the glass on body.
5) Adjust the glass position to make uniform clear-
ance between body and glass in four corners.
6) Bond the matching pins and dam rubber.
BOO270
9) Apply the primer to the adhesive layer of glass
using sponge.
10) Apply the primer to the adhesive layer of body.
CAUTION:
Primer once attached to the painted surface
of the body and internal trim is hard to wipe off.
Mask the circumference of such areas.
Let primer dry for about ten minutes before
installing the glass.

/I/ Matching pin Fastener

Do not touch surface coated with primer.

Application
Dam rubber of primer

11 (0.433)

7 1
Ill i
1 15 (0.591)
Glass side Body side

G5M0495

Unit: mm (in)
80039:

7) Remove the glass from body.

GW-24
 WINDSHIELD GLASS
G LASSNVINDOWS/MIR RORS
11) Cut off the cartridge nozzle tip and set it in seal-
ant gun as shown.

1
(0.39)

12) Apply the adhesive to the glass end surface as

shown.
13) Fit the matching pins using suction rubber cup
to install windshield glass.

14) Lightly press the windshield glass for tight fit.

15) Make the adhesive surface flush using spatula.
CAUTION:
When door is openedklosed after glass is
bonded, always lower door glass and then
open/close it carefully.
Move vehicle slowly.
16) After completion of all work, allow vehicle to
stand for about 24 hours.
NOTE:
For minimum drying time and time the vehicle must
be left standing before driving after bonding, follow
instructions or instruction manual from the adhe-
sive manufacturer.
17) After curing of adhesive, pour water on external
surface of vehicle to check that there are no water
leaks.
CAUTION:
When a vehicle is returned to the user, tell him
or her that the vehicle should not be subjected
to heavy impact for at least three days.
18) Jnstall the cowl panel. <Ref. to El-33, INSTAL-
LATION, Cowl Panel.>

GW-25
 REAR GATE GLASS
GLASSNVINDOWSIMI RRORS

10.Rear Gate Glass 4) After completion of all work, allow vehicle to

A: REMOVAL
1) Remove the rear wiper motor. <Ref. to WW-17,
REMOVAL, Rear Wiper Motor.>
2) Remove the electrical connector from the rear
defogger terminal.
3) Remove the glass in the same procedure as for
windshield glass. <Ref. to GW-23, REMOVAL,
Windshield Glass.>
B: INSTALLATION
1) Apply the adhesive evenly to the glass attach-
ment 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.
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.
CAUTION:
When a vehicle is returned to the user, tell him
or her that the vehicle should not be subjected
to heavy impact for at least three days.
5) Connect the rear defogger terminals.
6) Install the rear wiper. <Ref. to WW-17, INSTAL-
LATION, Rear Wiper Motor.>

Upper side

Lower side

BOO396

CAUTION:
When door is openedklosed after glass is
bonded, always lower door glass and then
open/close it carefully.
Move vehicle slowly.

GW-26
 REAR QUARTER GLASS
GLASSNVINDOWSIMIRRORS

11.Rear Quarter Glass

A: REMOVAL
Remove the glass in the same procedure as for windshield glass. <Ref. to GW-23, REMOVAL, Windshield
Glass.>

< \Molding

B-B
-
A-A 4

Dam rubber
7

-
7
Adhesive
Rear quarter glass

BOO21C

B: INSTALLATION 3) After completion of all work, allow vehicle to

1) Cut off the nozzle tip as shown in the figure. stand for about 24 hours.
NOTE:
Unit: mm (in) For minimum drying time and time the vehicle must
be left standing before driving after bonding, follow
10 (0.39) instructions or instruction manual from the adhe-
-Ti- sive manufacturer.
l l I -

LAdhesive
4) After curing of adhesive, pour the water on exter-
D l 5 (0.59) nal surface of vehicle to check that there are no wa-
12 - 15 ter leaks.
(0.47 - 0 .59 CAUTION:
5M0414
When a vehicle is returned to the user, tell him
or her that the vehicle should not be subjected
2) Install the glass in the same procedure as for to heavy impact for at least three days.
windshield the glass. <Ref. to GW-24, INSTALLA-
TION, Windshield Glass.>
CAUTION:
When door is opened/closed after glass is
bonded, always lower door glass and then
openklose it carefully.
Move vehicle slowly.

GW-27
 REAR WINDOW GLASS
GLASSMINDOWS/M I RRORS

12.Rear Window Glass 5 ) After curing of adhesive, pour the water on exter-
nal surface of vehicle to check that there are no wa-
A: REMOVAL ter leaks.
1) Disconnect the electrical connectors from the CAUTION:
rear defogger terminals. When a vehicle is returned to the user, tell him
2) Remove the glass in the Same Procedure as for or her that the vehicle should not be subjected
windshield glass. <Ref. to GW-23, REMOVAL, to heavy impact for at least three days.
Windshield Glass.>
B: INSTALLATION
1) Bond the dam rubber and matching pin.

Unit: mm (in)
BO0271

2) Install the glass in the same procedure as for

windshield glass. <Ref. to GW-24, INSTALLA-
TION, Windshield Glass.>
3) Connect the rear defogger terminals.
CAUTION:
When door is openedclosed after glass is
bonded, always lower door glass and then
opedclose door carefully.
Move vehicle slowly.
4) After completion of all work, allow the vehicle to
stand for about 24 hours.
NOTE:
For minimum drying time and time the vehicle must
be left standing before driving after bonding, follow
instructions or instruction manual from the adhe-
sive manufacturer.

GW-28
 INNER REARVIEW MIRROR
GLASSMI NDOWS/MI RRORS

13.lnner Rearview Mirror

A: REMOVAL
NOTE:
The spring cannot be reused. Prepare a new spring
before removal.
1) Turn the mirror base 90 degrees clockwise or
counterclockwise to remove it.

B5M1059
I

2) Remove the spring from the mirror base.

B5M1060

CAUTION:
Be careful not to damage the mirror surface.
B: INSTALLATION
Install in the reverse order of removal.
C: INSPECTION
Do not let mirror be damaged.
Do not let spring deteriorate.

GW-29
 POWER WINDOW CONTROL SWITCH
GLASS/WINDOWS/MIRRORS

14.Power Window Control 2. SUB-SWITCH

Switch 1) Disconnect the ground terminal from battery.
2) Remove the switch panel.
A: REMOVAL 3) Disconnect the connector.
1. MAIN SWITCH
1) Disconnect the ground terminal from battery.
2) Loosen the screw to remove power window main
switch.
3) Disconnect the connector.

B: INSTALLATlON
1. MAIN SWITCH
Install in the reverse order of removal.
2. SUB-SWITCH
Install in the reverse order of removal.

C: INSPECTION
1. MAIN SWITCH
Measure switch resistance.
Driver's switch:
Switch position Terminal No. Standard
UP 13 and 2.1 and 5 less than l R
1 and2
OFF 1 and 5 less than 1R
2 and 5
DOWN 13 and 1 , 2 and 5 less than 1R
AUTO DOWN 13 and 1,2 and 5 less than 1R

Switch position Terminal No. Standard

UP I 13 and 6, 7 and 5 less than la
OFF 6 and 7 and 5 less than 1R
DOWN 13 and 7 , 6 and 5 less than 1R

GW-30