Impreza 2001 2002 PDF

2002 Model Year
PDF Service Manual

GENERAL INFORMATION SECTION (Pub.No.G1840GE1)
ENGINE 1 SECTION (Pub.No.G1840GE2)
ENGINE 2 SECTION (Pub.No.G1840GE3)
TRANSMISSION SECTION (Pub.No.G1840GE4)
CHASSIS SECTION (Pub.No.G1840GE5)
BODY SECTION (Pub.No.G1840GE6)
WIRING SYSTEM SECTION (Pub.No.G1840GE7)

2002 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX
GENERAL INFORMATION
SECTION
FOREWORD FW
HOW TO USE THIS MANUALS HU
SPECIFICATIONS SPC
PRECAUTION PC
This service manual has been prepared
to provide SUBARU service personnel
NOTE NT
with the necessary information and data
for the correct maintenance and repair
of SUBARU vehicles. IDENTIFICATION ID
This manual includes the procedures
for maintenance, disassembling, reas-
sembling, inspection and adjustment of RECOMMENDED MATERIALS RM
components and diagnostics for guid-
ance of experienced mechanics.
Please peruse and utilize this manual PRE-DELIVERY INSPECTION PI
fully to ensure complete repair work for
satisfying our customers by keeping
their vehicle in optimum condition. PERIODIC MAINTENANCE SERVICES PM
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. G1840GE1

FOREWORD
FW
Page
1. Foreword .....................................................................................................2
FOREWORD
FOREWORD
1. Foreword
A: FOREWORD
These manuals are used when performing mainte-
nance, repair, or diagnosis of the Subaru IMPRE-
ZA.
Applied model: GG***** and GD***** from 2002MY.
The additional manuals below are also available:

AUTOMATIC TRANSMISSION SERVICE MANU-
AL (Pub. No. G0864ZE)
The manuals contain the latest information at the

time of publication. Changes in specifications,
methods, etc. may be made without notice.
FW-2
HOW TO USE THIS MANUALS
HU
Page
1. How to Use This Manuals ...........................................................................2
1. How to Use This Manuals

A: HOW TO USE THIS MANUALS
1. STRUCTURE
Each section consists of SCT that are broken down
into SC that are divided into sections for each com-
ponent. The specification, maintenance and other
information for the components are included, and
diagnosis information has also been added where
necessary.
2. INDEX
The first page has an index with tabs. And at the
end of each section is an alphabetical index.
3. COMPONENTS
For each component, a composition drawing is in-
cluded.
4. SPECIFICATIONS
If necessary, specifications are also included.
5. INSPECTION
Inspections are included to be carried out before
and after maintenance.
6. MAINTENANCE
Maintenance instructions are provided for each
component. When multiple components comprise
one process, refer to the instructions for that 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
Page
1. Impreza SA08731 .......................................................................................2
IMPREZA
SPECIFICATIONS
1. Impreza SA08731
A: DIMENSIONS SA08731G28
Model Sedan Wagon OUTBACK

Overall length mm (in) 4,405 (173.4)
Overall width mm (in) 1,730 (68.1) 1,695 (66.7) 1,710 (67.3)
Overall height (at C.W.) mm (in) 1,465 (57.7), 1,475 (58.1),
1,440 (56.7)
1,485 (58.5)★4 1,495 (58.9)★4
Compartment Length mm (in) 1,890 (74.4) 1,845 (72.6)
Width mm (in) 1,380 (54.3)
Height mm (in) 1,180 (46.5), 1,200 (47.2), 1,200 (47.2),
1,125 (44.3)★5 1,150 (45.3)★5 1,150 (45.3)★5
Wheelbase mm (in) 2,525 (99.4)
Tread Front mm (in) 1,460 (57.5)★1,
1,485 (58.5) 1,460 (57.5)
1,465 (57.7)
Rear mm (in) 1,475 (58.1), 1,450 (57.1)★1,
1,455 (57.3)
1,480 (58.3)★3 1,455 (57.3)
Minimum road Without catalytic mm (in) 150 (5.9), 150 (5.9),
160 (6.3)
clearance converter 155 (6.1)★2 155 (6.1)★2
With catalytic mm (in) 150 (5.9), 150 (5.9),
160 (6.3)
converter 155 (6.1)★3 155 (6.1)★3
★1: 1.6 L
★2: 2.0 L
★3: 2.0 L Turbo
★4: With roof rail
★5: With sun roof
B: ENGINE SA08731G29
Model 1.6 L Non-Turbo 2.0 L Turbo 2.0 L 2.5 L

Engine type Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke gasoline engine
Valve arrangement Overhead camshaft type
Bore × Stroke mm (in) 87.9 × 65.8 92 × 75 99.5 × 79
(3.461 × 2.591) (3.62 × 2.95) (3.92 × 3.11)
Displacement cm3 (cu in) 1,597 (97.45) 1,994 (121.67) 2,475 (151.03)
Compression ratio 10.0 ± 0.2 8.0 ± 0.2 10.0 ± 0.2
Firing order 1—3—2—4
Idle speed at Park/Neutral rpm
700 ± 100 750 ± 100 700 ± 100
position
Maximum output kW (HP)/rpm 70 (94)/5,200 92 (123)/5,600 160 (215)/5,600 112 (150)/5,600
Maximum torque N·m (kgf-m, ft-lb)/rpm 143 (14.6, 105.5) 184 (18.8, 136.0) 292 (29.8, 215.4) 223 (22.7, 164.5)
/3,600 /3,600 /3,600 /3,600
SPC-2
IMPREZA
SPECIFICATIONS
C: ELECTRICAL SA08731G30
Model 1.6 L Non-turbo 2.0 L Turbo 2.0 L 2.5 L

Ignition timing at BTDC/rpm MT: 10°±10°/700
5°±10°/700 10°±10°/700 12°±10°/750
idling speed AT: 15°±10°/700
Spark Type and Without NGK: BKR6E NGK: BKR6E NGK: BKR6E (without
plug manufacturer OBD (without catalyst) (without catalyst) catalyst)
CHAMPION: CHAMPION: CHAMPION: RC10YC4
RC8YC4 RC10YC4 — (with catalyst)
(with catalyst) (with catalyst) NGK: BKR5E-11 (with
NGK: BKR6E-11 NGK: BKR5E-11 catalyst)
(with catalyst) (with catalyst)
With OBD CHAMPION: CHAMPION:
CHAMPION: RC10YC4
RC8YC4 RC10YC4
NGK: PFR6G
Alternate Alternate Alternate
NGK: BKR6E-11 NGK: BKR5E-11 NGK: BKR6E-11
Generator 12V — 75A
Battery Type and For MT: 12V — 48AH
capacity Europe 12V — 48AH MT: 12V — 48AH (55D23L) (55D23L)
(5HR) and South (55D23L) AT: 12V — 52AH (65D23L) AT: 12V — 52AH
America (75D23L)
Others 12V — 27AH (34B19L)
D: TRANSMISSION SA08731G31

Transmission type 5MT 4AT 5MT 4AT 5MT 4AT 5MT 4AT
Clutch type DSPD TCC DSPD TCC DSPD TCC DSPD TCC
Gear ratio 1st 3.454,
3.454 2.785 3.454 2.785 2.785 3.454 2.785
3.166★1
2nd 1.947,
2.062 1.545 2.062 1.545 1.545 2.062 1.545
1.882★1
3rd 1.366,
1.448 1.000 1.448 1.000 1.000 1.448 1.000
1.296★1
4th 1.088 0.694 1.088 0.694 0.972 0.694 1.088 0.694
5th 0.871,
0.825 — 0.825 — 0.738 — —
0.780★1
Reverse 3.333 2.272 3.333 2.272 3.333 2.272 3.333 2.272
Dual range 1.447 — 1.447 — — — — —
Reduction 1st Type of gear — Helical — Helical — Helical — Helical
gear (Front reduction Gear ratio — 1.000 — 1.000 — 1.000 — 1.000
drive) Final Type of gear Hypoid Hypoid Hypoid Hypoid Hypoid Hypoid Hypoid Hypoid
reduction Gear ratio 3.900, 3.700,
4.111 4.444 3.900 4.111 4.111 4.111
4.444★1 4.111★1
Reduction Transfer Type of gear Helical — Helical — Helical — Helical —
gear (Rear reduction Gear ratio 1.100,
drive) 1.000 — 1.000 — — 1.000 —
1.000★1
Final Type of gear Hypoid Hypoid Hypoid Hypoid Hypoid Hypoid Hypoid Hypoid
reduction Gear ratio 3.545, 3.700,
4.111 4.444 3.900 4.111 4.111 4.111
4.444★1 4.111★1
5MT: 5 forward speeds with synchromesh and 1-reverse

4AT: Electronically controlled fully-automatic, 4-forward speeds and 1-reverse
DSPD: Dry Single Plate Diaphragm
TCC: Torque Converter Clutch
★1: Australia spec vehicle
SPC-3
IMPREZA
SPECIFICATIONS
E: STEERING SA08731G32
Model Turbo 2.0 L, 2.5 L OUTBACK OTHERS

Type Rack and Pinion
Turns, lock to lock RHD: 2.7
3.0 3.2
LHD: 3.0
Minimum turning circle m (ft) Curb to curb 11.0 (36.1) 10.8 (35.4) 10.4 (34.1)
Wall to wall 12.0 (39.4) 11.6 (38.1) 11.2 (36.7)
F: SUSPENSION SA08731G33
Front Macpherson strut type, Independent, Coil spring

Rear Dual-link type, Independent, Coil spring
G: BRAKE SA08731G34
Model 1.6 L Non-turbo 2.0 L, 2.5 L Turbo 2.0 L

Service brake system Dual circuit hydraulic with vacuum suspended power unit
Front Ventilated disc brake
Rear Drum brake Disc brake Ventilated disc brake
Parking brake Mechanical on rear brakes
H: TIRE SA08731G35
Rim size 14 × 51/2JJ 15 × 6JJ 16 × 61/2JJ 17 × 7JJ

Tire size 175/70R14 84T 185/65R15 88H P205/55R16 89V 215/45R17 87W
185/70R14 88H 195/60R15 88H 205/50R16 87V
Type Steel belted radial, Tubeless
I: CAPACITY SA08731G36

5MT 4AT 5MT 4AT 5MT 4AT 5MT 4AT
Fuel tank 2 (US gal, Imp gal) 50 (13.2, 11.0) 50 (13.2, 11.0) 60 (15.9, 13.2)
Engine Total 2 (US qt, Imp qt)
4.5 (4.8, 4.0) 5.0 (5.3, 4.4) 4.5 (4.8, 4.0)
oil capacity
Engine 2 (US qt, Imp qt)
oil Approx. Approx.
Approx. 4.5 (4.8, 4.0)
amount 5.0 (5.3, 4.4) 4.5 (4.8, 4.0)
for refill
Transmission 2 (US qt, Imp qt) 3.5 3.5
gear oil (3.7, 3.1), (3.7, 3.1),
3.5 3.5
4.0 — 4.0 — — —
(3.7, 3.1) (3.7, 3.1)
(4.2, 3.5) (4.2, 3.5)
★1 ★1
Automatic trans- 2 (US qt, Imp qt) 8.4 8.4 9.3 9.3
— — — —
mission fluid (8.9, 7.4) (8.9, 7.4) (9.8, 8.2) (9.8, 8.2)
AT differential 2 (US qt, Imp qt) 1.2 1.2 1.2 1.2
— — — —
gear oil (1.3, 1.1) (1.3, 1.1) (1.3, 1.1) (1.3, 1.1)
AWD rear differ- 2 (US qt, Imp qt)
0.8 (0.8, 0.6)
ential gear oil
Power steering 2 (US qt, Imp qt)
0.7 (0.7, 0.6)
fluid
Engine coolant 2 (US qt, Imp qt) 7.4 7.3 7.0 6.9 7.7 7.7 7.0 6.9
(7.8, 6.5) (7.7, 6.4) (7.4, 6.2) (7.3, 6.1) (8.1, 6.8) (8.1, 6.8) (7.4, 6.2) (7.3, 6.1)
★1: Dual range
SPC-4
IMPREZA
SPECIFICATIONS
J: WEIGHT SA08731G37
1. LHD VEHICLE SA08731G3703
Sedan
Option code★1 EC K4 K0 KS
Model 1.6 L
AWD
TS
Curb weight (C.W.) Front kgf (lb) 730 750 750 770 750 770 740 760
(1,609) (1,654) (1,654) (1,698) (1,654) (1,698) (1,631) (1,676)
Rear kgf (lb) 520 520 520 520 520 520 535 535
(1,146) (1,146) (1,146) (1,146) (1,146) (1,146) (1,179) (1,179)
Total kgf (lb) 1,250 1,270 1,270 1,290 1,270 1,290 1,275 1,295
(2,755) (2,800) (2,800) (2,844) (2,800) (2,844) (2,810) (2,855)
Maximum permissible Front kgf (lb) 890 890 890 890 890 890 890 890
axle weight (M.P.A.W.) (1,962) (1,962) (1,962) (1,962) (1,962) (1,962) (1,962) (1,962)
Rear kgf (lb) 890 890 890 890 890 890 890 890
(1,962) (1,962) (1,962) (1,962) (1,962) (1,962) (1,962) (1,962)
Maximum permissible Total kgf (lb) 1,700 1,700 1,700 1,700 1,700 1,700 1,700 1,700
weight (M.P.W.) (3,748) (3,748) (3,748) (3,748) (3,748) (3,748) (3,748) (3,748)
Option Air conditioner — — ❍ ❍ ❍ ❍ ❍ ❍
Cruise control — — — — — — — —
ABS — — — — — — — —
Aluminium wheel — — — — — — — —
Rear spoiler — — — — — — — —
Spoiler pac — — — — — — — —
Model 2.0 L
AWD
GX
(1,643) (1,698) (1,687) (1,742) (1,676) (1,753) (1,653) (1,720)
Rear kgf (lb) 535 530 530 525 525 530 550 545
(1,179) (1,168) (1,168) (1,157) (1,157) (1,168) (1,213) (1,202)
Total kgf (lb) 1,280 1,300 1,295 1,315 1,285 1,325 1,300 1,325
(2,822) (2,866) (2,855) (2,899) (2,833) (2,921) (2,866) (2,922)
axle weight (M.P.A.W.) (2,028) (2,028) (2,028) (2,028) (2,028) (2,028) (2,028) (2,028)
Rear kgf (lb) 910 910 910 910 910 910 910 910
(2,006) (2,006) (2,006) (2,006) (2,006) (2,006) (2,006) (2,006)
weight (M.P.W.) (3,880) (3,880) (3,880) (3,880) (3,880) (3,880) (3,880) (3,880)
ABS — — ❍ ❍ ❍ ❍ — ❍
Aluminium wheel — — ❍ ❍ — — ❍ ❍
Rear spoiler — — — — — — ❍ ❍
Spoiler pac — — — — — — — —
★1: For option code, refer to ID section. <Ref. to ID-7, Option code.>
SPC-5
IMPREZA
SPECIFICATIONS
Option code★1 EC
Model 2.5 L 2.0 L Turbo
AWD
RS WRX
5MT 4AT 5MT
Curb weight (C.W.) Front kgf (lb) 760 (1,676) 785 (1,731) 815 (1,797)
Rear kgf (lb) 535 (1,179) 530 (1,168) 550 (1,213)
Total kgf (lb) 1,295 (2,855) 1,315 (2,899) 1,365 (3,009)
Maximum permissible Front kgf (lb) 930 (2,050) 930 (2,050) 970 (2,138)
axle weight (M.P.A.W.) Rear kgf (lb) 910 (2,006) 910 (2,006) 920 (2,028)
Maximum permissible Total kgf (lb)
1,780 (3,924) 1,780 (3,924) 1,850 (4,079)
weight (M.P.W.)
Option Air conditioner — — —
Cruise control — — —
ABS ❍ ❍ ❍
Aluminium wheel — — —
Rear spoiler — — —
Spoiler pac — — —
SPC-6
IMPREZA
SPECIFICATIONS
Wagon
Model 1.6 L
AWD
TS
D/R 4AT D/R 4AT D/R 4AT D/R 4AT
(1,620) (1,653) (1,664) (1,698) (1,664) (1,698) (1,642) (1,676)
Rear kgf (lb) 545 545 545 545 545 545 560 560
(1,202) (1,202) (1,202) (1,202) (1,202) (1,202) (1,235) (1,235)
Total kgf (lb) 1,280 1,295 1,300 1,315 1,300 1,315 1,305 1,320
(2,822) (2,855) (2,866) (2,900) (2,866) (2,900) (2,877) (2,911)
axle weight (M.P.A.W.) (1,984) (1,984) (1,984) (1,984) (1,984) (1,984) (1,984) (1,984)
Rear kgf (lb) 910 910 910 910 910 910 910 910
(2,006) (2,006) (2,006) (2,006) (2,006) (2,006) (2,006) (2,006)
weight (M.P.W.) (3,814) (3,814) (3,814) (3,814) (3,814) (3,814) (3,814) (3,814)
ABS — — — — — — — —
Aluminium wheel — — — — — — — —
Rear spoiler — — — — — — — —
Spoiler pac — — — — — — — —
Model 2.0 L
AWD
GX
D/R 4AT D/R 4AT D/R 4AT D/R 4AT
(1,664) (1,698) (1,709) (1,742) (1,720) (1,753) (1,676) (1,720)
Rear kgf (lb) 570 565 565 560 570 565 580 575
(1,257) (1,246) (1,246) (1,235) (1,257) (1,246) (1,279) (1,268)
Total kgf (lb) 1,325 1,335 1,340 1,350 1,350 1,360 1,340 1,355
(2,921) (2,944) (2,955) (2,977) (2,977) (2,999) (2,955) (2,988)
axle weight (M.P.A.W.) (2,028) (2,028) (2,028) (2,028) (2,028) (2,028) (2,028) (2,028)
Rear kgf (lb) 960 960 960 960 960 960 960 960
(2,116) (2,116) (2,116) (2,116) (2,116) (2,116) (2,116) (2,116)
weight (M.P.W.) (3,969) (3,969) (3,969) (3,969) (3,969) (3,969) (3,969) (3,969)
ABS — — ❍ ❍ ❍ ❍ — ❍
Aluminium wheel — — ❍ ❍ — — ❍ ❍
Rear spoiler — — — — — — — —
Spoiler pac — — — — — — — —
D/R: Dual range

SPC-7
IMPREZA
SPECIFICATIONS
Option code★1 EC K4
Model 2.0 L Turbo
AWD
WRX
5MT
Curb weight (C.W.) Front kgf (lb) 805 (1,775) 825 (1,819)
Rear kgf (lb) 585 (1,290) 585 (1,290)
Total kgf (lb) 1,390 (3,065) 1,410 (3,109)
Maximum permissible Front kgf (lb) 970 (2,138) 970 (2,138)
axle weight (M.P.A.W.) Rear kgf (lb) 950 (2,094) 950 (2,094)
1,860 (4,101) 1,860 (4,101)
weight (M.P.W.)
Option Air conditioner — ❍
Cruise control — —
ABS ❍ ❍
Aluminium wheel — —
Rear spoiler — —
Spoiler pac — —
D/R: Dual range
SPC-8
IMPREZA
SPECIFICATIONS
2. RHD VEHICLE SA08731G3704
Sedan
Option code★1 EK K1
Model 1.6 L
AWD
TS
5MT 4AT 5MT 4AT
Curb weight (C.W.) Front kgf (lb) 735 (1,621) 755 (1,665) 750 (1,654) 770 (1,698)
Rear kgf (lb) 520 (1,146) 520 (1,146) 520 (1,146) 520 (1,146)
Total kgf (lb) 1,255 (2,767) 1,275 (2,811) 1,270 (2,800) 1,290 (2,844)
Maximum permissible Front kgf (lb) 890 (1,962) 890 (1,962) 890 (1,962) 890 (1,962)
axle weight (M.P.A.W.) Rear kgf (lb) 890 (1,962) 890 (1,962) 890 (1,962) 890 (1,962)
1,700 (3,748) 1,700 (3,748) 1,700 (3,748) 1,700 (3,748)
weight (M.P.W.)
Option Air conditioner — — ❍ ❍
Cruise control — — — —
ABS ❍ ❍ — —
Aluminium wheel — — — —
Rear spoiler — — — —
Spoiler pac ❍ ❍ — —
Model 2.0 L
AWD
GX
5MT 4AT 5MT 4AT
Rear kgf (lb) 535 (1,179) 530 (1,168) 535 (1,179) 530 (1,168)
Total kgf (lb) 1,300 (2,866) 1,320 (2,910) 1,305 (2,877) 1,325 (2,921)
1,760 (3,880) 1,760 (3,880) 1,760 (3,880) 1,760 (3,880)
weight (M.P.W.)
Option Air conditioner ❍ ❍ ❍ ❍
ABS ❍ ❍ ❍ ❍
Aluminium wheel ❍ ❍ — —
Rear spoiler ❍ ❍ — —
SPC-9
IMPREZA
SPECIFICATIONS
Option code★1 KA EK
Model 2.0 L 2.5 L 2.0 L Turbo
AWD
GX RS WRX
5MT 4AT 5MT 4AT 5MT 4AT 5MT
Curb weight (C.W.) Front kgf (lb) 750 775 780 805 830 855 830
(1,653) (1,709) (1,720) (1,775) (1,830) (1,885) (1,830)
Rear kgf (lb) 535 530 540 535 560 555 560
(1,179) (1,168) (1,191) (1,179) (1,235) (1,224) (1,235)
Total kgf (lb) 1,285 1,305 1,320 1,340 1,390 1,410 1,390
(2,833) (2,877) (2,910) (2,954) (3,065) (3,109) (3,065)
Maximum permissible Front kgf (lb) 920 920 930 930 970 970 970
axle weight (M.P.A.W.) (2,028) (2,028) (2,050) (2,050) (2,138) (2,138) (2,138)
Rear kgf (lb) 910 910 910 910 920 920 920
(2,006) (2,006) (2,006) (2,006) (2,028) (2,028) (2,028)
Maximum permissible Total kgf (lb) 1,760 1,760 1,780 1,780 1,850 1,850 1,850
weight (M.P.W.) (3,880) (3,880) (3,924) (3,924) (4,079) (4,079) (4,079)
Option Air conditioner — — ❍ ❍ ❍ ❍ ❍
Cruise control ❍ ❍ ❍ ❍ ❍ ❍ —
ABS ❍ ❍ ❍ ❍ ❍ ❍ ❍
Aluminium wheel — — — — — — —
Rear spoiler — — ❍ ❍ ❍ ❍ ❍
Spoiler pac — — — — — — —
SPC-10
IMPREZA
SPECIFICATIONS
Wagon
Model 1.6 L
AWD
TS
D/R 4AT D/R 4AT
Rear kgf (lb) 545 (1,202) 545 (1,202) 545 (1,202) 545 (1,202)
Total kgf (lb) 1,285 (2,833) 1,300 (2,866) 1,300 (2,866) 1,315 (2,900)
1,730 (3,814) 1,730 (3,814) 1,730 (3,814) 1,730 (3,814)
weight (M.P.W.)
Option Air conditioner — — ❍ ❍
ABS ❍ ❍ — —
Spoiler pac — — — —
Model 2.0 L
AWD
GX
D/R 4AT D/R 4AT
Rear kgf (lb) 570 (1,257) 565 (1,246) 570 (1,257) 565 (1,246)
Total kgf (lb) 1,345 (2,965) 1,355 (2,987) 1,350 (2,977) 1,360 (2,999)
1,800 (3,968) 1,800 (3,968) 1,800 (3,968) 1,800 (3,968)
weight (M.P.W.)
Option Air conditioner ❍ ❍ ❍ ❍
ABS ❍ ❍ ❍ ❍
Aluminium wheel ❍ ❍ — —
D/R: Dual range

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

SPC-12
PRECAUTION
PC
Page
1. Precaution ...................................................................................................2
PRECAUTION
PRECAUTION
1. Precaution 7. AIRBAG MODULE

A: PRECAUTION Adhere to the following when handing and storing
the airbag module to prevent bodily injury from 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
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.
Handle the ABS as a total system. Do not disas- • Do not face the bag in the direction that it opens
semble or attempt to repair individual parts. Doing towards the floor or walls.
so could prevent the ABS system from operating 8. AIRBAG SPECIAL TOOLS
when needed or cause it to operate incorrectly and
result in injury. To prevent unexpected deployment, only use spe-
cial tools.
2. BRAKE FLUID
9. WINDOW
If brake fluid gets in your eyes or on your skin, do
the following: Always wear safety glasses when working around
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- 10.WINDOW ADHESIVE
oughly with water.
Always 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. ROAD TESTS
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 airbag components or nearby, and
airbag wiring harnesses or nearby.
To prevent unexpected deployment, perform one of
the steps below and then wait at least 20 seconds
to discharge electricity before beginning work.
• Step 1: Turn the ignition switch OFF.
• Step 2: Disconnect the ground cable from bat-
tery.
6. AIRBAG DISPOSAL
To prevent bodily injury from unexpected airbag
deployment, do not dispose airbag modules in the
same way as other refuse. Follow the special in-
structions for disposal in this manual. Follow all
government regulations concerning disposal of
refuse.
PC-2
NOTE
NT
Page
1. Note.............................................................................................................2
NOTE
NOTE
1. Note
A: NOTE
This is information that can improve efficiency of
maintenance and assure sound work.
1. FASTENER NOTICE
Fasteners are used to prevent parts from damage
and dislocation due to looseness. Fasteners must
be tightened to the specified torque.
Do not apply paint, lubricant, rust retardant, or oth-
er substances to the surface around bolts, fasten-
ers, etc. Doing so will make it difficult to obtain the
correct torque and result in looseness and other
problems.
2. STATIC ELECTRICITY DAMAGE
Do not touch the ECM, connectors, logic boards,
and other such parts when there is a risk of static
electricity. Always use a static electricity prevention
cord or touch grounded metal before conducting
work.
3. IGNITION OFF BATTERY
When removing the battery cables, always be sure
to turn the ignition off to prevent electrical damage
to the ECM from rush current.
4. SERVICE PARTS
Use authentic service parts for maximum 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
NOTE
5. LIFTS AND JACKS

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

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

and tie-down
GI0122
NT-5
NOTE
NOTE
GI0103
20˚ 20˚
20˚ 20˚
20˚ 20˚
20˚ 20˚
45˚ 45˚ 45˚ 45˚

: Tie-down range GI0123
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 that the
vehicle being towed.
NT-6
NOTE
NOTE
8. FRONT HOOD STAY INSTALLATION

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

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

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

ADR compliance plate
(Australia model)
Tire inflation pressure label

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

Model number plate Built date plate (Australia model)
GI0154
GI0007A GI0008A
GI0009A
ID-2
IDENTIFICATION
IDENTIFICATION
GI0010A
GI0011A
ID-3
IDENTIFICATION
IDENTIFICATION
2. MEANING OF V.I.N.
The meaning of the VIN is as follows:
• Europe, Australia and General (Except GCC)
]JF1GD5LJ31G002001[
The starting and ending brackets ( ][ ) are stop marks.
Digits Code Meaning Details
1 to 3 JF1 Manufacturer body area JF1: Passenger car, FHI made
4 G Car line IMPREZA
5 D Body type D: 4 Door Sedan
G: Wagon
6 5 Displacement 5: 1.6 L AWD
9: 2.0 L AWD
A: 2.0 L AWD Turbo
E: 2.5 L AWD
7 L Steering position K: RHD (Right-hand drive)
L: LHD (Left-hand drive)
8 J Engine & transmission R: SOHC MPI 4-speed AT
J: SOHC MPI Full-time AWD 5-speed MT
K: SOHC MPI Full-time AWD 5-speed MT Dual range
D: DOHC Turbo Full-time AWD 5-speed MT
P: DOHC Turbo 4-speed AT
9 3 Drive type 3: Full-time AWD Single range
4: Full-time AWD Dual range
5: AWD AT
10 2 Model year 2: 2002MY
3: 2003MY
11 G Factory location G: FHI (Gunma)
12 to 17 002001 Serial number —
• GCC countries (Saudi Arabia, etc.)

]JF1GD33MX1G002001[
The starting and ending brackets ( ][ ) are stop marks.
1 to 3 JF1 Manufacturer body area JF1: Passenger car, FHI made
4 G Car line IMPREZA
5 D Body type D: 4 Door Sedan
G: Wagon
6 4 Displacement 4: 1.6 L AWD
8: 2.0 L AWD
7 5 Grade 5: TS
7: GX
8 M Restraint M: Manual belts, dual airbag
9 X Check digit —
10 2 Model year 2: 2002MY
3: 2003MY
11 G Transmission type G: Full-time AWD 5-speed MT single range
H: Full-time AWD 4-speed AT
J: Full-time AWD 5-speed MT dual range
12 to 17 002001 Serial number —
ID-4
IDENTIFICATION
IDENTIFICATION
3. MODEL NUMBER PLATE

The model number plate indicates: the applied model, the option code, the trim code, the engine type, the
transmission type, and the exterior color code. This information is helpful when placing orders for parts.
GD9AL7R
1 G Series IMPREZA
2 D Body style D: 4 Door Sedan
G: Wagon
3 9 Engine displacement 5: 1.6 L AWD
Drive system 9: 2.0 L AWD
Suspension system E: 2.5 L AWD
4 A Minor change 2002MY
5 L Destination K: Right-hand drive market
L: Left-hand drive market
6 7 Grade 4: TS
5: GX
6: RS
7: OUTBACK
8: WRX
7 R Transmission, fuel feed K: SOHC MPI 5-speed MT
system R: SOHC MPI 4-speed AT
P: DOHC B MPI 4-speed AT
J: SOHC MPI 5-speed MT AWD
D: DOHC B MPI 5-speed MT AWD
The engine and transmission type are as follows:

• Engine
EJ161RX3AA
1 and 2 EJ Engine type EJ: 4 cylinders
3 and 4 16 Displacement 16: 1.6 L
20: 2.0 L
25: 2.5 L
5 1 Fuel feed system 1: D-MPI SOHC-A
5: MPI Turbo
6 R Detailed specifications Used when ordering parts. See the parts catalog for details.
7 X Transmission W: MT
X: AT
8 to 10 3AA Detailed specifications Used when ordering parts. See the parts catalog for details.
ID-5
IDENTIFICATION
IDENTIFICATION
• Transmission
TV1B4VYAAA
1 T Transmission T: Transmission
2 V Transmission type Y: Full-time AWD MT center differential
V: Full-time AWD AT center differential
Z: Full-time AWD AT MPT
3 and 4 1B Classification 75: MT
1B: AT
5 4 Series MT 4: 5MT
AT 4: AT
6 V Transmission specifica- S: Part-time AWD 5-speed MT Single range
tions D: Part-time AWD 5-speed MT Dual range
V: Full-time AWD 5-speed MT with viscous coupling center dif-
ferential single range
X: Full-time AWD 5-speed MT with viscous coupling center dif-
ferential dual range
Z: Full-time AWD 4-speed AT with MPT
Y: Full-time AWD 4-speed AT with VTD
7 to 10 YAAA Detailed specifications Used when ordering parts. See the parts catalog for details.
• Rear differential 1
VA1REJ
1 V For AWD V: AWD
2 A Type A: A type
3 1 Hypoid gear diameter 1: 152 (6.0) dia.
mm (in) 2: 160 (6.3) dia.
4 R Installation position R: Rear
5 E Reduction gear ratio B: 3.900
E: 4.111
F: 4.444
6 J Specification differ- J: Case B
ences
• Rear differential 2
EG
Code Reduction gear ratio LSD
EG 3.900 No
ER 3.700 Viscous
EM 4.444 SURETRAC
EJ 4.111 Viscous
EF 3.545 Viscous
ID-6
IDENTIFICATION
IDENTIFICATION
• Option code
ECPS
1 to 2 EC Destination EC: EC
KO: KO
K4: K4
KS: KS
EK: EK
KA: KA
K1: K1
3 to 4 PS Main option of vehicle —
ID-7
IDENTIFICATION
IDENTIFICATION
ID-8
RECOMMENDED MATERIALS
RM
Page
1. Recommended Materials ............................................................................2
1. Recommended Materials
A: RECOMMENDED MATERIALS
1. GENERAL
To insure the best performance, always use the
specified oil, gasoline, adhesive, sealant, etc. or
that of equivalent quality.
2. FUEL
Always use a gasoline of the same or higher octane
value than specified in the owner's manual. 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 catalytic converter installed to reduce
air pollution. Using leaded gasoline will damage the
catalytic converter.
• Leaded gasoline
On vehicles without catalytic converter, use gaso-
line with an octane value of 90 RON or higher.
RM-2
3. LUBRICANTS
Use either the lubricants in the table below or equivalent lubricants. See the table below to choose the correct
SAE viscosity.
Lubricant Recommended Alternative
API Spec. CCMC Spec. ACEA Spec.
Engine oil SL or SJ Grade “Energy conserving” G4 or G5 A1, A2 or A3 API: SH or SG
SERVICE S
PI
L
SAE
5W-30
EN
NG
R
E
VI
GY R
CONS E
B1M0495
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
GI0003A
RM-3
SAE viscosity SAE viscosity No. and applicable temperature SAE J300
Manual transmission oil
Rear differential
GI0004A
Front differential
GI0005A
4. FLUID
Use the fluids specified in the table below. Do not mix two different kinds or makes of fluid.
Fluid Recommended Alternative Remarks
Automatic transmission fluid DEXRON III — —
Power steering fluid DEXRON III — —
Brake fluid FMVSS No. 116 DOT3 FMVSS No. 116 DOT4 —
Clutch fluid FMVSS No. 116 DOT3 FMVSS No. 116 DOT4 —
5. COOLANT
Use genuine coolant to protect the engine. The table below shows the ratio of coolant to distilled water.
Coolant Recommended Item number Alternative
Coolant SUBARU coolant 000016218 None
Water for dilution Distilled water — Tap water
RM-4
6. REFRIGERANT
Standard air conditioners on Subaru vehicles use HFC134a refrigerant. Do not mix it with other refrigerants.
Also, do not use any air compressor oil except for DH-PR.
Air conditioner Recommended Item number Alternative
Refrigerant HFC134a — None
Compressor oil DH-PR — None
7. GREASE
Use the grease and supplementary lubricants shown in the table below.
Grease Application point Recommended Item number Alternative
Supplementary lubricants • O2 sensor SUBARU CRC 004301003 —
• Bolts, etc.
Grease MT main shaft FX clutch grease 000040901 —
Clutch master cylinder Slicolube G-40M 004404003 —
push rod
• Steering shaft bear- SUNLIGHT2 003602010 —
ing
• Gear shift bush
Steering gear box Valiant grease M-2 003608001 —
Disc brake Niglube RX-2 725191040 —
Drum brake Molykote No. 7439 72519460 —
• Brake pad Molykote AS-880N 26298AC000 —
• Brake shoe
Front axle SFJ SSG-6003 28093TA000 —
• Front EBJ NTG 2218 28093AA000 —
• Rear axle EBJ
Rear axle BJ Molylex No. 2 723223010 —
Rear axle DOJ VU-3A702 23223GA050 —
• Control cable Slicolube G-30M 004404002 —
• Throttle linkage
• Water pump
• Door latch
• Door striker
8. ADHESIVES
Use the adhesives shown in the table below, or equivalent.
Adhesive Application point Recommended Item number Alternative
Adhesive Windshield and body Essex Chemical Crop’s Ure- — Sunstar 580
thane E
Soft vinyl Cemedine 540 — 3M’s EC-776 EC-847 or EC-1022
(Spray type)
Momentary sealant Cemedine 3000 — Armstrong’s Eastman 910
RM-5
9. SEAL MATERIAL
Use seal material shown in the table below, or equivalent.
Seal material Application point Recommended Item number Alternative
Seal material • Engine case Three Bond 1215 004403007 Dow Corning’s No. 7038
• Torque converter
clutch case
Transmission Three Bond 1217B K0877YA020 —
Rear differential Three Bond 1324 004403042 —
Rear differential Three Bond 1105 004403010 Dow Corning’s No. 7038
Weatherstrip Starcalking B-33A 000018901 Butyl Rubber sealant
Steering adjusting screw Three Bond 1102 004403006 —
SOHC cam cap Three Bond 1280B K0877YA018 —
RM-6
PRE-DELIVERY INSPECTION
PI
Page
1. Pre-delivery Inspection................................................................................2
1. Pre-delivery Inspection
A: GENERAL
The purposes of the pre-delivery inspection (PDI)
are as follows.
• Remove the additional parts used for ensuring
the vehicle quality during transportation and restore
the vehicle to its normal state.
• Check if the vehicle before delivery is in a normal
state.
• Check for any damage or missing parts that may
have taken place during transportation or storage.
• Make sure to provide a complete vehicle to the
customer.
Because of the above reasons, all dealerships
must always carry out the PDIs before delivering a
vehicle.
In addition, all franchised shops and PDI centers
must check the status of every vehicle received to
identify who is responsible for any possible defects.
PI-2
B: PDI PROCEDURE
Follow the procedures shown in the table below.
Static Checks Just After Vehicle Receipt
Step Check point
1. Appearance check (1) If the vehicle is covered with protective coating, visually check the vehicle
body for damage and dents. If the protective coating has been removed,
visually check the body paints for small areas of damage or stains.
(2) Visually check the glass and light lenses for any damage and cracks or
excessive gaps to the body sheet metal.
(3) Visually check the plated parts for any damage.
2. Tire check (4) Check the tires for damage, abnormal conditions, and dents on the
wheels.
(5) Check the tire air pressure.
3. Fuse installation (6) If the vehicle is about to be delivered to the customer, attach a room lamp
fuse.
4. Connection of air conditioner harness (7) If the vehicle is about to be delivered to the customer, connect the air
conditioner harness.
5. Check the doors for lock/unlock and open/close (8) Using the key, check if the door can be locked and unlocked normally.
operations. (9) Open and close all doors to see that there are no abnormal conditions.
6. Check the trunk lid for open/close operations. (10) Operate the trunk lock release lever to check that the trunk opens nor-
mally.
(11) Using the key, check if the trunk lid can be unlocked normally.
(12) Open and close the trunk lid to see that there are no abnormal condi-
tions.
7. Check the rear gate for lock/unlock and open/ (13) Using the key, check if the rear gate can be lock and unlocked normally.
close operations. (14) Open and close the rear gate to see that there are no abnormal condi-
tions.
(15) Operate the power door locking switch to check that the rear gate is
locked and unlocked normally.
8. Operation check of fuel lid opener lock release (16) Operate the fuel lid opener to check that the fuel lid is unlocked nor-
lever mally.
9. Accessory check Check that the following accessories are provided:
• Owner's manual
• Warranty booklet
• Service booklet
• Spare key
• Jack
• Tool set
• Spare tire
10. Operation check of hood lock release system (17) Operate the hood lock release lever to check that the hood opens nor-
mally.
11. Battery (18) Check the battery for any abnormal conditions such as rust and trace of
battery fluid leaks.
12. Brake fluid (19) Check the fluid amount.
13. Engine oil (20) Check the oil amount.
14. Transmission fluid (21) Check the fluid amount.
(22) For AT, check the front differential oil.
15. AT front differential oil (23) Check the AT front differential oil amount.
16. Coolant (24) Check the coolant amount.
17. Clutch fluid (25) Check the clutch fluid amount.
18. Window washer fluid (26) Check the window washer fluid amount.
19. Hood latch check (27) Check that the hood is closed and latched securely.
20. Keyless entry system (28) Check that the keyless entry system operates normally.
21. Seat (29) Check the seat surfaces for smears or dirt.
(30) Check the seat installation conditions and functionality.
22. Seat belt (31) Check the seat belt installation conditions and functionality.
23. Wheel alignment (32) Check that the wheel alignments are properly adjusted.
PI-3
Checks with the Engine Running

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

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

Step Check point
41. ATF level (1) Check that the ATF level is normal.
42. Power steering fluid level (2) Check that the power steering fluid level is normal.
43. Fluid leak check (3) Check for fluid/oil leaks.
44. Water leak check (4) Spray the vehicle with water and check for water leaks.
45. 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
1. APPEARANCE CHECK 4. CONNECTION OF AIR CONDITIONER

• If the vehicle is covered with protective coating, HARNESS
visually check the vehicle body for damage and A vehicle just delivered has its air conditioner har-
dents. ness disconnected to protect the air conditioner
• If there is no protective coating, check the body compressor. Connect the harness as shown in the
paints for small areas of damage or stains and re- figure.
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. TIRE CHECK
• Check the tire outer faces for any damage.
• Check the tire air pressure by referring to the fol- GI0085
lowing table.
Tire size Tire inflation pressure
kPa (kg/cm2, psi)
Front Rear
175/70R14 220 (2.2, 32) 220 (2.2, 32)
185/70R14 220 (2.2, 32) 220 (2.2, 32)
195/60R15 220 (2.2, 32) 220 (2.2, 32)
205/50R16 220 (2.2, 32) 220 (2.2, 32)
215/45R17 230 (2.3, 33) 220 (2.2, 32)
3. FUSE INSTALLATION
A vehicle just delivered has no fuse for the room
lamp circuit to prevent battery discharge. Attach a
15 A fuse (A) as shown in the figure.
GI0084A
PI-5
5. CHECK THE DOORS FOR LOCK/UN- 6. CHECK THE TRUNK LID FOR OPEN/
LOCK AND OPEN/CLOSE OPERATIONS. CLOSE OPERATIONS.
Using the key, lock and unlock the door several • Operate the trunk lock release lever and verify
times to check for normal operation. Open and that the trunk lid opens.
close the door several times for smooth movement. • Using the key, open the trunk lid several times to
check for normal operation.
• Open and close the trunk lid several times for
smooth movement.
Unlock
Lock
GI0148
• Vehicles with manual door locks:

Sit in the driver seat, close the door completely, GI0170
and move the lock lever to the lock position. Then,
pull the inside door handle to ensure the door will 7. CHECK THE REAR GATE FOR LOCK/
not open. UNLOCK AND OPEN/CLOSE OPERA-
• Vehicles with power door locks: TIONS.
Sit in the driver seat, close the driver's door com- • Using the key, lock and unlock the rear gate sev-
pletely, and place the door lock knob (A) to the lock eral times to check for normal operation.
position. Then pull all inside door handles (B) to en- • Open and close the rear gate several times for
sure that all doors will not open. smooth movement.
For other doors, place the door lock knob (A) to the
lock positions and then pull the inside door handles
to ensure that the doors will not open.
Lock
Unlock
GI0171
• Operate the driver’s side door lock knob to check

GI0079A
that the rear gate is locked and unlocked normally.
8. OPERATION CHECK OF FUEL LID
OPENER LOCK RELEASE LEVER
Operate the fuel lid opener and verify that the fuel
lid opens normally. Check that the filler cap is se-
curely closed.
PI-6
9. ACCESSORY CHECK 10.OPERATION CHECK OF HOOD LOCK

Check that the following accessories are provided RELEASE SYSTEM
in the luggage compartment or cargo area. Operate the hood release knob (A) and check that
• Owner's manual the hood is unlocked normally.
• Warranty booklet
• Service booklet
• Spare key
• Jack
• Tool set
• Spare tire
Jack
GI0082A
Operate the lever (A) and check that the hood is

opened normally. Then support the hood with hood
stay.
Jack handle GI0149
Jack
Jack handle GI0150
(A)
GI0151
PI-7
11.BATTERY 15.AT FRONT DIFFERENTIAL OIL

Check the battery terminals to make sure that no Check the AT front differential oil amount. If the
rust or corrosions due to fluid leaks are found. amount is insufficient, check that no leaks are
Check that the battery caps are securely tightened. found. Then, add the necessary amount of the
specified AT front differential oil.
GI0086A
GI0089A
12.BRAKE FLUID
Check the brake fluid amount. If the amount is in- 16.COOLANT
sufficient, carry out a brake line test to identify Check the coolant amount on the reservoir. If the
brake fluid leaks and check the brake operation. Af- amount is insufficient, check that no leaks are
ter that, refill the brake fluid tank with the specified found. Then, add the necessary amount of coolant
type of fluid. with the specified concentration.
13.ENGINE OIL 17.CLUTCH FLUID
Check the engine oil amount. If the amount is insuf- Check the clutch fluid amount. If the amount is in-
ficient, check that no leaks are found. Then, add sufficient, check that no leaks are found. Then, add
the necessary amount of the specified engine oil. the necessary amount of the specified fluid.
GI0087A GI0090A
14.TRANSMISSION FLUID (A) Reservoir tank

Check the transmission fluid amount. If the amount (B) MIN level
is insufficient, check that no leaks are found. Then, (C) MAX level
add the necessary amount of the specified fluid.
18.WINDOW WASHER FLUID
Check the window washer fluid amount. If the
amount is insufficient, check that no leaks are
found. Then, add the necessary amount of washer
fluid commercially available.
19.HOOD LATCH CHECK
Retract the hood stay and close the hood. Check
that the hood is securely latched.
GI0088A
PI-8
20.KEYLESS ENTRY SYSTEM 24.READ MEMORY AND TEST MODE CON-

Check the keyless entry system operations as fol- NECTORS
lows. Turn the ignition switch to ON and check that the
• Remove the key from the ignition switch and check-engine light starts blinking. If the light blinks,
close all the doors including rear gate (wagon). return the ignition key to LOCK and disconnect the
• Press the “LOCK” button on the transmitter mo- test mode connector. Then, turn the ignition key to
mentarily once and check if all the doors are locked ON again. If the check-engine light blinks at that
and the hazard light flashes once. time in spite of the disconnected test mode connec-
tor, carry out an engine diagnosis.
• With OBD MODEL
B5M1182
• Press the “OPEN” button on the transmitter mo-

GI0095A
mentarily once and check if all doors are unlocked,
the hazard light flashes twice and the dome light il- • Without OBD MODEL
luminates.
• Close all doors and rear gate, press the “LOCK”
button of the transmitter. Press the “OPEN” button
of the transmitter and wait for 30 seconds. Check
that all doors and the rear gate are automatically
locked again.
21.SEAT
Check that each seat provides full functionality in
sliding and reclining. Check all available functions
of the rear seat such as a trunk-through center arm GI0119A
rest.
25.STARTING CONDITION
22.SEAT BELT
Start the engine and check that the engine starts
Pull out the seat belt and then release it. Check that smoothly. If any battery voltage problems are
the belt webbing retracts smoothly. found, recharge or replace the battery. If any ab-
23.WHEEL ALIGNMENT normal noises are observed, immediately stop the
engine and check and repair the necessary compo-
Check the wheel alignments. <Ref. to FS-8, Wheel nents.
Alignment.> and <Ref. to RS-9, Wheel Alignment.>
26.EXHAUST SYSTEM
Listen to the exhaust noise to see if no abnormal
noises are observed.
27.INDICATOR LIGHT
Check that all the indicator lights are off.
28.CLOCK
Check the clock for normal operations and enough
accuracy.
29.RADIO
Check the radio for full functionality and normal
noise level. Also check the CD unit operations.
PI-9
30.CIGARETTE LIGHTER 36.PARKING BRAKE

Check the cigarette lighter operations. Check the parking brake for normal operations.
31.LIGHTING SYSTEM 37.AT SHIFT CONTROL
• Check the headlight operations. Set the AT select lever to each gear position while
• Check the brake light operations. checking that the demanded gear position is cor-
• Check the other lights for normal operations. rectly attained.
32.WINDOW WASHER
Check that the window washer system injects
washer fluid to the specified area of windshield
shown in the figure.
Front injection position:
A: 350mm (13.78 in)
B: 162mm (5.91 in)
C: 300mm (11.81 in)
D: 500mm (23.62 in) GI0113A
A A
B B Selector Gear Position
Position 1st 2nd 3rd 4th
D Yes Yes Yes Yes
3 Yes Yes Yes —
2 Yes Yes — —
1 Yes — — —
C D
38.HEATER & VENTILATION
Nozzle GI0152 Operate the heater and ventilation system to check
for normal airflow and heating capacity.
Rear injection position:
A: 39 mm (2.36 in) 39.AIR CONDITIONER
B: 72° Operate the air conditioner. Check that the A/C
compressor operates normally and enough cooling
Nozzle is provided.
A
40.CRUISE CONTROL
Operate the cruise control system. Check that the
system is activated and deactivated correctly.
B
41.ATF LEVEL
Check that the ATF level is normal. If insufficient,
check that no leaks are found. Then add the neces-
GI0153 sary amount of the specified ATF.
33.WIPER
Check the front and rear wipers for normal opera-
tions.
34.POWER WINDOW OPERATION CHECK
Manipulate the power window switches one by one
to check that each of the power windows goes up
and down with no abnormal noises.
35.BRAKE TEST GI0098A
Check the foot brake for normal operations.
PI-10
42.POWER STEERING FLUID LEVEL 44.WATER LEAK TEST

Check that the power steering fluid level is normal. Spray the vehicle with water and check that no wa-
If insufficient, check that no leaks are found. Then ter enters the passenger compartment.
add the necessary amount of the specified power • Before performing the water leakage test, re-
steering fluid. move anything that may obstruct the operation or
which must be kept dry.
• Close all windows completely, and then close all
doors tightly. Close the hood and trunk lid before
starting the test.
• Connect a hose to a tap, and spray water on the
vehicle. The rate of water discharge must be ap-
prox. 20 — 25 2 (5.3 — 6.6 US gal, 4.4 — 5.5 Imp
gal) per minute.
When spraying water on areas adjacent to the floor
and wheel house, increase the pressure. When di-
GI0099A recting water on areas other than the floor portion
and wheel house, decrease the pressure. But the
(A) Reservoir tank force of water must be made strong occasionally by
(B) MIN level pressing the end of the hose.
(C) MAX level NOTE:
Be sure to keep the hose at least 10 cm (3.9 in)
43.FLUID LEAK CHECK from the vehicle.
Check the entire areas of the vehicle for any trace Check the following areas:
of coolant/oil/fluid leaks. • Front window and body framework mating por-
tion
• Door mating portions
• Glass mating portions
• Rear quarter window mating portions
• Rear window and body framework mating portion
• Around roof drips
If any dampness in the compartment is discovered
after the water has been applied, carefully check all
areas that may have possibly contributed to the
leak.
45.APPEARANCE CHECK 2
Check the vehicle body paints, plated faces, glass,
and lenses for any dirt or damage.
PI-11
PI-12
PERIODIC MAINTENANCE SERVICES
PM
Page
1. General Description ....................................................................................2
2. Schedule .....................................................................................................3
3. Engine Oil....................................................................................................6
4. Engine Oil Filter...........................................................................................8
5. Spark Plugs.................................................................................................9
6. Drive Belt(s) ..............................................................................................10
7. Camshaft Drive Belt ..................................................................................12
8. Fuel Line ...................................................................................................15
9. Fuel Filter ..................................................................................................16
10. Air Cleaner Element ..................................................................................17
11. Cooling System .........................................................................................18
12. Coolant......................................................................................................19
13. Idle Mixture................................................................................................21
14. Clutch System ...........................................................................................22
15. Hill-holder System .....................................................................................24
16. Transmission Oil .......................................................................................25
17. ATF ...........................................................................................................26
18. Front & Rear Differential Oil ......................................................................28
19. Brake Line .................................................................................................30
20. Brake Fluid ................................................................................................32
21. Disc Brake Pads and Discs.......................................................................33
22. Brake Linings and Drums..........................................................................34
23. Suspension ...............................................................................................36
24. Wheel Bearing...........................................................................................39
25. Axle Boots & Joints ...................................................................................40
26. Steering System (Power Steering)............................................................41
27. Supplemental Restraint System................................................................44
GENERAL DESCRIPTION
1. General Description
A: GENERAL
Be sure to perform periodic maintenance in order to
maintain vehicle performance and find problems
before they become serious.
PM-2
SCHEDULE
2. Schedule
A: MAINTENANCE SCHEDULE 1
1. MAINTENANCE SCHEDULE 1 – (1)
For periodic maintenance of over 50,000 km (30,000 miles) or 48 months, carry out inspections by referring
to the following tables. For a maintenance period gone beyond these tables, apply them repeatedly as a set
of 50,000 km (30,000 miles) or 48 months.
Maintenance Interval
[Number of months or km (miles), whichever occurs first]
Months 12 24 36 48 Remarks
× 1,000 km 5 12.5 25 37.5 50
× 1,000 miles 3 7.5 15 22.5 30
1 Engine oil R R R R
2 Engine oil filter R R R R
2. MAINTENANCE SCHEDULE 1 – (2)

For periodic maintenance of over 100,000 km (60,000 miles) or 48 months, carry out inspections by referring
to the following tables. For a maintenance period gone beyond these tables, apply them repeatedly as a set
of 100,000 km (60,000 miles) or 48 months.
× 1,000 km 1.6 25 50 75 100
× 1,000 miles 1 15 30 45 60
3 Spark plugs For Turbo R
Others R R
4 Drive belt(s) I I I I
5 Camshaft drive belt R
6 Fuel line I I
7 Fuel filter R
8 Air cleaner element I R I R
9 Cooling system I I
10 Coolant R R
11 Idle mixture I I I I I For models without catalyst con-
verter
12 Clutch system I I I I
13 Hill-holder system I I I I I
14 Transmission oil R R
15 ATF R R
16 Front & rear differen- R R
tial oil
17 Brake line I I
18 Brake fluid R R
19 Disc brake pads & I I I I
discs
20 Brake linings and I I
drums
21 Parking brake I I I I
22 Suspension I I I I
23 Wheel bearing (I)
PM-3
SCHEDULE
× 1,000 km 1.6 25 50 75 100
× 1,000 miles 1 15 30 45 60
24 Axle boots & joints I I I I
25 Steering system I I I I
(Power steering)
Symbols used:
R: Replace
I: Inspection
(R) or (I): Recommended service for safe vehicle operation.
NOTE:
(1) Periodic inspection and replacement of the camshaft drive chains on the 3.0 liter models are not required.
(2) When the vehicle is used in extremely dusty conditions, the air cleaner element should be replaced more often.
(3) ATF filter is a maintenance free part. ATF filter needs replacement, when it is physically damaged or ATF leaked.
PM-4
SCHEDULE
B: MAINTENANCE SCHEDULE 2
Item Every Repeat short Repeat Extremely Salt or other High humid- Repeat tow-
distance drive rough/muddy cold weather corrosive ity or moun- ing trailer
road drive area used or tain area
coastal area
Engine oil Replace Replace Replace
more fre- more fre- more fre-
quently quently quently
Engine oil filter Replace Replace Replace
more fre- more fre- more fre-
quently quently quently
Fuel line 6 months I
12,500 km
7,500 miles
Transmission oil Replace
more fre-
quently
ATF Replace
more fre-
quently
Front & rear dif- Replace
ferential oil more fre-
quently
Brake line 6 months I I I I
12,500 km
7,500 miles
Brake fluid 12 months R
25,000 km
15,000 miles
Brake pads 6 months I I I I
12,500 km
7,500 miles
Brake linings 6 months I I I I
and drums 12,500 km
7,500 miles
Parking brake 6 months I I I I
12,500 km
7,500 miles
Suspension 6 months I I I I
12,500 km
7,500 miles
Axle boots & 6 months I I I I I
joints 12,500 km
7,500 miles
Steering system 6 months I I I I I
(Power steering) 12,500 km
7,500 miles
PM-5
ENGINE OIL
3. Engine Oil 5) Fill engine oil through the filler pipe up to upper
point on level gauge. Make sure that the vehicle is
A: REPLACEMENT placed level when checking oil level. Use engine oil
1) Drain the engine oil by loosening engine oil drain of proper quality and viscosity, selected in accor-
plug. dance with the table in figure.
Engine oil amount for preparation
(Non-turbo model):
Approx. 4.5 2 (4.8 US qt, 4.0 Imp qt)
Engine oil amount for preparation
(Turbo model):
GI0012A
2) Open the engine oil filler cap for quick draining of

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

and hot starting by reducing viscous friction and
thus increasing cranking speed.
NOTE:
• When replenishing oil, it does not matter if the oil
GI0013A
to be added is a different brand from that in the en-
3) Replace the drain plug gasket. gine; however, use oil having the API classification
4) Tighten the engine oil drain plug after draining and SAE viscosity No. designated by SUBARU.
engine oil. • If vehicle is used in desert areas with very high
temperatures or for other heavy duty applications,
Tightening torque: the following viscosity oils may be used:
44 N·m (4.5 kgf-m, 33 ft-lb) API classification: SL or SJ
SAE Viscosity No.: 30, 40, 10W-50, 20W-40, 20W-
50
6) Close the engine oil filler cap.
7) Start the engine and warm it up for a time.
8) After the engine stops, recheck the oil level.
If necessary, add engine oil up to upper level on
level gauge.
GI0012A
GI0016A
PM-6
ENGINE OIL
B: INSPECTION
1) Park the vehicle on a level surface.
2) Remove the oil level gauge and wipe it clean.
3) Reinsert the level gauge all the way. Be sure that
the level gauge is correctly inserted and in the
proper orientation.
4) Remove it again and note the reading. If the 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 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-
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.
PM-7
ENGINE OIL FILTER
4. Engine Oil Filter

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

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

Recommended spark plug :
SOHC
CHAMPION: RC10YC4
CHAMPION: RC8YC4
NGK: BKR6E-11
DENSO: K20PR-U11
Spark plug gap
1.0 — 1.1 mm (0.039 — 0.043 in)
SOHC Without OBD
NGK: BKR6E (Without catalytic converter)
CHAMPION: RC10YC4 (With catalytic con-
verter)
NGK: BKR5E-11 (With catalytic converter)
Spark plug gap
0.7— 0.8 mm (0.028 — 0.031 in) (Without
catalytic converter)
1.0 — 1.1 mm (0.039 — 0.043 in) (With cat-
alytic converter)
DOHC Turbo
NGK: PFR6B
Spark plug gap
0.7— 0.8 mm (0.028 — 0.031 in)
6) Tighten the spark plug lightly with hand, and
then secure with a plug-wrench to the specified
torque.
Tightening torque:
20.6 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 a torque wrench is not available, tighten the
spark plug until gasket contacts cylinder head; then
tighten further 1/4 to 1/2 turns.
PM-9
DRIVE BELT(S)
6. Drive Belt(s) B: REPLACEMENT

A: INSPECTION 1. V-BELT COVER
1) Replace the belts, if cracks, fraying or wear is 1) Remove the V-belt cover.
found.
2) Check the drive belt tension and adjust it if nec-
essary by changing the generator installing position
and/or idler pulley installing position.
Belt tension
(A)
replaced: 7 — 9 mm (0.276 — 0.354 in)
reused: 9.0 — 10.0 mm (0.354 — 0.394 in)
(B)*
replaced: 7.5 — 8.5 mm (0.295 — 0.335 in)
GI0020
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)
NOTE:
Wipe off any oil or water on the belt and pulley.
1) Loosen the lock bolt (A).
2) Loosen the slider bolt (B).
3) Remove the front side belt (C).
4) Install a new belt, and tighten the slider bolt so as
to obtain the specified belt tension.
5) Tighten the slider bolt (B).
6) Tighten the lock bolt (A).
GI0019A
Tightening torque:
C/P Crankshaft pulley Lock bolt, through bolt:
GEN Generator 25 N·m (2.5 kgf-m, 18 ft-lb)
P/S Power steering oil pump pulley Slider bolt:
A/C Air conditioning compressor pulley 8 N·m (0.8 kgf-m, 5.8 ft-lb)
I/P Idler pulley
GI0021A
PM-10
DRIVE BELT(S)
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).
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 (B).
6) Tighten the lock nut (A).
Tightening torque:
22.6 N·m (2.3 kgf-m, 16.6 ft-lb)
GI0022A
PM-11
CAMSHAFT DRIVE BELT
7. Camshaft Drive Belt 10) Turn the crankshaft and align alignment marks
on crankshaft, and right and left camshaft sprock-
A: REPLACEMENT ets with notches of belt cover and cylinder block.
ST 499987500 CRANKSHAFT SOCKET
1. SOHC MODEL
1) Remove the radiator fan <Ref. to CO-10, Radia-
tor Main Fan System.> and air conditioner fan.
<Ref. to CO-18, Radiator Sub Fan System.>
2) Remove the V-belt cover.
GI0020
3) Remove the V-belts. <Ref. to ME-44, V-belt.>

4) Remove the air conditioning compressor drive
belt tensioner.
5) Remove the pulley bolt. To lock the crankshaft,
use ST.
ST 499977100 CRANKSHAFT PULLEY GI0025A
WRENCH 11) Remove the belt idler.
12) Remove the belt idler (No. 2).
GI0024A
6) Remove the crankshaft pulley. GI0026

7) Remove the left side belt cover. 13) Remove the timing belt.
8) Remove the front belt cover. 14) Remove the automatic belt tension adjuster as-
9) Remove the timing belt guide. (MT vehicle only) sembly.
S2M0294
GI0027
PM-12
CAMSHAFT DRIVE BELT
2. DOHC MODEL 10) Turn the crankshaft and align alignment marks
on crankshaft, and right and left camshaft sprock-
1) Remove the radiator fan and air conditioner fan.
ets with notches of belt cover and cylinder block. To
turn the crankshaft, use ST.
Notch Notch
Alignment Alignment
mark mark
Alignment Alignment
GI0137 mark mark
Notch Notch
2) Remove the V-belts. <Ref. to ME(TURBO)-44, Alignment Alignment
V-belt.> mark mark
belt tensioner.
4) Remove the pulley bolt. To lock the crankshaft Alignment
mark
use ST.
ST 499977300 CRANKSHAFT PULLEY
WRENCH
BO0139
11) Remove the belt idler.
ST
GI0138
5) Remove the crankshaft pulley.

belt tensioner.
7) Remove the belt cover (LH).
8) Remove the belt cover (RH).
9) Remove the front belt cover. GI0140
12) Remove the timing belt.

13) Remove the automatic belt tension adjuster as-
sembly.
GI0141
PM-13
CAMSHAFT DRIVE BELT
B: INSTALLATION C: INSPECTION
1. SOHC MODEL 1. SOHC MODEL
Install in the reverse order of removal. <Ref. to ME- 1) Remove the belt covers (RH) and (LH).
49, Timing Belt Assembly.> 2) While cranking the engine at least four rotations,
check the timing belt back surface for cracks or
2. DOHC MODEL damage. Replace the faulty timing belt as needed.
Install in the reverse order of removal. <Ref. to 3) Measure the timing belt width W. If it is less than
ME(TURBO)-48, Timing Belt Assembly.> 27 mm (1.06 in), check idlers, tensioner, water
CAUTION: pump pulley and cam sprocket to determine idler
When installing the timing belt, be sure to align alignment (squareness). Replace the worn timing
all alignment marks on the belt with corre- belt.
sponding marks on the sprockets. If incorrectly
installed, interference between pistons and
valves may occur.
w
GI0142
4) Install the belt covers (RH) and (LH).

2. DOHC MODEL
1) Remove the belt covers (RH) and (LH).
2) While cranking the engine at least four rotations,
check the timing belt back surface for cracks or
damage. Replace the faulty timing belt as needed.
3) Measure the timing belt width W. If it is less than
30 mm (1.18 in), check idlers, tensioner, water
pump pulley and cam sprocket to determine idler
alignment (squareness). Replace the worn timing
belt.
4) Install the belt covers (RH) and (LH).
GI0143
PM-14
FUEL LINE
8. Fuel Line
A: INSPECTION
The fuel line is located mostly internally, so check
pipes, areas near pipes, and engine compartment
piping for rust, hose damage, loose bands, etc. If
faulty parts are found, repair or replace them. <Ref.
to FU-71, Fuel Delivery, Return and Evaporation
Lines.> or <Ref. to FU(w/oOBD)-68, Fuel Delivery,
Return and Evaporation Lines.> or <Ref. to
FU(TURBO)-68, Fuel Delivery, Return and Evapo-
ration Lines.>
PM-15
FUEL FILTER
9. Fuel Filter
A: REPLACEMENT
For fuel filter replacement procedures, refer to “FU”
section.
<Ref. to FU-68, Fuel Filter.> or <Ref. to FU(w/
oOBD)-65, Fuel Filter.> or <Ref. to FU(TURBO)-
65, Fuel Filter.>
PM-16
AIR CLEANER ELEMENT
10.Air Cleaner Element 2. TURBO MODEL

A: REPLACEMENT
NOTE:
Do not attempt to clean the air cleaner element.
The filter paper of the element is wetted with a 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 GI0126
cleaned, the filtration layer thus formed will be lost
along with the viscous liquid. 1) Remove the clip (B) above the air cleaner case.
1. NON-TURBO MODEL (B)
GI0127
2) Remove the air cleaner.

GI0032 3) Install in the reverse order of removal.
1) Remove the bolt (A) which installs air cleaner CAUTION:
case to stays. Before installing the air cleaner upper cover,
2) Remove the clip (B) above the air cleaner case. align holes with protruding portion of air clean-
er lower case, then secure the upper cover to
lower case.
H2M2947A
3) Remove the air cleaner. EN0906

4) Install in the reverse order of removal.
CAUTION:
Fasten with a clip after inserting the lower tab
of the case.
PM-17
COOLING SYSTEM
11.Cooling System 2) Check the radiator cap valve open pressure us-
ing radiator cap tester.
A: INSPECTION NOTE:
1) Check the radiator for leakage, filling it with cool- Rust or dirt on the cap may prevent the valve from
ant and attach the radiator cap tester to filler neck. functioning normally: be sure to clean the cap be-
Then apply a pressure of 157 kPa (1.6 kg/cm2, 23 fore testing.
psi) and check the following points:
Raise the pressure until the needle of gauge stops
• Each portion of radiator for leakage
and see if the pressure can be retained for 5 to 6
• Hose joints and other connections for leakage
seconds. The radiator cap is normal if a pressure
NOTE: above the service limit value has been maintained
• When attaching or detaching tester and when for this period.
operating tester, use special care not to deform ra-
diator filler neck. Radiator cap valve open pressure
Standard value:
Non-TURBO model 93 — 123 kPa (0.95 — 1.25 kg/cm2, 14 — 18
Cap tester psi)
Service limit:
83 kPa (0.85 kg/cm2, 12 psi)
GI0124
TURBO model
Cap tester
GI0034
GI0125
• When performing this check, be sure to keep the

engine stationary and fill the radiator with coolant.
• Wipe off check points before applying pressure.
• Use care not to spill coolant when detaching the GI0035A
tester from radiator.
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 the thermostat does not open
at 76.0 to 80.0°C (169 to 176°F), replace it with a
new one.
4) If the electric fan does not operate when coolant
temperature exceeds 90 to 94°C (194 to 201°F),
check the thermoswitch or fan motor.
PM-18
COOLANT
12.Coolant 8) Slowly pour the prepared coolant from radiator

filler port to neck of filler, then pour into reservoir
A: REPLACEMENT tank up to “FULL” level.
1. REPLACEMENT OF COOLANT Coolant capacity (fill up to “FULL” level)
1.6 L AT model:
WARNING: Approx. 7.3 2 (7.7 US qt, 6.4 Imp qt)
The radiator is of the pressurized type. Do not 1.6 L MT model:
attempt to open the radiator cap immediately Approx. 7.4 2 (7.8 US qt, 6.5 Imp qt)
after the engine has been stopped. 2.0 L Non-turbo AT model:
1) Lift-up the vehicle. Approx. 6.9 2 (7.3 US qt, 6.1 Imp qt)
2) Remove the under cover. 2.0 L Non-turbo MT model:
3) Place a container under drain pipe. Approx. 7.0 2 (7.4 US qt, 6.2 Imp qt)
4) Loosen and remove the drain screw to drain en- 2.0 L Turbo AT model:
gine coolant into container. Approx. 7.7 2 (8.1 US qt, 6.8 Imp qt)
2.0 L Turbo MT model:
2.5 L AT model:
2.5 L MT model:
NOTE:
The SUBARU Genuine Coolant containing anti-
freeze and anti-rust agents is especially made for
EN0073 SUBARU engine, which has an aluminum crank-
case. Always use SUBARU Genuine Coolant,
5) For quick draining, open the radiator cap. since other coolant may cause corrosion.
CAUTION: 9) Securely install the radiator cap.
Be careful not to spill coolant on the floor. 10) Run the engine for more than 5 minutes at
6) Drain the coolant from reservoir tank. 2,000 to 3,000 rpm. (Run the engine until radiator
7) Tighten the radiator drain screw securely after becomes hot in order to purge the air trapped in
draining coolant. cooling system.)
11) Stop the engine and wait until coolant temper-
ature lowers. Then open the radiator cap to check
coolant level and add coolant up to radiator filler
neck. Next, add coolant into reservoir tank up to
“FULL” level.
12) After adding coolant, securely install the radia-
tor and reservoir tank caps.
PM-19
COOLANT
2. RELATIONSHIP OF SUBARU COOLANT 3. PROCEDURE TO ADJUST THE CON-

CONCENTRATION AND FREEZING TEM- CENTRATION OF THE COOLANT
PERATURE To adjust the concentration of the coolant accord-
The concentration and safe operating temperature ing to temperature, find the proper fluid concentra-
of the SUBARU coolant is shown in the diagram. tion in the above diagram and replace the
Measuring the temperature and specific gravity of necessary amount of coolant with an undiluted so-
the coolant will provide this information. lution of SUBARU genuine coolant (concentration
[Example] 50).
If the coolant temperature is 25°C (77°F) and its The amount of coolant that should be replaced can
specific gravity is 1.054, the concentration is 35% be determined using the diagram.
(point A), the safe operating temperature is –14°C [Example]
(7°F) (point B), and the freezing temperature is Assume that the coolant concentration must be in-
–20°C (–4°F) (point C). 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
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.
GI0037A
GI0038A
PM-20
IDLE MIXTURE
13.Idle Mixture
A: INSPECTION AND ADJUSTMENT
1. IDLE MIXTURE
Before measuring the idle mixture, make sure that
the ignition timing and the engine idle speed are
within specifications.
1) Set the gear position at “Neutral” for MT, or “N”
or “P” for AT.
2) Warm up the engine sufficiently until cooling fan
starts to operate.
3) Measure the idle mixture using CO meter.
Engine idle speed CO
700±100 rpm 1.0±0.5%
4) If out of specification, adjust the idle mixture us-

ing CO adjusting screw of mass air flow sensor.
5) After adjusting the CO value, check and adjust
the increment coefficient of CO resistor by using
Select Monitor.
(1) Select “Current data display & Save” on the
select monitor.
(2) If out of specified data, adjust the increment
coefficient of CO resistor while rotating the CO
adjusting screw.
Specified data:
0.28 — 4.22 V
GI0114A
NOTE:
If driving the vehicle on out of specified data, the
“trouble code 49” is indicated in many case.
PM-21
CLUTCH SYSTEM
14.Clutch System 2) Pedal-to-floor plate gap in disengaged position.

(1) With the engine idling, pull the parking brake
A: INSPECTION AND ADJUSTMENT lever completely.
(2) Slowly depress the clutch pedal while mov-
1. MECHANICAL CLUTCH TYPE
ing shift lever into reverse.
1) Inspect the free play of clutch pedal by operating (3) Stop depressing the clutch pedal when
pedal by hand. gearshifting is complete. With the clutch pedal in
If it is out of the specified value, adjust it by turning this position, measure the distance between the
wing nut on engine side of clutch cable at release upper side of pedal pad and the lower end of
fork. front panel (intersection of front panel with floor).
Tightening torque Check that the measured value is within the
(Adjusting nut on release fork): specified standard.
4.4 — 7.4 N·m Standard:
(0.45 — 0.75 kgf-m, 3.3 — 5.4 ft-lb) 80 mm (3.15 in) or more
Standard free play: 3) Pedal height
AT clutch pedal Check that the clutch pedal pad surface is level
10 — 20 mm (0.39 — 0.79 in) with or higher than brake pedal pad surface.
2. HYDRAULIC CLUTCH TYPE
1) Push the release lever to retract the push rod of
the operating cylinder and check if the fluid level in
the clutch reservoir tank rises or not.
Non-TURBO model
Release lever
Push rod
Free play:
10 20mm(0.39 0.79in)
GI0144
Fork lever free play allowance:

2 — 4 mm (0.08 — 0.16 in)
Free play: Full stroke: Operating cylinder
2 4mm 25.5mm(1 in) GI0128
(0.08 0.16in)
TURBO model
Release lever Operating cylinder
Lock nut
Adjusting nut
Release fork GI0145
Push rod
GI0129
2) If the fluid level rises, pedal free play is correct.

3) If the fluid level does not rise, or the push rod
cannot be retracted, adjust the clutch pedal. <Ref.
to CL-41, Clutch Pedal.>
4) Inspect the underside of master cylinder, clutch
damper and operating cylinder for clutch system,
hoses, piping and their couplings for fluid leaks.
If fluid leaks are found, correct them by retightening
their fitting bolt and/or replacing their parts.
PM-22
CLUTCH SYSTEM
5) Check the fluid level using the scale on the 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.
GI0040A
PM-23
HILL-HOLDER SYSTEM
15.Hill-holder System
A: INSPECTION AND ADJUSTMENT
1) Confirm the stopping and starting performance
by activating the hill-holder on an uphill road of 3°
or higher inclination.
(1) When the vehicle does not stop;
Tighten the adjusting nut of PHV cable.
(2) When the vehicle does not start properly;
A; When the hill-holder is released later than en-
gagement of clutch (engine tends to stall): Loos-
en the adjusting nut gradually until smooth
starting is enabled.
B; When the hill-holder is released earlier than
engagement to clutch (vehicle slips down slight-
ly): Tighten the adjusting nut so that hill-holder is
released later than engagement of clutch (status
in A). Then make adjustment the same as in A.
NOTE:
• Whenever turning the adjusting nut, hold the in-
ner cable with pliers to prevent it from turning.
• Replace the pressure hold valve (PHV), return
spring of PHV or PHV cable with a new one, if they
are defective and/or damaged.
GI0115A
PM-24
TRANSMISSION OIL
16.Transmission Oil
A: REPLACEMENT
1. MANUAL TRANSMISSION
1) Drain the gear oil by removing drain plug after al-
lowing the engine to cool for 3 to 4 hours.
NOTE:
Before starting work, cool off the engine well.
GI0041
2) Reinstall the drain plug after draining gear oil

and tighten it to the specified torque.
Tightening torque:
44 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 transmission gear oil through the oil level
gauge hole up to the upper point of level gauge.
Gear oil capacity:
Single range model
3.5 2 (3.7 US qt, 3.1 Imp qt)
Dual range model
4.0 2 (4.2 US qt, 3.5 Imp qt)
GI0042A
PM-25
ATF
17.ATF 4) Fluid temperature rising speed

• By idling the engine
A: INSPECTION Time for temperature rise to 70°C (158°F) with at-
1) Raise the ATF temperature to 70 to 80°C (158 to mospheric temperature of 0°C (32°F): More than
176°F) from 20 to 30°C (68 to 86°F) (when cold) by 25 minutes
driving a distance of 5 to 10 km (3 to 6 miles). <Reference>
NOTE: Time for temperature rise to 30°C (86°F) with atmo-
The level of ATF varies with fluid temperature. Pay spheric temperature of 0°C (32°F): Approx. 8 min-
attention to the fluid temperature when checking oil utes
level. • 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 the fluid level after a warm-up run of approx.
10 minutes. During the warm-up period, the auto-
matic transmission functions can also be checked.
B3M1020B
(A) ATF level gauge

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

positions (P, R, N, D, 3, 2, 1), set the select lever in
“P” range. Measure the fluid level with engine
idling.
NOTE:
After running, idle the engine for 1 or 2 minutes be-
fore measurement.
3) If the fluid level is below the center between up-
per and lower marks, add the recommended ATF
until the fluid level is found within the specified
range (above the center between upper and lower
marks). When the transmission is hot, the level
should be above the center of upper and lower
marks, and when it is cold, the level should be
found below the center of these two marks.
CAUTION:
• Use care not to exceed the upper limit level.
• ATF level varies with temperature. Remem-
ber that the addition of fluid to the upper limit
mark when the transmission is cold will result
in the overfilling of fluid.
PM-26
ATF
B: REPLACEMENT 2. ATF FILTER

1. AUTOMATIC TRANSMISSION FLUID NOTE:
ATF filter is a maintenance free part. ATF filter
1) Drain the ATF (Automatic Transmission Fluid) needs replacement, when it has physically dam-
by removing drain plug after allowing the engine to aged or ATF leaked.
cool for 3 to 4 hours.
For the replacement procedures of the ATF filter:
NOTE: <Ref. to AT-45, ATF Filter.>
Before starting work, cool off the engine well.
GI0043A
2) Reinstall the drain plug after draining ATF, and

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

A: REPLACEMENT 1) Drain the oil by removing drain plug.
2) Remove the filler plug for quick draining oil.
1. FRONT DIFFERENTIAL (MANUAL 3) Reinstall the drain plug after draining oil.
TRANSMISSION) NOTE:
For MT vehicle, manual transmission oil works as • Apply fluid packing to the drain plug threads be-
differential oil to lubricate differential. Refer to fore installation in Except Non-turbo AT model.
“Transmission Oil”. <Ref. to PM-25, Transmission • Non-turbo AT model uses a new aluminum gas-
Oil.> ket.
2. FRONT DIFFERENTIAL (AUTOMATIC Fluid packing:
TRANSMISSION) Three Bond 1105
1) Drain the differential gear oil by removing drain Tightening torque:
plug after allowing the engine to cool for 3 to 4 Except 1.6 L and Non-turbo AT model:
hours. 49.0 N·m (5.0 kgf-m, 36.2 ft-lb)
NOTE: 1.6 L and Non-turbo AT model:
Before starting work, cool off the engine well. 34 N·m (3.5 kgf-m, 25.3 ft-lb)
4) After installing the drain plug onto rear differen-
tial gear case firmly, fill oil up fully to the mouth of
filler plug.
• 1.6 L and Non-turbo AT MODEL
Filler bolt
GI0045
2) Reinstall the drain plug after draining differential

gear oil and tighten it to the specified torque. Drain bolt
GI0173
Tightening torque:
44 N·m (4.5 kgf-m, 32.5 ft-lb) • Except 1.6 L and Non-turbo MODEL
NOTE:
• Be sure to place a gasket between the transmis- Filler plug
sion case and drain plug.
• Replace the gasket with a new one.
• Each oil manufacturer has its base oil and addi-
3) Fill differential gear oil through the oil level
gauge hole up to the upper point of level gauge.
Differential gear oil capacity: Drain plug
1.1 — 1.3 2 (1.2 — 1.4 US qt, 1.0 — 1.1 lmp qt) GI0174
Oil capacity:
0.8 2 (0.8 US qt, 0.7 lmp qt)
NOTE:
Each oil manufacturer has its base oil and addi-
GI0046A
PM-28
FRONT & REAR DIFFERENTIAL OIL
5) Install the filler plug onto rear differential gear

case firmly.
NOTE:
• Apply fluid packing to the filler plug before instal-
lation in Except Non-turbo AT model.
• Non-turbo AT model uses a new aluminum gas-
ket.
Fluid packing:
Three Bond 1105
Tightening torque:
Except 1.6 L and Non-turbo AT model:
49.0 N·m (5.0 kgf-m, 36.2 ft-lb)
1.6 L and Non-turbo AT model:
34 N·m (3.5 kgf-m, 25.3 ft-lb)
PM-29
BRAKE LINE
19.Brake Line B: CHECKING

A: INSPECTION 1. SERVICE BRAKE
1. BRAKE LINE 1) Check the free play of brake pedal with a force of
less than 10 N (1 kgf, 2 lb).
1) Check scratches, swelling, corrosion and/or
traces of fluid leakage on the brake hoses or pipe Brake pedal free play:
joints. 1 — 3 mm (0.04 — 0.12 in)
2) Check the possibility of adjacent parts interfering
with brake pipes/hoses during driving, and loose
connections/clamps.
3) Check any trace of fluid leakage, scratches, etc.
on the master cylinder, wheel cylinder and pres-
sure control valve.
NOTE:
• 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.
GI0050A
• Visually check the brake hose (using a mirror
where it is difficult to see) for any damage. 2) If the free play is out of specifications above, ad-
just the brake pedal as follows:
(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 lb) to a stroke of 1 to 3 mm
(0.04 to 0.12 in).]
(3) Depress the surface of brake pad by hand.
GI00148A (4) If there is no free play between clevis pin
and clevis, turn the brake switch adjusting nut
until the clearance between stopper and screw
of brake switch becomes 0.3 mm (0.012 in).
Rear brake hoses
Rear brake pipe

GI0156
GI0051A
PM-30
BRAKE LINE
3) Check the pedal stroke. 4) Check valve is built into the vacuum hose. Dis-
While the engine is idling, depress the brake pedal connect the vacuum hose to inspect function of
with a 490 N (50 kgf, 110 lb) load and measure the check valve.
distance between brake pedal and steering wheel. Blow air into the vacuum hose from its brake boost-
With the brake pedal released, measure the dis- er side end: Air must flow out of engine side end of
tance between pedal and steering wheel again. hose. Next blow air into the hose from engine side:
The difference between the two measurements Air should not flow out of hose.
must be less than 95 mm (3.74 in). If the distance is Replace both check valve and vacuum hose if the
more than specified, there is possibility of air inside check valve is faulty. Engine side of vacuum hose
the hydraulic unit. is indicated by marking “ENGINE” as shown.
Brake pedal reserve distance: A
more than 95 mm (3.74 in)/ 490 N (50 kgf, 110
lb)
GI0053A
5) Check the vacuum hose for cracks or other dam-

age.
GI0052A NOTE:
4) Check to see if air is in the hydraulic brake line When installing the vacuum hose on the engine
by the feel of pedal operation. If air appears to exist and brake booster, do not use soapy water or lubri-
in the line, bleed it from the system. cating oil on their connections.
5) Check for even operation of all brakes, using a 6) Check vacuum hose to make sure it is tight and
brake tester or by driving the vehicle for a short dis- 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-31
BRAKE FLUID
20.Brake Fluid NOTE:

• Cover the bleeder with waste cloth, when loosen-
A: REPLACEMENT ing it, to prevent brake fluid from being splashed
1) Either jack-up the vehicle and place a safety over surrounding parts.
stand under it, or lift-up the vehicle. • During bleeding operation, keep the brake reser-
2) Remove both front and rear wheels. voir tank filled with brake fluid to eliminate entry of
3) Draw out the brake fluid from master cylinder air.
with syringe. • Brake pedal operation must be very slow.
4) Refill the reservoir tank with recommended • For convenience and safety, it is advisable to
brake fluid. have two men working.
Recommended brake fluid: • The amount of brake fluid required is approx. 500
FMVSS No. 116, fresh DOT3 or 4 brake fluid m2 (16.9 US fl oz, 17.6 Imp fl oz) for total brake
system.
NOTE:
6) Instruct your co-worker to depress the brake
• Avoid mixing different brands of brake fluid to
pedal slowly two or three times and then hold it de-
prevent degrading the quality of the fluid.
pressed.
• Be careful not to allow dirt or dust to get into the
7) Loosen the bleeder screw approx. 1/4 turn until a
reservoir tank.
small amount of brake fluid drains into container,
Bleeding sequence (1) → (2) → (3) → (4) and then quickly tighten the screw.
8) Repeat steps 6) and 7) above until there are no
air bubbles in the drained brake fluid and new fluid
flows through vinyl tube.
NOTE:
Add brake fluid as necessary while performing the
air bleed operation, in order to prevent the tank
from running short of brake fluid.
9) After completing the bleeding operation, hold
brake pedal depressed and tighten the screw and
GI0054A install bleeder cap.
Tightening torque:
(1) Front right 8 N·m (0.8 kgf-m, 5.8 ft-lb)
(2) Rear left
10) Bleed air from each wheel cylinder by following
(3) Front left
the previous 5 steps.
(4) Rear right 11) Depress the brake pedal with a force of approx.
(5) Secondary 294 N (30 kgf, 66 lb) and hold it there for approx. 20
(6) Primary seconds. At this time check the pedal to see if it
makes any unusual movement. Visually inspect the
5) Install one end of a vinyl tube onto the air bleeder
bleeder screws and brake pipe joints to make sure
and insert the other end of the tube into a container
that there is no fluid leakage.
to collect the brake fluid.
12) Install the wheels, and drive the vehicle for a
short distance between 2 to 3 km (1 to 2 miles) to
make sure that brakes are operating properly.
GI0055
PM-32
DISC BRAKE PADS AND DISCS
21.Disc Brake Pads and Discs 3) Check the disc rotor, and correct or replace if it is
damaged or worn.
A: INSPECTION • Non-turbo MODEL
1. DISC BRAKE PAD AND DISC Brake disc thickness mm (in)
1) Jack-up the vehicle and support with rigid racks. Front Rear
Then remove the wheels. Standard 24 (0.94) 10 (0.39)
2) Visually check the pad thickness through inspec- Wear limit 22 (0.87) 8.5 (0.335)
tion hole of disc brake assembly. Replace the pad if
• Turbo MODEL
necessary.
• Non-turbo MODEL Brake disc thickness mm (in)
Front Rear
Standard 24 (0.94) 18 (0.71)
Wear limit 22 (0.87) 16 (0.63)
4) Measure the disc rotor runout at a point less than

5 mm (0.20 in) from the outer periphery of the rotor.
Disc rotor runout limit:
Front: 0.070 mm (0.0028 in)
Rear: 0.075 mm (0.0030 in)
GI0056A NOTE:
When replacing a pad, always replace the pads for
Pad thickness including back metal mm (in) both the right and left wheels at the same time. Also
Front Rear replace the pad clips if they are twisted or worn.
Standard 17 (0.67) 14 (0.55)
Service limit 7.5 (0.295) 6.5 (0.256)
• Turbo MODEL
GI0147
Inspection
hole
GI0146
Pad thickness including back metal mm (in)

Front Rear
Standard 14.5 (0.570) 16 (0.629)
Service limit 6.0 (0.236) 6.0 (0.236)
GI0057A
PM-33
BRAKE LININGS AND DRUMS
22.Brake Linings and Drums 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-
ties and check brake linings for wear. If deformation or wear of back plate, shoe, etc. is
noticeable, replace the affected parts.
NOTE:
• Always replace both leading and trailing brake
shoes for the right and left wheels at the same time.
• When either the right and left brake assembly is
replaced, always replace the leading shoe and trail-
ing shoe of the other.
• The cotter pin, once removed, cannot be reused.
Thickness of lining (except back metal)
Service limit: 1.5 mm (0.059 in)
GI0060A
2. PARKING BRAKE (REAR DISC BRAKE)

Inspect the brake linings and drums of both sides of
the rear brake at the same time by removing brake
drums.
1) Inspect the brake shoes for damage or deforma-
tion and check brake linings for wear.
NOTE:
Always replace both primary and secondary brake
GI0059A shoes for the right and left wheels at the same time.
(1) Rotational direction of drum (Forward) Brake lining thickness excluding back metal
(2) Wheel cylinder
(3) Upper shoe return spring
Wear limit: 1.5 mm (0.059 in)
(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.
GI0061A
PM-34
BRAKE LININGS AND DRUMS
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 1. REAR DRUM BRAKE
(#200 or more). If it is unevenly worn, tapered, or The main brake is adjusted automatically, and so
the outside surface of brake drum is damaged, cor- there is no need to adjust it.
rect or replace it.
2. PARKING BRAKE (REAR DISC BRAKE)
Brake drum inside diameter
Standard value: 170 mm (6.69 in) For rear disc brake, adjust the parking brake after
Wear limit: 171 mm (6.73 in) bleeding air.
1) Remove the rear cover (rubber) installed at back
plate.
2) Turn the adjuster toward arrow mark (upward)
until it is locked slightly, by using a slot-type screw-
driver as shown in illustration.
GI0062A
3) If the deformation or wear of back plate, shoe,

etc. is noticeable, replace them.
4) When the shoe return spring tension is exces-
sively weakened, replace it, taking care to identify GI0063A
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-35
SUSPENSION
23.Suspension 5) Damage of dust seal

Visually inspect the ball joint dust seal. If it is dam-
A: INSPECTION aged, remove the transverse link. <Ref. to FS-16,
Front Transverse Link.> And measure free play of
1. SUSPENSION BALL JOINT ball joint. <Ref. to FS-18, Front Ball Joint.>
1) Jack-up the vehicle until front wheels are off (1) When looseness exceeds standard value,
ground. replace the ball joint.
2) Next, grasp the bottom of tire and move it in and (2) If the dust seal is damaged, replace with the
out. If relative movement is observed between the new ball joint.
brake disc cover and end of transverse link, ball NOTE:
joint may be excessively worn. When the transverse link ball joint has been re-
3) Next, grasp the end of transverse link and move moved or replaced, check the toe-in of front wheel.
it up and down. Relative movement between the If the front wheel toe-in is not at specified value, ad-
housing and transverse link boss indicates ball joint just the toe-in. <Ref. to FS-8, Wheel Alignment.>
may be excessively worn.
4) If relative movement is observed in the immedi-
ately preceding two steps, remove and inspect the
ball joint. If free play exceeds standard, replace the
ball joint. <Ref. to FS-18, Front Ball Joint.>
GI0066A
2. TRANSVERSE LINK'S REAR BUSHING

Check oil leaks at around liquid-filled bushing. If oil
GI0064A leaks, replace the bushing.
GI0067A
GI0065A
PM-36
SUSPENSION
3. WHEEL ARCH HEIGHT 5. WHEEL ALIGNMENT OF REAR SUS-

1) Unload cargoes and set the vehicle in curb PENSION
weight (empty) condition. 1) Check the alignment of rear suspension to en-
2) Then, check the wheel arch height of front and sure that following items are within standard val-
rear suspensions to ensure that they are within ues.
specified values. • Toe-in
3) When the wheel arch height is out of standard, • Camber angle
visually inspect the following components and re- • Thrust angle
place deformed parts. <Ref. to RS-9, Wheel Alignment.>
• Suspension components [Front strut assembly 2) When the camber angle does not conform to
and rear shock absorber assembly] standard value, visually inspect parts listed below.
• Body parts to which suspensions are installed. If deformation is observed, replace the damaged
4) When no components are deformed, adjust the parts.
wheel arch height by replacing coil spring in the • Suspension components [Shock absorber, link
suspension which wheel arch height is out of stan- F, link R, link UPR, arm R, sub frame, etc.]
dard. <Ref. to FS-8, Wheel Alignment.> <Ref. to • Body parts to which suspensions are installed.
RS-9, Wheel Alignment.> 3) When the toe-in and thrust angle are out of stan-
4. WHEEL ALIGNMENT OF FRONT SUS- dard value, adjust them so that they conform to re-
spective service standard.
PENSION
1) Check the alignment of front suspension to en- 6. OIL LEAKAGE OF STRUT AND SHOCK
sure that following items conform to standard val- ABSORBER
ues. Visually inspect the front strut and rear shock ab-
• Toe-in sorber for oil leakage as instructed. Replace front
• Camber angle strut and rear shock absorber if oil leaks excessive-
• Caster angle ly.
• Steering angle
<Ref. to FS-8, Wheel Alignment.> 7. TIGHTNESS OF BOLTS AND NUTS
2) When the caster angle does not conform to stan- Check the bolts and nuts shown in the figure for
dard value, visually inspect the following compo- looseness. Retighten the bolts and nuts to speci-
nents and replace deformed parts. fied torque. If the self-lock nuts and bolts are re-
• Suspension components [Strut assembly, cross- moved, replace them with new ones.
member, transverse link, etc.] Front suspension: <Ref. to FS-2, General Descrip-
• Body parts to which suspensions are installed. tion.>
3) When the toe-in and camber are out of standard Rear suspension: <Ref. to RS-2, General Descrip-
value, adjust them so that they conform to respec- tion.>
tive service standard.
4) When the right-and-left turning angles of tire are
out of standard, adjust to standard value.
PM-37
SUSPENSION
8. DAMAGE TO SUSPENSION PARTS

1) Check the following parts and the fastening por-
tion of the vehicle body for deformation or exces-
sive rusting which impairs the suspension. If
necessary, replace the damaged parts with new
ones. If minor rust formation, pitting, etc. are noted,
remove the rust and apply remedial anti-corrosion
measures.
• Front suspension
• Transverse link
• Crossmember
• Strut
• Rear suspension
• Crossmember
• Lateral links
• Trailing link
• Strut
• In the district where salt is sprayed to melt snow
on a road in winter, check suspension parts for
damage caused by rust every 12 months after
lapse of 60 months. Take rust prevention measure
as required.
PM-38
WHEEL BEARING
24.Wheel Bearing 6) While supporting the 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. Inner oil seal
1) Jack-up the front of vehicle.
Rear housing
2) While holding the front wheel by hand, swing it in
and out to check bearing free play. Tone wheel
(With ABS only)
3) Loosen the wheel nuts and remove front wheel.
Hub bolt
4) If bearing free play exists in step 2) above, at- Socket bolt
tach a dial gauge to the hub and measure axial dis- Bearing (With ABS only)
placement in axial direction. Snap ring
Outer oil seal
Service limit:
Straight-ahead position within 0.05 mm Hub GI0134
(0.0020 in)
5) Remove the bolts and self-locking nuts, and ex-
tract transverse link from front crossmember.
6) While lightly hammering the spring pin which se-
cures S.F.J. to transmission spindle, remove it.
7) Extract the S.F.J. from transmission spindle.
<Ref. to DS-18, Front Axle.>
8) While supporting the front drive shaft horizontal-
ly with one hand, turn the hub with the other to
check for noise or binding.
If the hub is noisy or binds, disassemble the front
axle and check condition of oil seals, bearing, etc.
Inner oil seal Hub bolt
Snap ring
Bearing
Housing
Outer oil seal
Hub
GI0133
2. REAR WHEEL BEARING

1) Jack-up the rear of vehicle.
2) While holding the rear wheel by hand, swing it in
and out to check bearing free play.
3) Loosen the wheel nuts and remove rear wheel.
4) If the bearing free play exists in step 2) above,
attach a dial gauge to the hub COMPL and mea-
sure axial displacement in axial direction.
Service limit:
Straight-ahead position within 0.05 mm
(0.0020 in)
5) Remove the DOJ of rear drive shaft from rear dif-
ferential. <Ref. to DS-39, Rear Drive Shaft.>
PM-39
AXLE BOOTS & JOINTS
25.Axle Boots & Joints

A: INSPECTION
1. FRONT AND REAR AXLE BOOTS
Inspect the front axle boots (A) and rear axle boots
(B) for deformation, damage or failure. If faulty, re-
place them with new ones. <Ref. to DS-33, Front
Drive Shaft.> <Ref. to DS-39, Rear Drive Shaft.>
GI0070A
(B)
GI0135
2. PROPELLER SHAFT
Inspect the propeller shaft for damage or failure. If
faulty, replace with a new one. <Ref. to DS-15, Pro-
peller Shaft.>
PM-40
STEERING SYSTEM (POWER STEERING)
26.Steering System (Power 2. STEERING SHAFT JOINT

Steering) 1) When the steering wheel free play is excessive,
disconnect the universal joint of steering shaft and
A: INSPECTION check it for any play and yawing torque (at the point
of the crossing direction). Also inspect for any dam-
1. STEERING WHEEL age to sealing or worn serrations. If the joint is
1) Set the steering wheel in a straight-ahead posi- loose, retighten the mounting bolts to the specified
tion, and check the wheel spokes to make sure torque.
they are correctly set in their specified positions.
Tightening torque:
2) Lightly turn the steering wheel to the right and
24 N·m (2.4 kgf-m, 17.4 ft-lb)
left to determine the point where front wheels start
to move.
Measure the distance of the movement of steering
wheel at the outer periphery of wheel.
Steering wheel free play:
0 — 17 mm (0 — 0.67 in)
GI0075A
3. GEARBOX
1) With wheels placed on a level surface, turn the
steering wheel 90° in both the right and left direc-
tions.
GI0074A While the wheel is being rotated, reach under the
Move the steering wheel vertically toward the shaft vehicle and check for looseness in gearbox.
to ascertain if there is play in the direction. Tightening torque:
Maximum permissible play: 59 N·m (6.0 kgf-m, 43.4 ft-lb)
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.
GI0076A
(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 the vehicle on a level surface, quickly turn
Steering wheel should return to its original posi- the steering wheel to the right and left.
tion after it has been turned and then released. While the 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 the 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 the adjusting screw to 7.4 N·m
(0.75 kgf-m, 5.4 ft-lb) and back off 25°.
PM-41
(3) Apply liquid packing to at least 1/3 of entire 5. POWER STEERING FLUID LEVEL
perimeter of adjusting screw thread.
NOTE:
The fluid level must be checked when the temper-
ature of reservoir tank surface is approx. 20°C
(68°F).
1) Place the vehicle with engine “OFF” on a flat and
level surface.
2) Check the fluid level using the scale on the out-
side of reservoir tank (A). If the level is below “MIN”
(B), add fluid to bring it up to “MAX” (C).
GI0077A
(4) Install the lock nut. While holding the adjust-

ing screw with a wrench, tighten the lock nut us-
ing 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-
GI0014A
vent it from turning, while tightening the lock nut.
4. TIE-ROD NOTE:
If the fluid level is at MAX level or above, drain fluid
1) Check the tie-rod and tie-rod ends for bends, to keep the level in specified range of indicator by
scratches or other damage. using a syringe or the like.
Recommended fluid:
Dexron IIE or III
Fluid capacity:
0.7 2 (0.7 US qt, 0.6 Imp qt)
6. POWER STEERING FLUID FOR LEAKS
Inspect the underside of oil pump and gearbox for
power steering system, hoses, piping and their
couplings for fluid leaks.
GI0105A
If fluid leaks are found, correct them by retightening
2) Check the connections of knuckle ball joints for their fitting bolts (or nuts) and/or replacing their
play, inspect for damage on dust seals, and check parts.
free play of ball studs. If the castle nut is loose, re- NOTE:
tighten it to the specified torque, then tighten further • Wipe the leakage fluid off after correcting fluid
up to 60° until the cotter pin hole is aligned. leaks, or a wrong diagnosis is taken later.
Tightening torque: • Also pay attention to clearances between hoses
27 N·m (2.75 kgf-m, 19.9 ft-lb) (or pipings) and other parts when inspecting fluid
leaks.
3) Check the lock nut on tie-rod end for tightness. If
it is loose, retighten it to the specified torque.
Tightening torque:
83 N·m (8.5 kgf-m, 61.5 ft-lb)
PM-42
7. HOSES OF OIL PUMP FOR DAMAGES

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

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

Inspect the fitting bolts and nuts of oil pump and
bracket for looseness, and retighten them if neces-
sary.
Inspect and/or retighten them when engine is cold.
PM-43
SUPPLEMENTAL RESTRAINT SYSTEM
27.Supplemental Restraint System

A: INSPECTION
Check the airbag system in accordance with the result of the self-diagnosis. <Ref. to AB-2, Basic Diagnostic
Procedure.>
1) Ensure that airbag connectors are connected. If not, properly connect. When the ignition switch is turned
ON with the connector(s) disconnected, the airbag warning light blinks to identify the fault.
GI0136
2) Turn the ignition switch to ON, and connect the airbag diagnosis terminal of the service connector (located
below lower cover) to ground terminal.
3) The warning light blinks to indicate a trouble code (a fault is identified). When the airbag system is in good
order (no trouble codes are stored in the memory), the warning light blinks on and off at 0.6 second intervals
(as long as the diagnosis terminal is connected to ground terminal).
4) When the warning light indicates a trouble code, check the airbag system in accordance with the trouble-
shooting procedure. <Ref. to AB-2, Basic Diagnostic Procedure.>
PM-44
ENGINE 1 SECTION
FUEL INJECTION (FUEL SYSTEMS) FU
EMISSION CONTROL EC
(AUX. EMISSION CONTROL DEVICES)
INTAKE (INDUCTION) IN
MECHANICAL ME
EXHAUST EX
of SUBARU vehicles. COOLING CO
sembling, inspection and adjustment of LUBRICATION LU
Please peruse and utilize this manual SPEED CONTROL SYSTEMS SP
their vehicle in optimum condition. IGNITION IG
SUBARU genuine parts. STARTING/CHARGING SYSTEMS SC
ENGINE (DIAGNOSTICS) EN

approval.

FUEL INJECTION (FUEL SYSTEMS)
FU
Page
2. Throttle Body.............................................................................................16
3. Intake Manifold..........................................................................................17
4. Engine Coolant Temperature Sensor........................................................31
5. Crankshaft Position Sensor.......................................................................32
6. Camshaft Position Sensor.........................................................................33
7. Knock Sensor............................................................................................34
8. Throttle Position Sensor............................................................................35
9. Intake Air Temperature and Pressure Sensor...........................................37
10. Atmospheric Pressure Sensor ..................................................................38
11. Idle Air Control Solenoid Valve .................................................................39
12. Air Assist Injector Solenoid Valve .............................................................40
13. Fuel Injector ..............................................................................................41
14. Front Oxygen (A/F) Sensor .......................................................................47
15. Rear Oxygen Sensor.................................................................................49
16. Engine Control Module..............................................................................51
17. Main Relay ................................................................................................52
18. Fuel Pump Relay.......................................................................................53
19. Fuel ...........................................................................................................54
20. Fuel Tank ..................................................................................................55
21. Fuel Filler Pipe ..........................................................................................58
22. Fuel Pump.................................................................................................62
23. Fuel Level Sensor .....................................................................................65
24. Fuel Sub Level Sensor..............................................................................66
25. Fuel Filter ..................................................................................................68
26. Fuel Cut Valve...........................................................................................69
27. Fuel Damper Valve ...................................................................................70
28. Fuel Delivery, Return and Evaporation Lines............................................71
29. Fuel System Trouble in General ...............................................................75
GENERAL DESCRIPTION
A: SPECIFICATIONS
Model 1600 cc and 2000 cc 2500 cc
Capacity 50 2 (13.2 US gal, 11.0 Imp gal) 60 2 (15.9 US gal, 13.2 Imp gal)
Fuel tank
Location Under rear seat
Type Impeller
Shutoff discharge pressure 370 — 677 kPa (3.77 — 6.9 kg/cm2, 53.6 — 98 psi)
Fuel pump
More than 65 2 (17.2 US gal, 14.3 Imp gal)/h
Discharge flow
[12 V at 300 kPa (3.06 kg/cm2, 43.5 psi)]
Fuel filter Cartridge type
FU-2
GENERAL DESCRIPTION
FU-3
GENERAL DESCRIPTION
B: COMPONENT
1. INTAKE MANIFOLD
(25)
T7 (2) (26)
T4
(21)
T3
(4) T7
(3) T5
T7
(5) (8) (9)
(6)
T8
(2)
T6
(7)
T3
(27) T2
(14)
T7 (10)
T7
T6 (21)
T8 (4)
(15) (3)
(5)
T8 (6)
(17)
(1) T8
(24)
(11)
(23)
T3 T8
T7
T7
T4
(22) T3
(28) (16)
(20) T1
T3
T1 T1 (19)
(19) (12) (24)
T1
(13)
(20) (18)
T1
T1
(20)
T7
T3
(19)
EN1383
FU-4
GENERAL DESCRIPTION
(1) Intake manifold gasket RH (15) O-ring (28) Accelerator cable bracket
(2) Fuel injector pipe (16) Plug cord holder LH
(3) Fuel injector (17) Fuel pipe protector RH Tightening torque: N·m (kgf-m, ft-lb)
(4) O-ring (18) Fuel pipe ASSY T1: 1.5 (0.15, 1.1)
(5) O-ring (19) Fuel hose T2: 3.4 (0.35, 2.5)
(6) O-ring (20) Clip T3: 5.0 (0.51, 3.7)
(7) Plug (21) Clip T4: 6.4 (0.65, 4.7)
(8) PCV valve (22) Air assist injector solenoid valve T5: 7.4 (0.75, 5.4)
(9) Purge control solenoid valve (23) Air assist injector solenoid valve T6: 17(1.7, 12.5)
(10) Nipple bracket T7: 19 (1.9, 14.0)
(11) Intake manifold (24) Guide pin T8: 25 (2.5, 18.4)
(12) Intake manifold gasket LH (25) Atmospheric pressure sensor
(13) Fuel pipe protector LH bracket
(14) Intake air temperature and pres- (26) Atmospheric pressure sensor
sure sensor (27) Plug cord holder RH
FU-5
GENERAL DESCRIPTION
2. AIR INTAKE SYSTEM
B2M3455C
(1) Gasket (4) Throttle body Tightening torque: N·m (kgf-m, ft-lb)
(2) Throttle position sensor T1: 1.6 (0.16, 1.2)
(3) Idle air control solenoid valve T2: 22 (2.2, 16.2)
FU-6
GENERAL DESCRIPTION
3. CRANKSHAFT POSITION, CAMSHAFT POSITION AND KNOCK SENSORS
B2M2282B
(1) Crankshaft position sensor (3) Camshaft position sensor Tightening torque: N·m (kgf-m, ft-lb)
(2) Knock sensor (4) Camshaft position sensor support T1: 6.4 (0.65, 4.7)
T2: 24 (2.4, 17.4)
FU-7
GENERAL DESCRIPTION
4. FUEL TANK
• 1600 CC and 2000 CC MODEL
T1
T1
(25)
(16)
(9) D
(8) (10) (11)

(6) D (11)
C
B (11)
A (14)
(13)
(7) (24)
T1 (12) (24)
(11)
C
(9) (11)
(8)
(5) (15)
B
(11)
(17)
(19) (18) (20)
A
(4) (11)
(21)
(11)
(22)
(2)
T3 (18)
T3
(19)
(11)
(23)
(3)
(2)
T2
T2
(1)
T2
EN0439
FU-8
GENERAL DESCRIPTION
(1) Heat shield cover (11) Clip (21) Fuel pipe ASSY
(2) Fuel tank band (12) Evaporation hose B (22) Evaporation hose F
(3) Protector RH (13) Joint pipe (23) Fuel return hose B
(4) Fuel tank (14) Evaporation hose C (24) Evaporation hose G
(5) Fuel pump gasket (15) Evaporation pipe ASSY (25) Evaporation hose H
(6) Fuel pump ASSY (16) Evaporation pipe
(7) Fuel meter unit (17) Evaporation hose D Tightening torque: N·m (kgf-m, ft-lb)
(8) Fuel cut valve gasket (18) Retainer T1: 4.4 (0.45, 3.3)
(9) Fuel cut valve (19) Quick connector T2: 7.4 (0.75, 5.4)
(10) Evaporation hose A (20) Evaporation hose E T3: 33 (3.4, 24.3)
FU-9
GENERAL DESCRIPTION
• 2500 CC MODEL
T1
T1
(30)
(17)
(10) E
(9) (11) (12)

(7) D (12)
C
B (12)
A (15)
T1 (14)
(8) (29)
(13) (29)
(12)
T1
D
(9) (12)
(8)
(28)
(6) (16)
E
B (12)
(12)
(18)
(21) (20) (22)
(19) A
(5) (27)
(12)
(12)
(26)
(23) F
(12)
(24)
(2)
T3 (20)
T3
(12)
(25)
(4)
(2)
T2
T2
(1)
(3) T2
T2
EN1503
FU-10
GENERAL DESCRIPTION
(1) Heat shield cover (13) Evaporation hose B (25) Fuel return hose B
(2) Fuel tank band (14) Joint pipe (26) Fuel sub meter gasket
(3) Protector LH (15) Evaporation hose C (27) Jet pump filter
(4) Protector RH (16) Evaporation pipe ASSY (28) Fuel sub meter unit
(5) Fuel tank (17) Evaporation pipe (29) Evaporation hose G
(6) Fuel pump gasket (18) Evaporation hose D (30) Evaporation hose H
(7) Fuel pump ASSY (19) Fuel return hose A
(8) Fuel meter unit (20) Retainer Tightening torque: N·m (kgf-m, ft-lb)
(9) Fuel cut valve gasket (21) Quick connector T1: 4.4 (0.45, 3.3)
(10) Fuel cut valve (22) Evaporation hose E T2: 7.4 (0.75, 5.4)
(11) Evaporation hose A (23) Fuel pipe ASSY T3: 33 (3.4, 24.3)
(12) Clip (24) Evaporation hose F
FU-11
GENERAL DESCRIPTION
5. FUEL LINE
(19)
(18)
B
(24) (20) (17)
A (16)
(25) (15)
(24)
(22)
(21) (13)
T
(23) (14)
B
(1) (1)
C
A C
(12)
(8)
(1) (1) (10)

(9) (1)
(1)
(1)
(1)
(10) (11)
(7)
(1)
(6) (2)
(1)
(5)
(4)
(3)
EN0440
FU-12
GENERAL DESCRIPTION
(1) Clip (11) Fuel pipe ASSY (21) Two-way valve drain hose A
(2) Fuel delivery hose A (12) Grommet (22) Connector
(3) Fuel filter bracket (13) Canister hose A (23) Two-way valve drain hose B
(4) Fuel filter holder (14) Canister (24) Clamp
(5) Fuel filter cup (15) Canister bracket plate (25) Front canister bracket
(6) Fuel filter (16) Cushion
(7) Evaporation hose (17) Canister bracket spacer Tightening torque: N·m (kgf-m, ft-lb)
(8) Fuel damper (18) Rear canister bracket T: 23 (2.3, 17.0)
(9) Fuel delivery hose B (19) Two-way valve return hose
(10) Fuel return hose (20) Two-way valve
FU-13
GENERAL DESCRIPTION
6. FUEL FILLER PIPE
(9)
(8)
(10)
(11)
(1)
(3)
T
(5) (2)
T
(3)
(6)
T
(4)
(3)
(7)
EN0441
(1) Fuel filler pipe ASSY (6) Air vent pipe (11) Filler pipe protector
(2) Evaporation hose holder (7) Air vent pipe holder
(3) Clip (8) Filler pipe packing Tightening torque: N·m (kgf-m, ft-lb)
(4) Clamp (9) Filler ring T: 7.5 (0.76, 5.53)
(5) Air vent hose (10) Filler cap
FU-14
GENERAL DESCRIPTION
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. nuts to the specified torque.
• Remove contamination including dirt and corro- • Place shop jacks or safety stands at the specified
sion before removal, installation or disassembly. points.
• Keep the disassembled parts in order and pro- • Before disconnecting electrical connectors of
tect them from dust or dirt. sensors or units, be sure to disconnect the ground
• Before removal, installation or disassembly, be cable from battery.
sure to clarify the failure. Avoid unnecessary re- • Place “NO FIRE” signs near the working area.
moval, installation, disassembly, and replacement. • Be careful not to spill fuel on the floor.
D: PREPARATION TOOL
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
24082AA190 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)
B2M3877
FU-15
THROTTLE BODY
2. Throttle Body 6) Disconnect the air by-pass hose from air assist
injector solenoid valve.
A: REMOVAL
1) Disconnect the ground cable from battery.
B2M3457A
G6M0095 (A) Throttle position sensor

(B) Idle air control solenoid valve
2) Remove the air cleaner case.
(C) Air by-pass hose from air assist injector sole-
noid valve
7) Disconnect the engine coolant hoses from throt-

tle body.
H2M2947
3) Disconnect the accelerator cable (A).

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

intake manifold.
B: INSTALLATION
Install in the reverse order of removal.
NOTE:
Always use a new gasket.
Tightening torque:
Throttle body;
B2M4254A
22 N·m (2.2 kgf-m, 16.2 ft-lb)
5) Disconnect the connectors from idle air control Air cleaner case;
solenoid valve and throttle position sensor. 6.5 N·m (0.66 kgf-m, 4.8 ft-lb)
FU-16
INTAKE MANIFOLD
3. Intake Manifold (3) Remove the bolts which hold power steering
pipes onto intake manifold protector.
A: REMOVAL NOTE:
1) Release the fuel pressure. Do not disconnect the power steering hose.
<Ref. to FU-54, RELEASING OF FUEL PRES-
SURE, OPERATION, Fuel.>
2) Open the fuel flap lid and remove fuel filler cap.
B2M4126
(4) Remove the bolts which install power steer-

ing pump bracket.
G6M0095
4) Remove the air intake duct and air cleaner as-

sembly.
<Ref. to IN-7, REMOVAL, Air Intake Duct.> and
<Ref. to IN-6, REMOVAL, Air Cleaner Case.>
B2M3151
(5) Disconnect the connector from power steer-

ing pump switch.
B2M4254A
7) Remove the power steering pump and tank from

brackets.
(1) Remove the resonator chamber.
<Ref. to IN-8, REMOVAL, Resonator Cham- EN0360
ber.>
(2) Remove the front side V-belt. (6) Remove the power steering tank from the
<Ref. to ME-44, REMOVAL, V-belt.> bracket by pulling it upwards.
EN0361
FU-17
INTAKE MANIFOLD
(7) Place the power steering pump and tank on 12) Remove the air cleaner case stay RH and en-
right side wheel apron. gine harness bracket, and disconnect the engine
harness connectors from bulkhead harness con-
nectors.
EN0208
8) Disconnect the spark plug cords from spark B2M4260

plugs.
9) Disconnect the PCV hose from intake manifold. 13) Disconnect the connectors from engine coolant
temperature sensor.
B2M4258
B2M4261
10) Disconnect the engine coolant hose from throt-
tle body. 14) Disconnect the knock sensor connector.
B2M4255 B2M4262
11) Disconnect the brake booster hose. 15) Disconnect the connector from crankshaft posi-
tion sensor.
B2M4259
B2M1252
FU-18
INTAKE MANIFOLD
16) Disconnect the connector from oil pressure 19) Remove the bolts which hold intake manifold
switch. onto cylinder heads.
B2M1253 B2M4128
17) Disconnect the connector from camshaft posi- 20) Remove the intake manifold.
tion sensor.
B2M0160
B2M4263
B: INSTALLATION
18) Disconnect the fuel hoses from fuel pipes. 1) Install the intake manifold onto cylinder heads.
WARNING: NOTE:
• Do not spill fuel. Always use new gaskets.
• Catch the fuel from hoses in a container or
cloth. Tightening torque:
25 N·m (2.5 kgf-m, 18.4 ft-lb)
S2M0500F
B2M4128
(A) Fuel delivery hose
(B) Return hose
(C) Evaporation hose
FU-19
INTAKE MANIFOLD
2) Connect the fuel hoses. 6) Connect the knock sensor connector.
S2M0500F B2M4262
7) Connect the connectors to engine coolant tem-

perature sensor.
(B) Return hose
3) Connect the connector to camshaft position sen-

sor.
B2M4261
8) Install the air cleaner case stay RH and engine

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

B2M1253
5) Connect the connector to crankshaft position

sensor.
B2M4259
B2M1252
FU-20
INTAKE MANIFOLD
10) Connect the engine coolant hose to throttle (3) Tighten the bolts which install power steer-
body. ing pump on bracket.
Tightening torque:
22 N·m (2.2 kgf-m, 16.2 ft-lb)
B2M4255
11) Connect the PCV hose to intake manifold.

B2M3151
(4) Install the power steering pipes onto right

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

13) Install the power steering pump and tank on
brackets. B2M4126
(1) Install the power steering tank on bracket.
(5) Install the front side V-belt.
<Ref. to ME-44, INSTALLATION, V-belt.>
(6) Install the resonator chamber.
Tightening torque:
33 N·m (3.4 kgf-m, 24.3 ft-lb)
EN0361
(2) Connect the connector to power steering

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

cruise control models) 1) Disconnect the engine ground cable from intake
manifold.
B2M4254A
16) Install the air intake duct and air cleaner as- B2M4265
sembly. 2) Disconnect the connector from ignition coil and

<Ref. to IN-7, INSTALLATION, Air Intake Duct.> ignitor assembly.
and <Ref. to IN-6, INSTALLATION, Air Cleaner
Case.>
17) Connect the connector to fuel pump relay.
B2M3472
3) Remove the ignition coil and ignitor assembly.

EN0344
18) Connect the battery ground cable to battery.
B2M3473
4) Disconnect the connector from intake air tem-

G6M0095 perature and pressure sensor.
B2M3474
FU-22
INTAKE MANIFOLD
5) Remove the intake air temperature and pressure 10) Disconnect the air by-pass hoses from air as-
sensor from intake manifold. sist solenoid valve.
B2M3475 B2M4266
6) Disconnect the connectors from throttle position 11) Remove the air assist injector solenoid valve
sensor and idle air control solenoid valve. from intake manifold.
B2M3479 B2M3478
7) Disconnect the air by-pass hose from throttle 12) Disconnect the pressure regulator vacuum
body. hose from intake manifold.
B2M3480 H2M2961
8) Remove the throttle body. 13) Remove the fuel pipe protector LH.
H2M2951 B2M4129
9) Disconnect the connector from air assist injector

solenoid valve.
FU-23
INTAKE MANIFOLD
14) Remove the fuel pipe protector RH. 20) Remove the purge control solenoid valve.
B2M4130 B2M3487
15) Disconnect the connectors from fuel injectors. 21) Remove the bolt which installs injector pipe on
intake manifold as shown in the figure.
B2M4270
H2M2965
16) Disconnect the connector from purge control
solenoid valve. 22) Remove the bolt which installs injector pipe on
intake manifold.
B2M3485
H2M2966
17) Disconnect the air by-pass hose from purge
control solenoid valve. 23) Remove the two bolts which hold fuel pipes on
18) Remove the harness bands (A) and harness the left side of intake manifold.
bracket (B) which hold engine harness onto intake
manifold.
B2M4272
B2M4271A
19) Remove the engine harness from intake mani-

fold.
FU-24
INTAKE MANIFOLD
24) Remove the fuel injectors. 27) Loosen the clamp which holds front right side
(1) Remove the fuel injector securing clip. fuel hose to injector pipe, and remove the pipe from
fuel hose.
B2M3488
B2M4274
(2) Remove the fuel injector while lifting up the
fuel injector pipe. 28) Remove the fuel injector pipe.
H2M2970 H2M2975
25) Disconnect the air by-pass hoses from intake 29) Remove the bolt which installs fuel pipes on in-
manifold. take manifold.
B2M4149A B2M3491
26) Loosen the clamp which holds front left side 30) Remove the fuel pipe assembly and pressure
fuel hose to injector pipe, and remove the pipe from regulator from intake manifold.
fuel hose.
B2M4273
FU-25
INTAKE MANIFOLD
D: ASSEMBLY 5) Connect the left side fuel hose to injector pipe,

1) Install the fuel pipe assembly and pressure reg- and tighten the clamp screw.
ulator, etc. to intake manifold.
2) Tighten the bolt which installs fuel pipes on in-
take manifold.
Tightening torque:
5.0 N·m (0.51 kgf-m, 3.7 ft-lb)
B2M4273
6) Connect the air assist hoses.
B2M3491
3) Connect the right side fuel hose to injector pipe,

and tighten the clamp screw.
B2M4149A
B2M4274
4) Install the fuel injector pipe.
H2M2975
FU-26
INTAKE MANIFOLD
7) Install the fuel injectors. 9) Tighten the two bolts which install fuel pipes on
NOTE: the left side of intake manifold.
Always use new O-rings. Tightening torque:
5.0 N·m (0.51 kgf-m, 3.7 ft-lb)
B2M3492G
B2M4272
(A) O-ring
(B) Fuel injector
10) Tighten the bolt which installs injector pipe on
intake manifold.
NOTE: Tightening torque:
Do not forget to install the fuel injector securing clip. 5.0 N·m (0.51 kgf-m, 3.7 ft-lb)
B2M3488
H2M2966
8) Tighten the bolt which installs injector pipe on in- 11) Install the purge control solenoid valve.
take manifold.
Tightening torque:
5.0 N·m (0.51 kgf-m, 3.7 ft-lb)
B2M3487
H2M2965
FU-27
INTAKE MANIFOLD
12) Connect the hoses to purge control solenoid 16) Install the fuel pipe protector RH.
valve.
Tightening torque:
CAUTION: 19 N·m (1.9 kgf-m, 14.0 ft-lb)
Carefully connect the evaporation hoses.
B2M4130
B2M1893E
17) Install the fuel pipe protector LH.
(A) To fuel pipe Tightening torque:
(B) To intake manifold 19 N·m (1.9 kgf-m, 14.0 ft-lb)
13) Install the engine harness onto intake manifold.
Tightening torque:
16 N·m (1.6 kgf-m, 11.8 ft-lb)
14) Connect the connectors to fuel injectors and
purge control solenoid valve.
15) Hold the engine harness by harness band (A)
and harness bracket (B).
B2M4129
18) Connect the pressure regulator vacuum hose

to intake manifold.
B2M4271A
NOTE:
Do not use the harness band on harnesses where
they are supposed to be protected by the fuel pipe
protector.
H2M2961
FU-28
INTAKE MANIFOLD
19) Install the air assist injector solenoid valve to 23) Connect the connector to throttle position sen-
bracket. sor and idle air control solenoid valve.
Tightening torque:
5.0 N·m (0.51 kgf-m, 3.7 ft-lb)
B2M3479
24) Connect the air by-pass hose to throttle body.

B2M3478
20) Connect the air by-pass hoses to air assist so-

lenoid valve.
B2M3480
25) Install the intake air temperature and pressure

sensor.
B2M4266
Tightening torque:
21) Connect the connector to air assist solenoid 3.4 N·m (0.35 kgf-m, 2.5 ft-lb)
valve.
22) Install the throttle body to intake manifold.
NOTE:
Replace the gasket with a new one.
Tightening torque:
22 N·m (2.2 kgf-m, 16.2 ft-lb)
B2M3475
NOTE:
Replace the O-ring with a new one.
H2M2951
H2M2999
FU-29
INTAKE MANIFOLD
26) Connect the connector to intake air tempera-

ture and pressure sensor.
27) Install the ignition coil and ignitor assembly.
B2M3473
28) Connect the connector to ignition coil and igni-

tor assembly.
29) Install the engine ground cable to intake mani-
fold.
Tightening torque:
19 N·m (1.9 kgf-m, 14.0 ft-lb)
B2M2779
E: INSPECTION
Make sure the fuel pipe and fuel hoses are not
cracked and that connections are tight.
FU-30
ENGINE COOLANT TEMPERATURE SENSOR
4. Engine Coolant Temperature B: INSTALLATION

Sensor Install in the reverse order of removal.
Tightening torque:
A: REMOVAL 16 N·m (1.6 kgf-m, 11.8 ft-lb)
B2M4275
G6M0095

sembly.
3) Disconnect the connector from engine coolant
temperature sensor.
B2M4261
4) Remove the engine coolant temperature sensor.
FU-31
CRANKSHAFT POSITION SENSOR
5. Crankshaft Position Sensor B: INSTALLATION

A: REMOVAL
1) Disconnect the ground cable from battery. Tightening torque:
T: 6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
G6M0095
B2M1252B
2) Remove the bolt which installs crankshaft posi-
tion sensor to cylinder block.
G2M0408
3) Remove the crankshaft position sensor, and dis-

connect the connector from it.
G2M0409
FU-32
CAMSHAFT POSITION SENSOR
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.
B2M2322
G6M0095
B: INSTALLATION
2) Disconnect the connector from camshaft posi- Install in the reverse order of removal.
tion sensor.
Tightening torque:
Camshaft position sensor support;
6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
Camshaft position sensor;
6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
B2M4263
3) Remove the bolt which installs camshaft position

sensor to camshaft position sensor support.
B2M2375

sensor support to camshaft cap LH.
B2M2321
FU-33
KNOCK SENSOR
7. Knock Sensor B: INSTALLATION

1) Install the knock sensor to cylinder block.
A: REMOVAL
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 engine rear.
G6M0095
H2M3511C
2) Connect the knock sensor connector.
H2M2947
3) Disconnect the knock sensor connector.
B2M4262
3) Install the air cleaner case.
B2M4262
4) Remove the knock sensor from cylinder block.
H2M2947
S2M1673
G6M0095
FU-34
THROTTLE POSITION SENSOR
8. Throttle Position Sensor B: INSTALLATION

A: REMOVAL
1.6 N·m (0.16 kgf-m, 1.2 ft-lb)
CAUTION:
When installing the throttle position sensor, ad-
just to the specified data.
G6M0095
2) Disconnect the connector from throttle position

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

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

(1) Take out the ECM.
(2) Turn the ignition switch to ON.
(3) Adjust the throttle position sensor to proper
position to allow the voltage signal to ECM to be
H2M2979 in specification.
Connector & terminal/Specified voltage
(B136) No. 15 — (B136) No. 17/0.45 — 0.55 V
[Fully closed.]
B2M4131A
FU-35
(4) Tighten the throttle position sensor holding (4) Connect the Subaru Select Monitor to data
screws. link connector.
Tightening torque:
1.6 N·m (0.16 kgf-m, 1.2 ft-lb)
B2M3148
5) Turn the ignition switch to ON, and Subaru Se-

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

Pressure Sensor Install in the reverse order of removal.
Tightening torque:
A: REMOVAL 3.4 N·m (0.35 kgf-m, 2.5 ft-lb)
B2M3497
G6M0095
2) Disconnect the spark plug cord from ignition coil NOTE:

and ignitor assembly. Replace the O-ring with a new one.
B2M3495 H2M2999

perature and pressure sensor.
B2M4276
4) Remove the intake air temperature and pressure

sensor.
B2M3497
FU-37
ATMOSPHERIC PRESSURE SENSOR
10.Atmospheric Pressure Sen- B: INSTALLATION

sor Install in the reverse order of removal.
Tightening torque:
EN1001
G6M0095
2) Disconnect the connector from atmospheric

pressure sensor.
3) Remove the atmospheric pressure sensor from
bracket.
EN1001
FU-38
IDLE AIR CONTROL SOLENOID VALVE
11.Idle Air Control Solenoid B: INSTALLATION

Valve Install in the reverse order of removal.
NOTE:
A: REMOVAL Always use a new gasket.
Tightening torque:
1.6 N·m (0.16 kgf-m, 1.2 ft-lb)
G6M0095
2) Disconnect the connector from idle air control B2M3501

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

throttle body.
B2M3501
FU-39
AIR ASSIST INJECTOR SOLENOID VALVE
12.Air Assist Injector Solenoid B: INSTALLATION

Tightening torque:
B2M3503
G6M0095
2) Disconnect the connector from air assist injector

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

from intake manifold.
B2M3503
FU-40
FUEL INJECTOR
13.Fuel Injector (3) Remove the bolts which install power steer-
ing pump to bracket.
A: REMOVAL
1. RH SIDE
1) Release the fuel pressure.
2) Open the fuel filler flap lid and remove fuel filler
cap.
B2M3151

ing pump switch.
G6M0095
4) Remove the resonator chamber.

<Ref. to IN-8, REMOVAL, Resonator Chamber.>
5) Remove the spark plug cords from spark plugs
EN0360
(#1 and #3 cylinders).
(5) Remove the power steering tank from the
bracket by pulling it upwards.
B2M4127

EN0361
brackets.
(1) Remove the front side V-belt. (6) Place the power steering pump and tank on
<Ref. to ME-44, REMOVAL, V-belt.> the right side wheel apron.
(2) Remove the bolts which hold power steering
EN0208
B2M4126
FU-41
FUEL INJECTOR
7) Remove the fuel pipe protector RH. 10) Remove the fuel injector from intake manifold.
(1) Remove the fuel injector securing clip.
B2M4130
B2M4283
8) Disconnect the connector from fuel injector.
fuel injector pipe.
B2M4280
9) Remove the bolts which hold injector pipe to in-

B2M3509
take manifold.
B2M4281
B2M4282
FU-42
FUEL INJECTOR
2. LH SIDE 8) Move the washer tank, and secure it away from

working area.
cap.
B2M3140

G6M0095
4) Remove the two bolts which install washer tank

on body.
B2M4287
10) Remove the fuel pipe protector LH.
B2M3139
5) Disconnect the connector from front window

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

from washer motor, then plug connection with a
suitable cap. B2M4294
FU-43
FUEL INJECTOR
12) Remove the bolt which installs injector pipe to (2) Remove the fuel injector while lifting up the
intake manifold. fuel injector pipe.
B2M4133 H2M3241
B: INSTALLATION
1. RH SIDE
NOTE:
Replace the O-rings with a new one.
H2M2994
13) Remove the bolt which holds fuel pipe on the

left side intake manifold.
B2M3492G
(A) O-ring
(B) Fuel injector
Tightening torque:
5.0 N·m (0.51 kgf-m, 3.7 ft-lb)
H2M2995
14) Remove the fuel injector from intake manifold.

B2M4282
H2M2997
FU-44
FUEL INJECTOR
Tightening torque: 2. LH SIDE

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

1) Before installing the front oxygen (A/F) sensor,
A: REMOVAL apply anti-seize compound only to the threaded
1) Disconnect the ground cable from battery. portion of front oxygen (A/F) sensor to make the
next removal easier.
Anti-seize compound:
SS-30 by JET LUBE
CAUTION:
Never apply anti-seize compound to the protec-
tor of front oxygen (A/F) sensor.
G6M0095
2) Disconnect the connector from front oxygen (A/

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

Tightening torque:
21 N·m (2.1 kgf-m, 15.2 ft-lb)
B2M4243
3) Lift-up the vehicle.

4) Apply SUBARU CRC or its equivalent to the
threaded portion of front oxygen (A/F) sensor, and
leave it for 1 minute or more.
SUBARU CRC (Part No. 004301003)
5) Remove the front oxygen (A/F) sensor.
CAUTION: G2M0411
When removing the oxygen (A/F) sensor, wait
until the exhaust pipe cools, otherwise it will 3) Lower the vehicle.
damage exhaust pipe. 4) Connect the connector of front oxygen (A/F)
sensor.
G2M0411
B2M4243
FU-47
G6M0095
FU-48
REAR OXYGEN SENSOR
15.Rear Oxygen Sensor B: INSTALLATION

1) Before installing the rear oxygen sensor, apply
A: REMOVAL anti-seize compound only to the threaded portion of
1) Disconnect the ground cable from battery. rear oxygen sensor to make the next removal eas-
ier.
SS-30 by JET LUBE
CAUTION:
tor of rear oxygen sensor.
G6M0095
2) Disconnect the connector from rear oxygen sen-

sor.
B2M0742A
2) Install the rear oxygen sensor.

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

threaded portion of rear oxygen sensor, and leave
it for 1 minute or more.
5) Remove the rear oxygen sensor.
CAUTION: B2M0741
When removing the oxygen sensor, wait until
the exhaust pipe cools, otherwise it will dam- 3) Lower the vehicle.
age exhaust pipe. 4) Connect the connector to rear oxygen sensor.
B2M0741 B2M4244
FU-49
REAR OXYGEN SENSOR
G6M0095
FU-50
ENGINE CONTROL MODULE
16.Engine Control Module B: INSTALLATION

A: REMOVAL
1) Disconnect the ground cable from battery. CAUTION:
When replacing the ECM, be careful not to use
the wrong spec. ECM to avoid any damage to
fuel injection system.
G6M0095
2) Remove the lower inner trim of passenger side.

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

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

the ECM.
FU-51
MAIN RELAY
17.Main Relay B: INSTALLATION

A: REMOVAL
G6M0095
2) Remove the passenger’s side front side sill cov-

er.
3) Remove the bolt which holds main relay bracket
on body.
4) Disconnect the connectors from main relay.
EN0534
FU-52
FUEL PUMP RELAY
18.Fuel Pump Relay B: INSTALLATION

A: REMOVAL
G6M0095

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

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

Set a container under the vehicle and remove the
A: OPERATION drain plug from fuel tank.
• 1600 cc and 2000 cc MODEL
1. RELEASING OF FUEL PRESSURE
WARNING:
• Place “NO FIRE” signs near the working area.
• Be careful not to spill fuel on the floor.
EN0999
• 2500 cc MODEL
EN0344
2) Start the engine and run it until it stalls.

3) After the engine stalls, crank it for 5 more sec-
onds.
2. DRAINING FUEL
EN0839
WARNING:
• Place “NO FIRE” signs near the working area. 6) Tighten the fuel drain plug.
• Be careful not to spill fuel on the floor. Tightening torque:
1) Set the vehicle on a lift. 26 N·m (2.7 kgf-m, 19.2 ft-lb)
2) Disconnect the ground cable from battery. • 1600 cc and 2000 cc MODEL
G6M0095 EN0999
3) Open the fuel filler flap lid and remove fuel filler • 2500 cc MODEL
cap.
EN0839
FU-54
FUEL TANK
20.Fuel Tank 9) Loosen the clamp and disconnect the fuel filler
hose and air vent hose from fuel filler pipe.
A: REMOVAL
WARNING:
1) Set the vehicle on a lift.
3) Drain fuel from the fuel tank.
<Ref. to FU-54, DRAINING FUEL, OPERATION, EN0539
Fuel.>
4) Remove the rear seat. 10) Move the clips, and disconnect quick connec-
5) Disconnect the connector (A) of fuel tank cord to tor.
rear harness. <Ref. to FU-71, REMOVAL, Fuel Delivery, Return
6) Push the grommet (B) which holds fuel tank cord and Evaporation Lines.>
on floor panel into under the body. 11) Disconnect the fuel hoses.
(B)
(A) EN0540
EN0537
7) Remove the rear crossmember. <Ref. to RS-21, 12) Support the fuel tank with transmission jack,
REMOVAL, Rear Crossmember.> and remove the bolts from bands and dismount fuel
8) Disconnect the two-way valve hose (A) from tank from the vehicle.
two-way valve and disconnect the canister hose (B) WARNING:
from canister. A helper is required to perform this work.
(A) (B)
EN0840
EN0541
FU-55
FUEL TANK
B: INSTALLATION 5) Connect the fuel hoses, and secure them with

1) Support the fuel tank with transmission jack and clips and quick connector.
push the fuel tank harness into access hole with <Ref. to FU-73, INSTALLATION, Fuel Delivery,
grommet. Return and Evaporation Lines.>
2) Set the fuel tank and temporarily tighten the
bolts of fuel tank bands.
WARNING:
A helper is required to perform this work.
EN0540
6) Tighten the band mounting bolts.

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

valve and connect the canister hose (B) to canister.
(A) (B)
EN0541
7) Install the rear crossmember. <Ref. to RS-21,

INSTALLATION, Rear Crossmember.>
EN0840
8) Connect the connector (A) to fuel tank cord and
4) Connect the fuel filler hose and air vent hose. plug the service hole with gromment (B).
(B)
(A)
EN0539 EN0537
9) Set the rear seat and floor mat.
FU-56
FUEL TANK
EN0344
C: INSPECTION
1) Make sure there are no cracks, holes, or other
damage on the fuel tank.
2) Make sure that the fuel hoses and fuel pipes are
not cracked and that connections are tight.
FU-57
FUEL FILLER PIPE
21.Fuel Filler Pipe 9) Drain fuel from the fuel tank. Set a container un-
der the vehicle and remove the drain plug from fuel
A: REMOVAL tank.
WARNING: • 1600 cc and 2000 cc MODEL
cap.
EN0999
• 2500 cc MODEL
G6M0095
5) Remove the screws holding packing in place.

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

8) Remove the rear right side wheel.
EN0999
• 2500 cc MODEL
B2M1748
EN0839
FU-58
FUEL FILLER PIPE
11) Remove the fuel filler pipe protector. 16) Move the clip and separate air vent hose (B).
(A)
(B)
EN0544 EN0548
12) Separate the evaporation hoses from clip of 17) Remove the fuel filler pipe to under side of the
fuel filler pipe. vehicle.
18) Remove the air vent pipe together with clip
from body.
EN0545
13) Disconnect the air vent hose from fuel filler EN0549
pipe.
B: INSTALLATION
1) Hold the fuel filler flap open.
2) Set the fuel saucer (A) with rubber packing (C)
and insert the fuel filler pipe into hole from the inner
side of apron.
3) Align the holes in fuel filler pipe neck and set cup
(B), and tighten the screws.
NOTE:
If the edges of rubber packing are folded toward in-
EN0546 side, straighten it with a screwdriver.
14) Remove the bolt which holds fuel filler pipe
bracket on body.
B2M1196A
EN0547
15) Loosen the clamp and separate fuel filler hose

(A) from fuel filler pipe.
FU-59
FUEL FILLER PIPE
4) Install the air vent pipe. 7) Insert the air vent hose approx. 25 to 30 mm
(0.98 to 1.18 in) into the lower end of air vent pipe
and hold clip.
L = 27.5±2.5 mm (1.083±0.098 in)
EN0549
5) Connect the air vent hose to fuel filler pipe.
B2M1195A
(1) Hose
(2) Clip
(3) Pipe
8) Tighten the bolt which holds fuel filler pipe brack-

et on body.
EN0546
Tightening torque:
7.5 N·m (0.75 kgf-m, 5.4 ft-lb)
6) Insert the fuel filler hose (A) approx. 35 to 40 mm
(1.38 to 1.57 in) over the lower end of fuel filler pipe
and tighten the clamp.
CAUTION:
Do not allow clips to touch the air vent hose (B)
and rear suspension crossmember.
(A)
(B) EN0547
9) Tighten the bolts which hold evaporation hoses

onto clip of fuel filler pipe.
EN0548
EN0545
FU-60
FUEL FILLER PIPE
10) Install the fuel filler pipe protector.
EN0544
11) Install the rear right wheel.
B2M1748
12) Lower the vehicle.

13) Tighten the wheel nuts.
EN0344
G6M0095
FU-61
FUEL PUMP
22.Fuel Pump 6) Tighten the fuel drain plug.
A: REMOVAL Tightening torque:

26 N·m (2.7 kgf-m, 19.2 ft-lb)
WARNING:
NOTE:
Fuel pump assembly consists of fuel pump and fuel
level sensor.
SURE, OPERATION, Fuel.> EN0999
cap. 7) Raise the rear seat and turn floor mat up.
3) Disconnect the ground cable from battery. 8) Remove the access hole lid.
EN0553
G6M0095
4) Lift-up the vehicle. 9) Disconnect the connector from fuel pump.

5) Drain fuel from the fuel tank. Set a container un-
tank.
EN0554
10) Disconnect the quick connector and then dis-

connect fuel delivery hose (A).
EN0999
<Ref. to FU-71, REMOVAL, Fuel Delivery, Return
and Evaporation Lines.>
FU-62
FUEL PUMP
11) Move the clip and then disconnect the fuel re- 5) Drain fuel from the fuel tank. Set a container un-
turn hose (B). der the vehicle and remove the drain plug from fuel
tank.
(A)
(B)
EN0555
EN0839
12) Remove the nuts which install fuel pump as-
sembly onto fuel tank. 6) Tighten the fuel drain plug.
Tightening torque:
26 N·m (2.7 kgf-m, 19.2 ft-lb)
EN0556
13) Take off the fuel pump assembly from fuel tank.
• 2500 cc MODEL EN0839
1) Release the fuel pressure. <Ref. to FU-54, RE- 7) Raise the rear seat and turn floor mat up.
LEASING OF FUEL PRESSURE, OPERATION, 8) Remove the access hole lid.
Fuel.>
cap.
EN0553
9) Disconnect the connector from fuel pump.
G6M0095
S2M0172
FU-63
FUEL PUMP
10) Disconnect the quick connector and then dis- • 2500 cc MODEL
connect fuel delivery hose (A). <Ref. to FU(TUR-
BO)-68, Fuel Delivery, Return and Evaporation
Lines.>
11) Move the clips, and then disconnect the fuel re-
turn hose (B) and jet pump hose (C).
S2M0063A
C: INSPECTION
Connect the lead harness to connector terminal of
fuel pump and apply battery power supply to check
S2M0060A whether the pump operates.
12) Remove the nuts which install fuel pump as- WARNING:
sembly onto fuel tank. • Wipe off the fuel completely.
• Keep the battery as far apart from fuel pump
as possible.
• Be sure to turn the battery supply ON and
OFF on battery side.
• Do not run the fuel pump for a long time un-
der non-load condition.
S2M0061
3 2 1
6 5 4
B: INSTALLATION
Install in the reverse order of removal. Do the fol-
lowing:
EN1502
(1) Always use new gaskets.
(2) Ensure sealing portion is free from fuel or for-
eign particles before installation.
(3) Tighten the nuts in alphabetical sequence
shown in the figure to specified torque.
Tightening torque:
4.4 N·m (0.45 kgf-m, 3.3 ft-lb)
(C) (A) (E)
(H)
(G)
(F) (B) (D)

EN0557
FU-64
FUEL LEVEL SENSOR
23.Fuel Level Sensor 3) Remove the bolt which installs fuel level sensor
on mounting bracket.
A: REMOVAL • 1600 cc and 2000 cc MODEL
WARNING:
;;;;
;
;
NOTE:
Fuel level sensor is built in the fuel pump assembly.
1) Remove the fuel pump assembly.
<Ref. to FU-62, REMOVAL, Fuel Pump.>
2) Disconnect the connector from fuel pump brack-
et.
• 1600 cc and 2000 cc MODEL EN0560
• 2500 cc MODEL
EN0559

S2M0145
B: INSTALLATION
S2M0145
FU-65
FUEL SUB LEVEL SENSOR
24.Fuel Sub Level Sensor 6) Remove the service hole cover.
A: REMOVAL
NOTE:
Fuel sub level sensor is equipped to only 2500 cc
model.
WARNING:
G2M0863
7) Disconnect the connector from fuel sub meter.

8) Disconnect the fuel jet pump hose.
G6M0095

der the vehicle and remove the drain plug from fuel S2M0151
tank.
9) Remove the bolts which install fuel sub meter
unit on fuel tank.
EN0839
4) Tighten the fuel drain plug. S2M0152
Tightening torque: 10) Remove the fuel sub meter unit.

26 N·m (2.7 kgf-m, 19.2 ft-lb)
S2M0153
EN0839
5) Remove the rear seat.
FU-66
B: INSTALLATION
Tightening torque:
4.4 N·m (0.45 kgf-m, 3.3 ft-lb)
B2M3178
FU-67
FUEL FILTER
25.Fuel Filter
A: REMOVAL
WARNING:
2) Disconnect the fuel delivery hoses from fuel fil-
ter.
S2M0195
3) Remove the filter from holder.

B: INSTALLATION
CAUTION:
• If fuel hoses are damaged at the connecting
portion, replace it with a new one.
• If clamps are badly damaged, replace with
new ones.
2) Tighten the hose clamp screws.
Tightening torque:
1.25 N·m (0.13 kgf-m, 0.94 ft-lb)
S2M0195
C: INSPECTION
1) Check the inside of fuel filter for dirt and water
sediment.
2) If it is clogged, or if replacement interval has
been reached, replace it.
3) If water is found in it, shake and expel the water
from inlet port.
FU-68
FUEL CUT VALVE
26.Fuel Cut Valve B: INSTALLATION

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

A: REMOVAL
2) Remove the fuel damper valve from fuel return
line.
EN0852
FU-70
FUEL DELIVERY, RETURN AND EVAPORATION LINES
28.Fuel Delivery, Return and 3) Open the fuel filler flap lid and remove fuel filler
cap.
Evaporation Lines 4) Remove the floor mat. <Ref. to EI-53, REMOV-
A: REMOVAL AL, Floor Mat.>
1) Set the vehicle on a lift. 5) Remove the fuel delivery pipes and hoses, fuel
2) Release the fuel pressure. return pipes and hoses, evaporation pipes and hos-
es.
EN0564
FU-71
6) In the engine compartment, detach the fuel de- 9) Separate the quick connector on fuel delivery
livery hoses, return hoses and evaporation hose. and return line.
(1) Clean the pipe and connector, if they are
covered with dust.
(2) Hold the connector (A) and push retainer (B)
down.
(3) Pull out the connector (A) from retainer (B).
NOTE:
Replace the retainer with new ones.
S2M0500F

(B) Return hose

8) Disconnect the two-way valve hose (A) from
two-way valve and disconnect the canister hose (B) S2M0228A
from canister.
(A) Connector
(A) (B) (B) Retainer
(C) Pipe
EN0840
FU-72
B: INSTALLATION CAUTION:
1) Connect the quick connector on fuel delivery • Pull the connector to ensure it is connected
line. securely.
NOTE: • Ensure the two retainer pawls are engaged in
their mating positions in the connector.
• Always use a new retainer.
• Make sure that the connected portion is not dam- • Be sure to inspect the hoses and their con-
aged or has dust. If necessary, clean the seal sur- nections for any leakage of fuel.
face of pipe.
S2M0231A
S2M0229A
(A) Connector
(1) Set the new retainer (B) to connector (A). (B) Retainer
(2) Push the pipe into connector completely. (C) Pipe
NOTE:
2) Connect the fuel delivery hose to pipe with an
At this time, two clicking sounds are heard. overlap of 20 to 25 mm (0.79 to 0.98 in).
Type A: When the fitting length is specified.
Type B: When the fitting length is not specified.
2 : 2.5±1.5 mm (0.098±0.059 in)
L: 22.5±2.5 mm (0.886±0.098 in)
S2M0230A
(A) Connector
(B) Retainer
(C) Pipe
B2M1194B
(1) Fitting
(2) Clamp
(3) Hose
FU-73
3) Connect the evaporation hose to pipe by approx.

15 mm (0.59 in) from the hose end.
L = 17.5±2.5 mm (0.689±0.098 in)
CAUTION:
Be sure to inspect the hoses and their connec-
tions for any leakage of fuel.
B2M1195A
(1) Hose
(2) Clip
(3) Pipe
C: INSPECTION
1) Make sure that there are no cracks on the fuel
pipes and fuel hoses.
2) Make sure that the fuel pipe and fuel hose con-
nections are tight.
FU-74
FUEL SYSTEM TROUBLE IN GENERAL
29.Fuel System Trouble in General

A: INSPECTION
Trouble and possible cause Corrective action
1. Insufficient fuel supply to the injector
1) Fuel pump will not operate.
Inspect connections, especially ground, and tighten
❍ Defective terminal contact.
securely.
❍ Trouble in electromagnetic or electronic circuit parts. Replace the fuel pump.
2) Lowering of fuel pump function. Replace the fuel pump.
3) Clogged dust or water in the fuel filter. Replace the fuel filter, clean or replace fuel tank.
4) Clogged or bent fuel pipe or hose. Clean, correct or replace the 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 the air breather tube or pipe.
7) Damaged diaphragm of pressure regulator. Replace.
2. Leakage or blow out fuel
1) Loosened joints of the fuel pipe. Retightening.
2) Cracked fuel pipe, hose and fuel tank. Replace.
3) Defective welding part on the fuel tank. Replace.
4) Defective drain packing of the fuel tank. Replace.
Clean, correct or replace the air breather tube or air vent
5) Clogged or bent air breather tube or air vent tube.
tube.
3. Gasoline smell inside of compartment
Loose joints at air breather tube, air vent tube and fuel
1) Retightening.
filler pipe.
2) Defective packing air tightness on the fuel saucer. Correct or replace the packing.
3) Cracked fuel separator. Replace the separator.
4) Inoperative fuel pump modulator or circuit. Replace.
4. Defective fuel meter indicator
1) Defective operation of fuel meter unit. Replace.
2) Defective operation of fuel meter. Replace.
5. Noise
1) Large operation noise or vibration of fuel pump. Replace.
NOTE: season, drain water which may have accumulat-
• When the vehicle is left unattended for an ex- ed in the fuel filter and fuel tank in the manner
tended period of time, water may accumulate in the same as that described under “Affected areas”
fuel tank. below.
To prevent water condensation. (4) Affected areas
(1) Top off the fuel tank or drain the fuel com- When water condensation is notched in the fuel
pletely. filter, drain water from both the fuel filter and fuel
(2) Drain water condensation from the fuel filter. tank or use a water removing agent (or anti-
• Refilling the fuel tank. freeze solution) in the fuel tank.
Refill the fuel tank while there is still some fuel left in • Observe the instructions, notes, etc., indicated
the tank. on the label affixed to the anti-freeze solution (wa-
• Protecting the fuel system against freezing and ter removing agent) container before use.
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
effect of anti-freeze solution each time the fuel
level drops to about one-half. After the winter
FU-75
FU-76
EMISSION CONTROL
EC
Page
2. Front Catalytic Converter ............................................................................3
3. Rear Catalytic Converter.............................................................................6
4. Canister.......................................................................................................7
5. Purge Control Solenoid Valve .....................................................................8
6. Two-way Valve............................................................................................9
GENERAL DESCRIPTION
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)
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 ground
cable from battery.
EC-2
FRONT CATALYTIC CONVERTER
2. Front Catalytic Converter 7) Separate the center exhaust pipe from rear ex-
haust pipe.
A: REMOVAL CAUTION:
1) Set the vehicle on a lift. Be careful, the exhaust pipe is hot.
B2M3109
G6M0095
8) Remove the nuts which hold front exhaust pipe
3) Disconnect the front oxygen (A/F) sensor con-
onto cylinder heads.
nector.
B2M3200
B2M4243
9) Remove the front and center exhaust pipe from
hanger bracket.
sor connector.
CAUTION:
Be careful not to pull down the front exhaust
pipe and center exhaust pipe.
B2M4244

6) Remove the under cover. B2M3111
EC-3
10) Separate the front catalytic converter from front 3) Tighten the nuts which hold front exhaust pipe
exhaust pipe. onto cylinder heads.
The rear catalytic converter is integrated with front 30 N·m (3.1 kgf-m, 22.4 ft-lb)
catalytic converter. Therefore, the procedure for re-
moving rear catalytic converter is the same as the
description above.
B2M3200
4) Tighten the bolts which install front and center

S2M0923 exhaust pipe to rear exhaust pipe.
Tightening torque:
B: INSTALLATION 18 N·m (1.8 kgf-m, 13.0 ft-lb)
NOTE:
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)
B2M3109
5) Tighten the bolt which holds front and center ex-

haust pipe assembly to hanger bracket.
Tightening torque:
35 N·m (3.6 kgf-m, 26.0 ft-lb)
S2M0923
2) Install the front and center exhaust pipe assem-

bly to the vehicle. And temporarily tighten the bolt
which installs center exhaust pipe to hanger brack-
et.
B2M3111
6) Install the under cover.
B2M3111
EC-4

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

connector.
B2M4244
G6M0095
NOTE:
The rear catalytic converter is integrated with front
catalytic converter. Therefore, the procedure for in-
stalling rear catalytic converter is the same as the
description above.
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-5
REAR CATALYTIC CONVERTER
3. Rear Catalytic Converter

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

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

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

A: REMOVAL
16 N·m (1.6 kgf-m, 11.6 ft-lb)
G6M0095
H2M2985
2) Remove the bolt which installs purge control so-
lenoid valve onto intake manifold. CAUTION:
H2M2985
3) Take out the purge control solenoid valve B2M1893E

through the bottom of intake manifold.
4) Disconnect the connector and hoses from purge A: To fuel pipe
control solenoid valve. B: To intake manifold
C: INSPECTION
Make sure hoses are not cracked or loose.
H2M2986
EC-8
TWO-WAY VALVE
6. Two-way Valve
A: REMOVAL
2) Remove the canister from body. <Ref. to EC-7,
REMOVAL, Canister.>
3) Remove the two-way valve with bracket as a sin-
gle unit from body.
EN0901
4) Remove the two-way valve from bracket.

B: INSTALLATION
C: INSPECTION
1) Make sure that the hoses are not cracked or
loose.
EC-9
TWO-WAY VALVE
EC-10
INTAKE (INDUCTION)
IN
Page
2. Air Cleaner Element ....................................................................................5
3. Air Cleaner Case.........................................................................................6
4. Air Intake Duct.............................................................................................7
5. Resonator Chamber....................................................................................8
GENERAL DESCRIPTION
INTAKE (INDUCTION)
A: COMPONENT
T3
T3
(5)
(7)
(6) (4)
(3)
T3
(9)
(8)
T1
(2)
(1) T4 T3
(11) T2
(11)
T2 (20)
(19)
(20)
(13)
(19)
(11)
(14)
(10)
(16) (12)
T5
T6
T5
(18) T5
(17)
(15)
EN1336
IN-2
GENERAL DESCRIPTION
INTAKE (INDUCTION)
(1) Spacer (11) Clip (20) Spacer

(2) Bush (12) Air cleaner element
(3) Resonator chamber (13) Air cleaner case B Tightening torque: N·m (kgf-m, ft-lb)
(4) Cushion rubber (14) Air cleaner case stay LH (MT vehi- T1: 33 (3.4, 24.6)
(5) Air intake duct A (1600 cc and cles) T2: 6.5 (0.66, 4.8)
2000 cc model) (15) Air cleaner case stay LH (AT vehi- T3: 7.5 (0.76, 5.5)
(6) Air intake duct A (2500 cc model) cles) T4: 14 (1.4, 10)
(7) Air intake duct B (16) Air cleaner case stay RH T5: 16 (1.6, 11.6)
(8) Holder (17) Engine harness bracket T6: 3 (0.3, 2.2)
(9) Cushion (18) Clamp
(10) Air cleaner case A (19) Bush
IN-3
GENERAL DESCRIPTION
INTAKE (INDUCTION)
B: CAUTION
tion.
points.
sensor or units, be sure to disconnect the ground
cable from battery.
IN-4
AIR CLEANER ELEMENT
INTAKE (INDUCTION)
2. Air Cleaner Element

A: REMOVAL
1) Remove the clip (A) above the air cleaner case.
H2M2947B
2) Remove the air cleaner element.

B: INSTALLATION
CAUTION:
Fasten with a clip after inserting the lower tab
of the case.
C: INSPECTION
Replace if excessively damaged or dirty.
IN-5
AIR CLEANER CASE
INTAKE (INDUCTION)
3. Air Cleaner Case

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

cleaner case.
3) Remove the bolts which install air cleaner case
to stays.
H2M2947

B: INSTALLATION
C: INSPECTION
Inspect for cracks and loose connections.
IN-6
AIR INTAKE DUCT
INTAKE (INDUCTION)
4. Air Intake Duct • 2500 cc MODEL
A: REMOVAL
1) Remove the bolts which install air intake duct A
on the front side of body.
B6M1224
B: INSTALLATION
EN0061
C: INSPECTION
1) Inspect for cracks and loose connections.
• 2500 cc MODEL 2) Inspect that no foreign objects are mixed in the
air intake duct.
B6M1222
2) Remove the bolt which installs air intake duct B

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

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

A: REMOVAL
1) Remove the air intake duct. <Ref. to IN-7, RE- Tightening torque:
MOVAL, Air Intake Duct.> 33 N·m (3.4 kgf-m, 24.6 ft-lb)
2) Remove the resonator chamber.
B6M1237
B6M1237
C: INSPECTION
Inspect for cracks and loose connections.
IN-8
MECHANICAL
ME
Page
2. Compression .............................................................................................24
3. Idle Speed .................................................................................................25
4. Ignition Timing...........................................................................................26
5. Intake Manifold Vacuum............................................................................27
6. Engine Oil Pressure ..................................................................................28
7. Fuel Pressure............................................................................................29
8. Valve Clearance........................................................................................30
9. Engine Assembly ......................................................................................34
10. Engine Mounting .......................................................................................42
11. Preparation for Overhaul...........................................................................43
12. V-belt.........................................................................................................44
13. Crankshaft Pulley ......................................................................................46
14. Belt Cover .................................................................................................48
15. Timing Belt Assembly................................................................................49
16. Camshaft Sprocket....................................................................................54
17. Crankshaft Sprocket..................................................................................56
18. Valve Rocker Assembly ............................................................................57
19. Camshaft...................................................................................................59
20. Cylinder Head Assembly...........................................................................63
21. Cylinder Block ...........................................................................................71
22. Engine Trouble in General ........................................................................95
23. Engine Noise...........................................................................................101
GENERAL DESCRIPTION
MECHANICAL
A: SPECIFICATIONS
Model 1600 cc 2000 cc 2500 cc
Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke gasoline
Type
engine
Valve arrangement Belt driven, single over-head camshaft, 4-valve/cylinder
87.9 x 65.8 99.5 x 79.0
Bore x Stroke mm (in) 92 x 75 (3.62 x 2.95)
(3.46 x 2.591) (3.917 x 3.110)
Displacement cm3 (cu in) 1,597 (97.45) 1,994 (121.67) 2,457 (150)
Compression ratio 10.0
Compression pres-
sure (at 200 — 300 kPa (kg/cm2, psi) 1,020 — 1,275 (10.4 — 13.0, 148 — 185)
rpm)
Engine Number of piston rings Pressure ring: 2, Oil ring: 1
Opening 10° BTDC 4° BTDC 1° BTDC
Intake valve timing
Closing 46° ABDC 48° ABDC 51° ABDC
Opening 42° BBDC 48° BBDC 50° BBDC
Exhaust valve timing
Closing 10° ATDC 4° ATDC 6° ATDC
Intake mm (in) 0.20±0.02 (0.0079±0.0008)
Valve clearance
Exhaust mm (in) 0.25±0.02 (0.0098±0.0008)
Idling speed [At neutral position
700±100 (No load)
on MT, or “P” or “N” position on rpm
850±100 (A/C switch ON)
AT]
Firing order 1→3→2→4
Ignition timing BTDC/rpm 5°±10°/700 10°±10°/700
NOTE:
STD: Standard I.D.: Inner Diameter O.D.: Outer Diameter US: Undersize OS: Oversize
Belt
tensioner 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 STD 0.025 — 0.125 mm (0.0010 — 0.0049 in)
Clearance between spacer and bush
tensioner Limit 0.175 mm (0.0069 in)
STD 0.20 — 0.55 mm (0.0079 — 0.0217 in)
Side clearance of spacer
Limit 0.81 mm (0.0319 in)
Valve STD 0.020 — 0.054 mm (0.0008 — 0.0021 in)
Clearance between shaft and arm
rocker arm Limit 0.10 mm (0.0039 in)
ME-2
GENERAL DESCRIPTION
MECHANICAL
Bend limit 0.025 mm (0.0010 in)

STD 0.030 — 0.090 mm (0.0012 — 0.0035 in)
Thrust clearance
Limit 0.10 mm (0.0039 in)
STD 39.378 — 39.478 mm (1.5503 — 1.5542 in)
Intake
Limit 39.278 mm (1.5464 in)
1600 cc
STD 39.565 — 39.665 mm (1.5577 — 1.5616 in)
Exhaust
Limit 39.465 mm (1.5537 in)
STD 38.732 — 38.832 mm (1.5249 — 1.5288 in)
Intake
Limit 38.632 mm (1.5209 in)
Cam lobe height 2000 cc
Camshaft STD 39.257 — 39.357 mm (1.5455 — 1.5495 in)
Exhaust
Limit 39.157 mm (1.5416 in)
STD 39.485 — 39.585 mm (1.5545 — 1.5585 in)
Intake
Limit 39.385 mm (1.5506 in)
2500 cc
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)
Surface warpage limit 0.05 mm (0.0020 in)
Cylinder
Surface grinding limit 0.1 mm (0.004 in)
head
Standard height 97.5 mm (3.84 in)
Refacing angle 90°
STD 1.0 mm (0.039 in)
Intake
Valve seat Limit 1.7 mm (0.067 in)
Contacting width
STD 1.4 mm (0.055 in)
Exhaust
Limit 2.1 mm (0.083 in)
Inner diameter 6.000 — 6.012 mm (0.2362 — 0.2367 in)
Valve guide Intake 20.0 — 20.5 mm (0.787 — 0.807 in)
Protrusion above head
Exhaust 16.5 — 17.0 mm (0.650 — 0.669 in)
STD 1.0 mm (0.039 in)
Intake
Limit 0.6 mm (0.024 in)
Head edge thickness
STD 1.2 mm (0.047 in)
Exhaust
Limit 0.6 mm (0.024 in)
Intake 5.950 — 5.965 mm (0.2343 — 0.2348 in)
Stem diameter
Valve Exhaust 5.945 — 5.960 mm(0.2341 — 0.2346 in)
Intake 0.035 — 0.062 mm (0.0014 — 0.0024 in)
STD
Stem oil clearance Exhaust 0.040 — 0.067 mm (0.0016 — 0.0026 in)
Limit — 0.15 mm (0.0059 in)
Intake 120.6 mm (4.75 in)
Overall length
Exhaust 121.7 mm (4.79 in)
Free length 54.30 mm (2.1378 in)
Squareness 2.5°, 2.4 mm (0.094 in)
Valve 214 — 246 N (21.8 — 25.1 kgf, 48.1 — 55.3 lb)/
spring 45.0 mm (1.772 in)
Tension/spring height
526 — 582 N (53.6 — 59.3 kgf, 118.3 — 130.8 lb)/
34.7 mm (1.366 in)
ME-3
GENERAL DESCRIPTION
MECHANICAL
Surface warpage limit (mating with cylinder head) 0.05 mm (0.0020 in)
A 87.905 — 87.915 mm (3.4608 — 3.4612 in)
1600 cc STD
B 87.895 — 87.905 mm (3.4604 — 3.4608 in)
A 92.005 — 92.015 mm (3.6222 — 3.6226 in)
Cylinder bore 2000 cc STD
B 91.995 — 92.005 mm (3.6218 — 3.6222 in)
A 99.505 — 99.515 mm (3.9175 — 3.9179 in)
Cylinder 2500 cc STD
B 99.495 — 99.505 mm (3.9171 — 3.9175 in)
block
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
Limit 0.050 mm (0.0020 in)
Enlarging (boring) limit 0.5 mm (0.020 in)
A 87.885 — 87.895 mm (3.4600 — 3.4604 in)
STD
B 87.875 — 87.885 mm (3.4596 — 3.4600 in)
1600 cc 0.25 mm (0.0098 in)
88.125 — 88.135 mm (3.4695 — 3.4699 in)
OS
0.50 mm (0.0197 in)
88.375 — 88.385 mm (3.4793 — 3.4797 in)
OS
A 91.985 — 91.995 mm (3.6214 — 3.6218 in)
STD
B 91.975 — 91.985 mm (3.6211 — 3.6214 in)
Outer diameter 2000 cc 0.25 mm (0.0098 in)
92.225 — 92.235 mm (3.6309 — 3.6313 in)
Piston OS
0.50 mm (0.0197 in)
92.475 — 92.485 mm (3.6407 — 3.6411 in)
OS
A 99.485 — 99.495 mm (3.9167 — 3.9171 in)
STD
B 99.475 — 99.485 mm (3.9163 — 3.9167 in)
2500 cc 0.25 mm (0.0098 in)
99.725 — 99.735 mm (3.9262 — 3.9266 in)
OS
0.50 mm (0.0197 in)
99.975 — 99.985 mm (3.9360 — 3.9364 in)
OS
Standard inner diameter of piston pin hole 23.000 — 23.006 mm (0.9055 — 0.9057 in)
Outer diameter 22.994 — 23.000 mm (0.9053 — 0.9055 in)
Standard clearance between piston pin and hole in pis-
0.004 — 0.008 mm (0.0002 — 0.0003 in)
Piston pin ton
Piston pin must be fitted into position with thumb at 20°C
Degree of fit
(68°F).
STD 0.20 — 0.35 mm (0.0079 — 0.0138 in)
Top ring
Limit 1.0 mm (0.039 in)
Second STD 0.35 — 0.50 mm (0.0138 — 0.0197 in)
Piston ring gap
ring Limit 1.0 mm (0.039 in)
STD 0.20 — 0.50 mm (0.0079 — 0.0197 in)
Piston ring Oil ring
Limit 1.5 mm (0.059 in)
Clearance STD 0.055 — 0.090 mm (0.0022 — 0.0035 in)
Top ring
between piston Limit 0.15 mm (0.0059 in)
ring and piston Second STD 0.030 — 0.070 mm (0.0012 — 0.0028 in)
ring groove ring Limit 0.15 mm (0.0059 in)
Bend twist per 100 mm (3.94
Limit 0.10 mm (0.0039 in)
Connecting in) in length
rod STD 0.070 — 0.330 mm (0.0028 — 0.0130 in)
Side clearance
Limit 0.4 mm (0.016 in)
ME-4
GENERAL DESCRIPTION
MECHANICAL
1600 cc STD 0.010 — 0.038 mm (0.0004 — 0.0015 in)

2000 cc Limit 0.05 mm (0.0020 in)
Oil clearance
STD 0.012 — 0.037 mm (0.0005 — 0.0015 in)
2500 cc
Limit 0.05 mm (0.0020 in)
STD 1.492 — 1.501 mm (0.0587 — 0.0591 in)
0.03 mm (0.0012 in)
1.510 — 1.513 mm (0.0594 — 0.0596 in)
US
1600 cc
0.05 mm (0.0020 in)
2000 cc 1.520 — 1.523 mm (0.0598 — 0.0600 in)
Connecting US
rod bearing 0.25 mm (0.0098 in)
1.620 — 1.623 mm (0.0638 — 0.0639 in)
Thickness at US
center portion STD 1.490 — 1.502 mm (0.0587 — 0.0591 in)
0.03 mm (0.0012 in)
1.504 — 1.512 mm (0.0592 — 0.0595 in)
US
2500 cc 0.05 mm (0.0020 in)
1.514 — 1.522 mm (0.0596 — 0.0599 in)
US
0.25 mm (0.0098 in)
1.614 — 1.622 mm (0.0635 — 0.0639 in)
US
Connecting Clearance between piston pin STD 0 — 0.022 mm (0 — 0.0009 in)
rod bushing and bushing Limit 0.030 mm (0.0012 in)
Crank pin and Out-of-roundness 0.020 mm (0.0008 in) or less
crank journal Grinding limit 0.250 mm (0.0098 in)
STD 47.984 — 48.000 mm (1.8880 — 1.8898 in)
0.03 mm (0.0012 in)
47.954 — 47.970 mm (1.8879 — 1.8886 in)
US
1600 cc 0.05 mm (0.0020 in)
47.934 — 47.950 mm (1.8872 — 1.8878 in)
US
0.25 mm (0.0098 in)
47.734 — 47.750 mm (1.8793 — 1.8799 in)
Crank pin outer US
diameter STD 51.984 — 52.000 mm (2.0466 — 2.0472 in)
0.03 mm (0.0012 in)
51.954 — 51.970 mm (2.0454 — 2.0461 in)
US
2000 cc
0.05 mm (0.0020 in)
2500 cc 51.934 — 51.950 mm (2.0446 — 2.0453 in)
US
0.25 mm (0.0098 in)
51.734 — 51.750 mm (2.0368 — 2.0374 in)
US
Crankshaft STD 59.992 — 60.008 mm (2.3619 — 2.3625 in)
0.03 mm (0.0012 in)
59.962 — 59.978 mm (2.3607 — 2.3613 in)
US
#1, #3 0.05 mm (0.0020 in)
59.942 — 59.958 mm (2.3599 — 2.3605 in)
US
0.25 mm (0.0098 in)
59.742 — 59.758 mm (2.3520 — 2.3527 in)
Crank journal US
outer diameter STD 59.992 — 60.008 mm (2.3619 — 2.3625 in)
0.03 mm (0.0012 in)
59.962 — 59.978 mm (2.3607 — 2.3613 in)
US
#2, #4, #5 0.05 mm (0.0020 in)
59.942 — 59.958 mm (2.3599 — 2.3605 in)
US
0.25 mm (0.0098 in)
59.742 — 59.758 mm (2.3520 — 2.3527 in)
US
STD 0.030 — 0.115 mm (0.0012 — 0.0045 in)
Thrust clearance
Limit 0.25 mm (0.0098 in)
STD 0.010 — 0.030 mm (0.0004 — 0.0012 in)
Oil clearance
Limit 0.040 mm (0.0016 in)
ME-5
GENERAL DESCRIPTION
MECHANICAL
STD 1.998 — 2.011 mm (0.0787 — 0.0792 in)

0.03 mm (0.0012 in)
2.017 — 2.020 mm (0.0794 — 0.0795 in)
US
#1, #3 0.05 mm (0.0020 in)
2.027 — 2.030 mm (0.0798 — 0.0799 in)
US
0.25 mm (0.0098 in)
2.127 — 2.130 mm (0.0837 — 0.0839 in)
Crankshaft Crankshaft bear- US
bearing ing thickness STD 2.000 — 2.013 mm (0.0787 — 0.0793 in)
0.03 mm (0.0012 in)
2.019 — 2.022 mm (0.0795 — 0.0796 in)
US
#2, #4, #5 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-6
GENERAL DESCRIPTION
MECHANICAL
B: COMPONENT
1. TIMING BELT
B2M3122A
(1) Belt cover No. 2 (RH) (9) Automatic belt tension adjuster Tightening torque: N·m (kgf-m, ft-lb)
(2) Timing belt guide (MT vehicles ASSY T1: 5 (0.5, 3.6)
only) (10) Belt idler No. 2 T2: 10 (1.0, 7.2)
(3) Crankshaft sprocket (11) Camshaft sprocket No. 2 T3: 25 (2.5, 18.1)
(4) Belt cover No. 2 (LH) (12) Timing belt T4: 39 (4.0, 28.9)
(5) Camshaft sprocket No. 1 (13) Front belt cover T5: 78 (8.0, 57.9)
(6) Belt idler (No. 1) (14) Belt cover (LH) T6: <Ref. to ME-46, Installation,
(7) Tensioner bracket (15) Crankshaft pulley (1600 cc and Crankshaft Pulley.>
(8) Belt idler (No. 2) 2000 cc model) T7: <Ref. to ME-46, Installation,
(16) Crankshaft pulley (2500 cc model) Crankshaft Pulley.>
ME-7
GENERAL DESCRIPTION
MECHANICAL
2. CYLINDER HEAD AND CAMSHAFT
B2M1954D
(1) Rocker cover (RH) (11) Cylinder head (LH) Tightening torque: N·m (kgf-m, ft-lb)
(2) Intake valve rocker ASSY (12) Camshaft (LH) T1: <Ref. to ME-63, Installation,
(3) Exhaust valve rocker ASSY (13) Camshaft cap (LH) Cylinder Head Assembly.>
(4) Camshaft cap (RH) (14) Oil filler cap T2: 5 (0.5, 3.6)
(5) Oil seal (15) Gasket T3: 10 (1.0, 7.2)
(6) Camshaft (RH) (16) Oil filler pipe T4: 18 (1.8, 13.0)
(7) Plug (17) O-ring T5: 25 (2.5, 18.1)
(8) Spark plug pipe gasket (18) Rocker cover (LH) T6: 6.4 (0.65, 4.7)
(9) Cylinder head (RH) (19) Stud bolt
(10) Cylinder head gasket
ME-8
GENERAL DESCRIPTION
MECHANICAL
3. VALVE ROCKER ASSEMBLY
B2M1956A
(1) Intake valve rocker arm (6) Intake rocker shaft Tightening torque: N·m (kgf-m, ft-lb)
(2) Valve rocker nut (7) Exhaust rocker shaft T1: 5 (0.5, 3.6)
(3) Valve rocker adjust screw (8) Exhaust valve rocker arm T2: 10 (1.0, 7.2)
(4) Spring T3: 25 (2.5, 18.1)
(5) Rocker shaft support
ME-9
GENERAL DESCRIPTION
MECHANICAL
4. CYLINDER HEAD AND VALVE ASSEMBLY
B2M1955D
(1) Exhaust valve (5) Intake valve oil seal (9) Exhaust valve oil seal
(2) Intake valve (6) Valve spring
(3) Valve guide (7) Retainer
(4) Valve spring seat (8) Retainer key
ME-10
GENERAL DESCRIPTION
MECHANICAL
5. CYLINDER BLOCK
EN1498
(1) Oil pressure switch (14) Baffle plate Tightening torque: N·m (kgf-m, ft-lb)
(2) Cylinder block (RH) (15) Oil filter connector T1: 5 (0.5, 3.6)
(3) Service hole plug (16) Oil strainer T2: 6.4 (0.65, 4.7)
(4) Gasket (17) Gasket T3: 10 (1.0, 7.2)
(5) Oil separator cover (18) Oil pan T4: 25 (2.5, 18.1)
(6) Water by-pass pipe (19) Drain plug T5: 47 (4.8, 34.7)
(7) Oil pump (20) Metal gasket T6: 69 (7.0, 50.6)
(8) Front oil seal (21) Oil level gauge guide T7: First 12 (1.2, 8.7)
(9) Rear oil seal (22) 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 pump hose T10: 25 (2.5, 18.1)
(13) Water pump T11: 54 (5.5, 39.8)
ME-11
GENERAL DESCRIPTION
MECHANICAL
6. CRANKSHAFT AND PISTON
B2M3429A
ME-12
GENERAL DESCRIPTION
MECHANICAL
(1) Flywheel (MT) (9) Circlip (17) Crankshaft bearing #2, #4

(2) Reinforcement (AT) (10) Connecting rod bolt (18) Crankshaft bearing #5
(3) Drive plate (AT) (11) Connecting rod
(4) Top ring (12) Connecting rod bearing Tightening torque: N·m (kgf-m, ft-lb)
(5) Second ring (13) Connecting rod cap T1: 44.6 (4.55, 32.9)
(6) Oil ring (14) Crankshaft T2: 72 (7.3, 52.8)
(7) Piston (15) Woodruff key
(8) Piston pin (16) Crankshaft bearing #1, #3
ME-13
GENERAL DESCRIPTION
MECHANICAL
7. ENGINE MOUNTING
T2
T2
(2)
(2)
T1
(1)
T1
(1)
T3
T3
EN1005
(1) Front cushion rubber (2) Front engine mounting bracket Tightening torque: N·m (kgf-m, ft-lb)
T1: 35 (3.6, 25.8)
T2: 42 (4.3, 31.0)
T3: 85 (8.7, 63)
ME-14
GENERAL DESCRIPTION
MECHANICAL
C: CAUTION • Rotating parts and sliding parts such as piston,

• Wear working clothing, including a cap, protec- bearing and gear should be coated with oil prior to
tive goggles, and protective shoes during opera- assembly.
tion. • Be careful not to let oil, grease or coolant contact
• Remove contamination including dirt and corro- the timing belt, clutch disc and flywheel.
sion before removal, installation or disassembly. • All removed parts, if to be reused, should be re-
• Keep the disassembled parts in order and pro- installed in the original positions and directions.
tect them from dust or dirt. • Bolts, nuts and washers should be replaced with
• Before removal, installation or disassembly, be new ones as required.
sure to clarify the failure. Avoid unnecessary re- • Even if necessary inspections have been made
moval, installation, disassembly, and replacement. in advance, proceed with assembly work while
• Be careful not to burn your hands, because each making rechecks.
part in the vehicle is hot after running. • Remove or install engine in an area where chain
• Be sure to tighten fasteners including bolts and hoists, lifting devices, etc. are available for ready
nuts to the specified torque. use.
• Place shop jacks or safety stands at the specified • Be sure not to damage coated surfaces of body
points. panels with tools or stain seats and windows with
• Before disconnecting electrical connectors of coolant or oil. Place a cover over fenders, as re-
sensors or units, be sure to disconnect the ground quired, for protection.
cable from battery. • Prior to starting work, prepare the following:
• All parts should be thoroughly cleaned, paying Service tools, clean cloth, containers to catch cool-
special attention to the engine oil passages, pis- ant and oil, wire ropes, chain hoist, transmission
tons and bearings. jacks, etc.
• Lift-up or lower the vehicle when necessary.
Make sure to support the correct positions.
D: PREPARATION TOOL
1. SPECIAL TOOLS
18231AA010 CAMSHAFT • Used for removing and installing camshaft
(Newly adopted SPROCKET sprocket. (LH side)
tool) WRENCH • Also the CAMSHAFT SPROCKET WRENCH
(499207100) can be used.
NOTE:
For common use with turbo model, this ST is
changed and registered as a newly adoped tool.
Though the previous ST also can be used.
B2M3859
24082AA190 CARTRIDGE Troubleshooting for electrical systems.
(Newly adopted
tool)
B2M3876
ME-15
GENERAL DESCRIPTION
MECHANICAL

B2M3877
498267800 CYLINDER • Used for replacing valve guides.
HEAD TABLE • Used for removing and installing valve springs.
B2M3850
498277200 STOPPER SET Used for installing automatic transmission assem-
bly to engine.
B2M2043
498457000 ENGINE STAND Used with ENGINE STAND (499817000).
ADAPTER RH
B2M3851
ME-16
GENERAL DESCRIPTION
MECHANICAL

ADAPTER LH
B2M3852
498497100 CRANKSHAFT Used for stopping rotation of flywheel when loos-
STOPPER ening and tightening crankshaft pulley bolt, etc.
B2M3853
498547000 OIL FILTER Used for removing and installing oil filter.
WRENCH
B2M3872
498747000 PISTON GUIDE Used for installing piston in cylinder.
(1600 cc model)
398744300
(2000 cc model)
498747300
(2500 cc model)
B2M3854
ME-17
GENERAL DESCRIPTION
MECHANICAL

498857100 VALVE OIL Used for press-fitting of intake and exhaust valve
SEAL GUIDE guide oil seals.
B2M3855
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
499057000 TORX PLUS Used for removing flywheel (Dual mass flywheel).
B2M4159
ME-18
GENERAL DESCRIPTION
MECHANICAL

499097700 PISTON PIN Used for removing piston pin.
REMOVER
ASSY
B2M3858
499207400 CAMSHAFT Used for removing and installing camshaft
SPROCKET sprocket. (RH side)
WRENCH
B2M4158
499497000 TORX PLUS Used for removing and installing camshaft cap.
B2M3873
499587100 OIL SEAL Used for installing oil pump oil seal.
INSTALLER
B2M3875
ME-19
GENERAL DESCRIPTION
MECHANICAL

499587200 CRANKSHAFT • Used for installing crankshaft oil seal.
OIL SEAL • Used with CRANKSHAFT OIL SEAL GUIDE
INSTALLER (499597100).
B2M3861
499587500 OIL SEAL Used for installing camshaft oil seal.
INSTALLER
B2M3874
499587700 CAMSHAFT OIL Used for installing cylinder head plug.
SEAL
INSTALLER
B2M3860
499597000 OIL SEAL GUIDE • Used for installing camshaft oil seal.
• Used with OIL SEAL INSTALLER (499587500).
B2M3862
ME-20
GENERAL DESCRIPTION
MECHANICAL

OIL SEAL GUIDE • Used with CRANKSHAFT OIL SEAL
B2M3863
499718000 VALVE SPRING Used for removing and installing valve spring.
REMOVER
B2M3864
499767200 VALVE GUIDE Used for removing valve guides.
REMOVER
B2M3867
499767400 VALVE GUIDE Used for reaming valve guides.
REAMER
B2M3868
ME-21
GENERAL DESCRIPTION
MECHANICAL

499767700 VALVE GUIDE Used for installing valve guides.
(Intake side) ADJUSTER
499767800
(Exhaust side)
B2M3865
499817100 ENGINE STAND • Stand used for engine disassembly and assem-
bly.
• Used with ENGINE STAND ADAPTER RH
(498457000) & LH (498457100).
B2M3869
499977100 CRANK PULLEY Used for stopping rotation of crankshaft pulley
WRENCH when loosening and tightening crankshaft pulley
bolts. (2500 cc model)
B2M3870
bolts. (1600 cc and 2000 cc model)
B2M4157
ME-22
GENERAL DESCRIPTION
MECHANICAL

499987500 CRANKSHAFT Used for rotating crankshaft.
SOCKET
B2M3871
2. GENERAL PURPOSE TOOLS

TOOL NAME REMARKS
Compression Gauge Used for measuring compression.
Tachometer (Secondary pick-up type) Used for measuring idle speed.
Timing Light Used for measuring ignition timing.
E: PROCEDURE
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-23
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 the fuel pressure. <Ref. to FU-54, RE-
LEASING OF FUEL PRESSURE, OPERATION,
Fuel.> or <Ref. to FU(w/oOBD)-51, RELEASING
OF FUEL PRESSURE, OPERATION, Fuel.>
4) Remove all the spark plugs. <Ref. to IG-5, RE-
MOVAL, Spark Plug.> or <Ref. to IG(w/oOBD)-5,
REMOVAL, Spark Plug.>
5) Fully open the throttle valve.
6) Check the starter motor for satisfactory perfor-
mance and operation.
7) Hold the compression gauge tight against spark
plug hole.
CAUTION:
When using a screw-in type compression
gauge, the screw (put into cylinder head spark
plug hole) should be less than 18 mm (0.71 in)
long.
8) Crank the engine by means of starter motor, and
then read the maximum value on the gauge when
the pointer is steady.
B2M3133
9) Perform at least two measurements per cylinder,

and make sure that the values are correct.
Compression (350 rpm and fully open throttle):
Standard;
1,275 kPa (13.0 kgf/cm2, 185 psi)
Limit;
1,020 kPa (10.4 kgf/cm2, 148 psi)
Difference between cylinders;
49 kPa (0.5 kgf/cm2, 7 psi), or less
ME-24
IDLE SPEED
MECHANICAL
3. Idle Speed 5) When using the tachometer (Secondary pick-up

type).
A: INSPECTION (1) Attach the pick-up clip to No. 1 cylinder
1) Before checking idle speed, check the following: spark plug cord.
(1) Ensure the air cleaner element is free from (2) Start the engine, and then read the engine
clogging, ignition timing is correct, spark plugs idle speed.
are in good condition, and the 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 then turn the igintion switch
to OFF.
4) When using the SUBARU SELECT MONITOR
<Ref. to ME-15, SPECIAL TOOLS, PREPARA-
TION TOOL, General Description.>
(1) Insert the cartridge to SUBARU SELECT B2M3131
MONITOR.
NOTE:
(2) Connect the SUBARU SELECT MONITOR
• When using the OBD-II general scan tool, care-
to data link connector.
fully 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):
B2M3148
700±100 rpm
(3) Turn the igintion switch to ON, and SUBA- 7) Check the idle speed when loaded. (Turn the air
RU SELECT MONITOR switch to ON. conditioning switch to “ON” and operate the com-
(4) Select the {2. Each System Check} in Main pressor for at least 1 minute before measurement.)
Menu. Idle speed [A/C “ON”, no load and gears in neu-
(5) Select the {Engine Control System} in Se- tral (MT) or N or P (AT) position]:
lection Menu. 850±100 rpm
(6) Select the {1. Current Data Display & Save}
in Engine Control System Diagnosis. CAUTION:
(7) Select the {1.12 Data Display} in Data Dis- Never rotate the idle adjusting screw. If the idle
play Menu. speed is out of specifications, refer to General
On-board Diagnosis Table under “Engine Con-
(8) Start the engine, and then read the engine
trol System”. <Ref. to EN-2, Basic Diagnostic
idle speed.
Procedure.> or <Ref. to EN(w/oOBD)-2, Basic
Diagnostic Procedure.>
ME-25
IGNITION TIMING
MECHANICAL
4. Ignition Timing
A: INSPECTION
CAUTION:
ment.
2) To check the ignition timing, connect a timing
light to #1 cylinder spark plug cord, and illuminate
the timing mark with timing light.
3) Start the engine at idle speed and check the ig-
nition timing.
Ignition timing [BTDC/rpm]:
5°±10°/700 (1600cc MODEL)
10°±10°/700 (2000cc and 2500 cc MODEL)
B2M3130
If the timing is not correct, check the ignition control

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

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

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
dency becomes more evident as engine temperature rises. damaged vacuum hose
2. When engine speed is reduced slowly from higher speed, Back pressure too high, or exhaust system clogged
needle stops temporarily when it is lowering or becomes steady
above normal position.
3. Needle intermittently drops to position lower than normal Leakage around cylinder
position.
4. Needle drops suddenly and intermittently from normal posi- Sticky valves
tion.
5. When engine speed is gradually increased, needle begins to Weak or broken valve springs
vibrate rapidly at certain speed, and then vibration increases as
engine speed increases.
6. Needle vibrates above and below normal position in narrow Defective ignition system or throttle chamber idle adjustment
range.
ME-27
ENGINE OIL PRESSURE
MECHANICAL
6. Engine Oil Pressure 7) Start the engine, and then measure the oil pres-
sure.
A: INSPECTION
S2M0242
G6M0095
Oil pressure:
98 kPa (1.0 kg/cm2, 14 psi) or more at 800 rpm
2) Remove the generator from bracket. <Ref. to 294 kPa (3.0 kg/cm2, 43 psi) or more at 5,000
SC-14, REMOVAL, Generator.> rpm
3) Disconnect the connector from oil pressure
switch. CAUTION:
• If the oil pressure is out of specification,
4) Remove the oil pressure switch from engine cyl-
check the oil pump, oil filter and lubrication
inder block. <Ref. to LU-21, REMOVAL, Oil Pres-
line. <Ref. to LU-25, INSPECTION, Engine Lubri-
sure Switch.>
cation System Trouble in General.>
5) Connect the oil pressure gauge hose to cylinder
• If the oil pressure warning light is turned ON
block.
and oil pressure is in specification, replace the
oil pressure switch. <Ref. to LU-25, 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-21, INSTALLATION,
Oil Pressure Switch.>
Tightening torque:
G6M0095
25 N·m (2.5 kgf-m, 18.1 ft-lb)
9) Install the generator and V-belt in the reverse or-
der of removal, and then adjust the V-belt deflec-
tion. <Ref. to ME-44, INSTALLATION, V-belt.>
ME-28
FUEL PRESSURE
MECHANICAL
7. Fuel Pressure 6) Measure the fuel pressure while disconnecting

the pressure regulator vacuum hose from intake
A: INSPECTION manifold.
WARNING: Fuel pressure:
Before removing the fuel pressure gauge, re- Standard; 284 — 314 kPa (2.9 — 3.2 kg/cm2,
lease the fuel pressure. 41 — 46 psi)
NOTE:
If out of specification, check or replace the pressure
regulator and pressure regulator vacuum hose.
2) Open the fuel flap lid, and then remove the fuel
filler cap.
S2M0554
7) After connecting the pressure regulator vacuum

hose, measure the fuel pressure.
Fuel pressure:
Standard; 206 — 235 kPa (2.1 — 2.4 kg/cm2,
30 — 34 psi)
H2M2535
3) Disconnect the fuel delivery hoses from fuel

damper, and then connect the fuel pressure gauge.
S2M0554
NOTE:
The fuel pressure gauge registers 10 to 20 kPa (0.1
to 0.2 kg/cm2, 1 to 3 psi) higher than standard val-
ues during high-altitude operations.
S2M0195
4) Connect the connector of fuel pump relay.
EN0344
5) Start the engine.
ME-29
VALVE CLEARANCE
MECHANICAL
8. Valve Clearance 8) When inspecting the #2 and #4 cylinders;

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

plugs RH side. <Ref. to IG-5, RH SIDE, RE-
MOVAL, Spark Plug.> or <Ref. to IG(w/oOBD)-
5, RH SIDE, REMOVAL, Spark Plug.>
(2) Disconnect the PCV hose from rocker cover
(RH).
rocker cover (RH).
ME-30
VALVE CLEARANCE
MECHANICAL
10) Measure the #1 cylinder valve clearance by us- 13) After inspection, install the related parts in the
ing thickness gauge. reverse order of removal.
CAUTION: Tightening torque:
• Insert the thickness gauge (A) in as horizon- Resonator chamber;
tal a direction as possible with respect to the 33 N·m (3.4 kgf-m, 24 ft-lb)
valve stem end face.
• Measure the exhaust valve clearances while
lifting-up the vehicle.
Valve clearance:
Intake;
0.20±0.02 mm (0.0079±0.0008 in)
Exhaust;
0.25±0.02 mm (0.0098±0.0008 in)
B6M1237
B2M2028B
11) If necessary, adjust the valve clearance. <Ref.

to ME-32, ADJUSTMENT, Valve Clearance.>
12) Similar to measurement procedures used for
#1 cylinder, measure the #2, #3 and #4 cylinder
valve clearances.
NOTE:
• Be sure to set the cylinder pistons to their re-
spective top dead centers on compression stroke
before measuring valve clearances.
• To set the #3, #2 and #4 cylinder pistons to their
top dead centers on compression stroke, turn the
crankshaft pulley clockwise 90° at a time starting
with arrow mark on camshaft sprocket (LH) facing
up.
B2M2029B
ME-31
VALVE CLEARANCE
MECHANICAL
B: ADJUSTMENT 2) Adjust the #1 cylinder valve clearance.

(1) Loosen the valve rocker nut and screw.
CAUTION:
(2) Place suitable thickness gauge.
Adjustment of the valve clearance should be
(3) While noting the valve clearance, tighten the
performed while engine is cold.
valve rocker adjust screw.
1) Set the #1 cylinder piston to top dead center of (4) When specified valve clearance is obtained,
compression stroke by rotating crankshaft pulley tighten the valve rocker nut.
clockwise using ST.
ST 499977300 CRANK PULLEY WRENCH Tightening torque:
(1600 cc and 2000 cc model) 10 N·m (1.0 kgf-m, 7.2 ft-lb)
ST 499977100 CRANK PULLEY WRENCH CAUTION:
(2500 cc model) • Insert the thickness gauge in as horizontal a
NOTE: direction as possible with respect to the valve
When arrow mark (A) on the camshaft sprocket stem end face.
(LH) comes exactly to the top, #1 cylinder piston is • Adjust the exhaust valve clearances while
brought to the top dead center of compression lifting up the vehicle.
stroke. Valve clearance:
Intake;
0.20±0.02 mm (0.0079±0.0008 in)
Exhaust;
0.25±0.02 mm (0.0098±0.0008 in)
B2M2027B
B2M2030
3) Ensure the valve clearances are within specifi-

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

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

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

<Ref. to IN-7, REMOVAL, Air Intake Duct.> and B2M4251
<Ref. to IN-6, REMOVAL, Air Cleaner Case.> 11) Disconnect the following connectors and ca-
7) Remove the under cover. bles.
8) Remove the radiator from vehicle. <Ref. to CO- (1) Front oxygen (A/F) sensor connector (With
39, REMOVAL, Radiator.> OBD)
9) Collect the refrigerant, and then remove the
pressure hoses. (With A/C)
(1) Place and connect the attachment hose to
refrigerant recycle system.
(2) Collect the refrigerant from A/C system.
(3) Disconnect the A/C pressure hoses from
A/C compressor.
B2M4243
(2) Front oxygen sensor connector (Without

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

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

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

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

(B) A/C compressor connector
B2M3390
ME-35
ENGINE ASSEMBLY
MECHANICAL
13) Remove the power steering pump from brack- (6) Place the power steering pump on right side
et. wheel apron.
(1) Remove the resonator chamber.
(2) Loosen the lock bolt and slider bolt, and
then remove the front side V-belt.<Ref. to ME-
44, FRONT SIDE BELT, REMOVAL, V-belt.>
(3) Remove the pipe with bracket.
EN0208
14) Remove the front and center exhaust pipe.

<Ref. to EX-7, REMOVAL, Front Exhaust Pipe.> or
<Ref. to EX(w/oOBD)-9, REMOVAL, Front Exhaust
Pipe.>
B2M4126
15) Remove the nuts which hold lower side of
(4) Remove the bolts which install power steer- transmission to engine.
ing pump bracket.
B2M2047
B2M3151
16) Remove the nuts which install front cushion
(5) Remove the power steering tank from rubber onto front crossmember.
bracket by pulling it upward.
S2M1927
EN0361
ME-36
ENGINE ASSEMBLY
MECHANICAL
17) Separate the torque converter clutch from drive 20) Support the engine with a lifting device and
plate. (AT model) wire 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 other bolts while rotating the en-
gine using ST.
(2500 cc model)
B2M3391
21) 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 the trans-
mission lowers under its own weight.
S2M0207
18) Remove the pitching stopper.
G2M0298A
(A) Transmission
(B) Garage jack
H3M1839
BO0002
22) Separation of the engine and transmission.
19) Disconnect the fuel delivery hose, return hose
(1) Remove the starter. <Ref. to SC-5, 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 to prevent fuel from splashing.
• Catch fuel from the hose into container.
B3M2044
S2M0500
ME-37
ENGINE ASSEMBLY
MECHANICAL
23) 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-lb)
2) Install the engine onto transmission.
(1) Position the engine in engine compartment
and align it with transmission.
CAUTION:
Be careful not to damage the adjacent parts or
body panels with crank pulley, oil level gauge,
etc.
H2M1961A
24) Remove the engine from vehicle.

(1) Slightly raise the engine.
(2) Raise the transmission with garage jack.
(3) Move the engine horizontally until main
shaft is withdrawn from clutch cover.
(4) Slowly move the engine away from engine
compartment.
CAUTION: B2M3391
body panels with crank pulley, oil level gauge, (2) Apply a small amount of grease to the spline
etc. of main shaft. (MT model)
3) Tighten the bolts which hold upper side of trans-
mission to engine.
Tightening torque:
50 N·m (5.1 kgf-m, 36.9 ft-lb)
B2M3391
25) Remove the front cushion rubbers.
B3M2044
4) Remove the lifting device and wire ropes.
B2M3391
5) Remove the garage jack.
ME-38
ENGINE ASSEMBLY
MECHANICAL
6) Install the pitching stopper. 10) Install the power steering pump on bracket.
Tightening torque:
T1: 50 N·m (5.1 kgf-m, 37 ft-lb)
T2: 58 N·m (5.9 kgf-m, 43 ft-lb)
EN0361
(2) Install the power steering pump on bracket,

H3M1839A and then tighten the bolts.
7) Remove the ST from torque converter clutch Tightening torque:
case. (AT model) 20.1 N·m (2.05 kgf-m, 14.8 ft-lb)
NOTE:
Be careful not to drop the ST into torque converter
clutch case when removing ST.
8) Install the starter. <Ref. to SC-6, 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. B2M3151A
(2) Tighten other bolts while rotating the engine
by using ST. (3) Tighten the bolts which install power steer-
ing pump bracket, and then install the spark plug
CAUTION: cords.
Be careful not to drop the bolts into torque con-
verter clutch housing.
(2500 cc model)
Tightening torque:
25 N·m (2.5 kgf-m, 18.1 ft-lb)
B2M4126
(4) Connect the power steering switch connec-

tor.
S2M0207
(3) Clog the plug onto service hole.
EN0360
ME-39
ENGINE ASSEMBLY
MECHANICAL
(5) Install the front side V-belt, and adjust it. 13) Install the front and center exhaust pipe.
<Ref. to ME-44, FRONT SIDE BELT, INSTAL- <Ref. to EX-8, INSTALLATION, Front Exhaust
LATION, V-belt.> Pipe.> and <Ref. to EX(w/oOBD)-10, INSTALLA-
(6) Install the resonator chamber. TION, Front Exhaust Pipe.>
14) Connect the following hoses.
Tightening torque:
(1) Fuel delivery hose, return hose and evapo-
33 N·m (3.4 kgf-m, 24.6 ft-lb)
ration hose
(2) Heater inlet and outlet hoses
15) Connect the following connectors.
(1) Engine ground cables
Tightening torque:
14 N·m (1.4 kgf-m, 10.1 ft-lb)
(3) Generator connector and terminal
(4) A/C compressor connectors
B6M1237
(5) Power steering pressure switch
11) Tighten the nuts which hold lower side of trans- 16) Connect the following cables.
mission to engine. (1) Accelerator cable
Tightening torque: (2) Cruise control cables (With cruise control)
50 N·m (5.1 kgf-m, 36.9 ft-lb) 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-37, INSTALLATION, Hose and Tube.>
NOTE:
Use new O-rings.
B3M2047
Tightening torque:
25 N·m (2.5 kgf-m, 18.1 ft-lb)
12) Tighten the nuts which install front cushion rub-
ber 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.
B2M3385
19) Install the radiator to vehicle. <Ref. to CO-42,

INSTALLATION, Radiator.>
20) Install the air intake duct and air cleaner case.
<Ref. to IN-7, INSTALLATION, Air Intake Duct.>
and <Ref. to IN-6, INSTALLATION, Air Cleaner
Case.>
B2M3880A 21) Install the under cover.
22) Install battery in the vehicle, and then connect
the cables.
ME-40
ENGINE ASSEMBLY
MECHANICAL
23) Fill engine coolant. C: INSPECTION

<Ref. to CO-26, FILLING OF ENGINE COOLANT, 1) Make sure the pipes and hoses are installed cor-
REPLACEMENT, Engine Coolant.> rectly.
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-22, OPERATION, Refrigerant Charg-
ing Procedure.>
26) Remove the front hood stay, and then close the
front hood.
27) Take off the vehicle from lift arms.
ME-41
ENGINE MOUNTING
MECHANICAL
10.Engine Mounting
A: REMOVAL
1) Remove the engine assembly. <Ref. to ME-34,
REMOVAL, Engine Assembly.>
2) Remove the engine mounting from engine as-
sembly.
B: INSTALLATION
Tightening torque:
Engine mounting;
34 N·m (3.5 kgf-m, 25.3 ft-lb)
C: INSPECTION
Make sure there are no cracks or other damage.
ME-42
PREPARATION FOR OVERHAUL
MECHANICAL
11.Preparation for Overhaul

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

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

4) Remove the A/C belt tensioner.
A: REMOVAL
1. FRONT SIDE BELT
NOTE:
Perform the following procedures 1) to 4) with the
engine installed to body.
B2M2585
B: INSTALLATION
1. FRONT SIDE BELT
CAUTION:
Wipe off any oil or water on the belt and pulley.
B2M3401 1) Install the belt (C), and tighten the slider bolt so
as to obtain the specified belt tension <Ref. to ME-
2) Loosen the lock bolt (A). 45, INSPECTION, V-belt.>
3) Loosen the slider bolt (B). 2) Tighten the lock bolt (A)
4) Remove the front side belt (C). 3) Tighten the slider bolt (B).
Tightening torque:
Lock bolt through bolt:
25 N·m (2.5 kgf-m, 18.1 ft-lb)
Slider bolt:
8 N·m (0.8 kgf-m, 5.5 ft-lb)
B2M4291A
2. REAR SIDE BELT

B2M4291A
B2M2584A
ME-44
V-BELT
MECHANICAL
2. REAR SIDE BELT C: INSPECTION

1) Install the belt, and tighten the slider bolt (B) so 1) Replace the belts, if cracks, fraying or wear is
as to obtain the specified belt tension. <Ref. to ME- found.
45, INSPECTION, V-belt.> 2) Check the drive belt tension and adjust it if nec-
2) Tighten the lock nut (A). essary by changing the generator installing position
and/or idler pulley installing position.
Tightening torque:
Lock nut (A); Belt tension
22.6 N·m (2.3 kgf-m, 16.6 ft-lb) (A)
replaced: 7 — 9 mm (0.276 — 0.354 in)
reused: 9 — 11 mm (0.354 — 0.433 in)
(B)*
replaced: 7.5 — 8.5 mm (0.295 — 0.335 in)
reused: 9.0 — 10.0 mm (0.354 — 0.394 in)
B2M2584A
B2M4123A
C/P Crankshaft pulley

GEN Generator
P/S Power steering oil pump pulley
A/C Air conditioning compressor pulley
I/P Idler pulley
ME-45
CRANKSHAFT PULLEY
MECHANICAL
13.Crankshaft Pulley (4) Tighten the crankshaft pulley bolts.

127 N·m (13.0 kgf-m, 94.0 ft-lb)
1) Remove the V-belt. <Ref. to ME-44, REMOVAL,
V-belt.>
2) Remove the crankshaft pulley bolt. To lock the
crankshaft, use ST.
ST 499977300 (1600 cc and 2000 cc model)
ST 499977100 (2500 cc model)
CRANKSHAFT PULLEY WRENCH
B2M2586A
3) Confirm that the tightening angle of crankshaft

pulley bolt is 45 degrees or more. If not, conduct the
following procedures.
CAUTION:
If the tightening angle of crankshaft pulley bolt
is less than 45 degrees, the bolt should be dam-
B2M2586D
aged. In this case, the bolt must be replaced.
• 2500 cc MODEL (1) Replace the crankshaft pulley bolts and
clean them.
Crankshaft pulley bolt:
12369AA011
(2) Clean the crankshaft thread using an air
gun.
(3) Tighten the bolts temporarily with tightening
torque of 44 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
H2M2393E degrees.
3) Remove the crankshaft pulley. CAUTION:
Conduct the tightening procedures by confirm-
B: INSTALLATION ing the turning angle of crankshaft pulley bolt
1) Install the crankshaft pulley. referring to the gauge indicated on belt cover.
2) Install the pulley bolt. (1600 cc and 2000 cc mod- 4) Install the pulley bolt. (2500 cc model)
el) To lock the crankshaft, use ST.
To lock the crankshaft, use ST. ST 499977100 CRANK PULLEY WRENCH
ST 499977300 CRANK PULLEY WRENCH (1) Clean the crankshaft pulley thread using an
(1) Clean the crankshaft pulley thread using an air gun.
air gun. (2) Apply engine oil to the crankshaft pulley bolt
(2) Apply engine oil to the crankshaft pulley bolt seat and thread.
seat and thread. (3) Tighten the bolts temporarily with tightening
(3) Tighten the bolts temporarily with tightening torque of 44 N·m (4.5 kgf-m, 33 ft-lb).
ME-46
CRANKSHAFT PULLEY
MECHANICAL
(4) Tighten the crankshaft pulley bolts. 7) Install the A/C belt.
Tightening torque:
177 N·m (18.0 kgf-m, 130.2 ft-lb)
B2M2584
C: INSPECTION
H2M2393A 1) Make sure the V-belt is not worn or otherwise
5) Confirm that the tightening angle of crankshaft damaged.
pulley bolt is 65 degrees or more. If not, conduct the 2) Check the tension of the belt. <Ref. to ME-45,
following procedures (1) through (4). INSPECTION, V-belt.>
(1) Replace the crankshaft pulley bolts and
clean them.
12369AA011
gun.
degrees.
CAUTION:
Conduct the tightening procedures by confirm-
ing the turning angle of crankshaft pulley bolt
referring to the gauge indicated on belt cover.
6) Install the A/C belt tensioner.
B2M2585
ME-47
BELT COVER
MECHANICAL
14.Belt Cover
A: REMOVAL
V-belt.>
2) Remove the crankshaft pulley. <Ref. to ME-46,
REMOVAL, Crankshaft Pulley.>
4) Remove the front belt cover.
B2M2587B
(A) Belt cover (LH)

(B) Front belt cover
B: INSTALLATION
1) Install the front belt cover.
Tightening torque:
5 N·m (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)
B2M2587B
(A) Belt cover (LH)

(B) Front belt cover
3) Install the crankshaft pulley. <Ref. to ME-46, IN-

STALLATION, Crankshaft Pulley.>
4) Install the V-belt. <Ref. to ME-44, INSTALLA-
TION, V-belt.>
C: INSPECTION
Make sure the cover is not damaged.
ME-48
TIMING BELT ASSEMBLY
MECHANICAL
15.Timing Belt Assembly

A: REMOVAL
1. TIMING BELT
V-belt.>
3) Remove the belt cover. <Ref. to ME-48, RE-
MOVAL, Belt Cover.>
4) Remove the timing belt guide. (MT vehicle only)
EN0621
S2M0294
(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 crank
(which indicates rotation direction) on timing belt 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 the
mark (a) of sprocket to cylinder block notch (b)
and ensure the right side cam sprocket mark (c),
cam cap and cylinder head matching surface (d)
and/or left side cam sprocket mark (e) and belt
cover notch (f) are properly adjusted.
B2M2591
Specified data:
Z1: 46.8 tooth length
Z1 Z2
B2M2590A
B2M4789A
6) Remove the belt idler (No. 2).
ME-49
MECHANICAL
7) Remove the belt idler No. 2. 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.
S2M1008 • Push the adjuster rod vertically.
• Be sure to slowly move the adjuster rod down
8) Remove the timing belt. applying a pressure of 294 N (30 kgf, 66 lb).
• Press-in the push adjuster rod gradually tak-
ing more than 3 minutes.
• Do not allow press pressure to exceed 9,807
N (1,000 kgf, 2,205 lb).
• Press the adjuster rod as far as the end sur-
face of cylinder. Do not press the adjuster rod
into the cylinder. Doing so may damage the cyl-
inder.
• Do not release the press pressure until stop-
per pin is completely inserted.
B2M2594
(1) Attach the automatic belt tension adjuster
2. BELT IDLER AND AUTOMATIC BELT assembly to the vertical pressing tool.
TENSION ADJUSTER ASSEMBLY (2) Slowly move the adjuster rod down with a
pressure of 294 N (30 kgf, 66 lb) until the adjust-
1) Remove the belt idler (No. 1). er rod is aligned with the stopper pin hole in the
cylinder.
B2M2596
2) Remove the automatic belt tension adjuster as- H2M2382

sembly. (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.
H2M2375
H2M2383A
ME-50
MECHANICAL
2) Install the automatic belt tension adjuster as- 2. TIMING BELT

sembly.
1) Preparation for the installation of automatic belt
Tightening torque: tension adjuster assembly. <Ref. to ME-50, AUTO-
25 N·m (2.5 kgf-m, 18.1 ft-lb) MATIC BELT TENSION ADJUSTER ASSEMBLY
AND BELT IDLER, INSTALLATION, Timing Belt
Assembly.>
2) Installation of timing belt
(1) Turn the camshaft sprocket No. 2 using
ST1, and then turn the camshaft sprocket No. 1
using ST2 so that their alignment marks (A)
come to top positions.
ST1 18231AA010 CAMSHAFT SPROCKET
WRENCH
NOTE:
H2M2384 Also the CAMSHAFT SPROCKET WRENCH
3) Install the belt idler (No. 1). (499207100) can be used.
ST2 499207400 CAMSHAFT SPROCKET
Tightening torque: WRENCH
39 N·m (4.0 kgf-m, 28.9 ft-lb)
B2M2602B
B2M2596
(2) While aligning alignment mark on the timing
belt (B) with marks on sprockets (A), position the
timing belt properly.
CAUTION:
Ensure belt's rotating direction is correct.
S2M2312A
3) Install the belt idler No. 2.

Tightening torque:
39 N·m (4.0 kgf-m, 28.9 ft-lb)
ME-51
MECHANICAL
4) Install the belt idler (No. 2). (2) Check and adjust the clearance between
timing belt and timing belt guide by using thick-
Tightening torque:
ness gauge.
39 N·m (4.0 kgf-m, 28.9 ft-lb)
Clearance:
1.0±0.5 mm (0.039±0.020 in)
S2M1008
5) After ensuring that the marks on timing belt and S2M0297

camshaft sprockets are aligned, remove the stop-
per pin from belt tension adjuster. (3) Tighten the remaining bolts.
Tightening torque:
10 N·m (1.0 kgf-m, 7.2 ft-lb)
H2M2387
6) Install the timing belt guide. (MT vehicles only)

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

LATION, Belt Cover.>
8) Install the crankshaft pulley. <Ref. to ME-46,
TION, V-belt.>
S2M0294
ME-52
MECHANICAL
C: INSPECTION CAUTION:
1. TIMING BELT move the adjuster rod down.
1) Check the timing belt teeth for breaks, cracks, • Do not use a lateral type vise.
and wear. If any fault is found, replace belt. • Push the adjuster rod vertically.
2) Check the condition of back side of belt; if any • Press-in the push adjuster rod gradually tak-
crack is found, replace the belt. ing more than 3 minutes.
CAUTION: • Do not allow press pressure to exceed 9,807
• Be careful not to let oil, grease or coolant N (1,000 kgf, 2,205 lb).
contact the belt. Remove quickly and thorough- • Press the adjuster rod as far as the end sur-
ly if this happens. face of the cylinder. Do not press the adjuster
• Do not bend the belt sharply. rod into the cylinder. Doing so may damage the
cylinder.
Bending radius: h 4) Measure the extension of rod beyond the body.
60 mm (2.36 in) or more If it is not within specifications, replace with a new
one.
Rod extension: H
5.7±0.5 mm (0.224±0.020 in)
G2M0115

ER
H2M2381A
1) Visually check oil seals for leaks, and rod ends
for abnormal wear or scratches. If necessary, re- 3. BELT TENSION PULLEY
place faulty parts.
1) Check the mating surfaces of timing belt and
CAUTION: contact point of adjuster rod for abnormal wear or
Slight traces of oil at rod's oil seal does not in- scratches. Replace the automatic belt tension ad-
dicate a problem. juster assembly if faulty.
2) Check that the adjuster rod does not move when 2) Check the tension pulley for smooth rotation.
a pressure of 294 N (30 kgf, 66 lb) is applied to it. Replace if noise or excessive play is noted.
This is to check adjuster rod stiffness. 3) Check the tension pulley for grease leakage.
3) If the adjuster rod is not stiff and moves freely
when applying 294 N (30 kgf, 66 lb), check it using 4. BELT IDLER
the following procedures: 1) Check the belt idler for smooth rotation. Replace
(1) Slowly press the adjuster rod down to the if noise or excessive play is noted.
end surface of the cylinder. Repeat this motion 2 2) Check the belt outer contacting surfaces of idler
or 3 times. pulley for abnormal wear and scratches.
(2) With the adjuster rod moved all the way up, 3) Check the belt idler for grease leakage.
apply a pressure of 294 N (30 kgf, 66 lb) to it.
Check adjuster rod stiffness.
(3) If the adjuster rod is not stiff and moves
down, replace the automatic belt tension adjust-
er assembly with a new one.
ME-53
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
V-belt.> Tightening torque:
2) Remove the crankshaft pulley. <Ref. to ME-46, 78 N·m (8.0 kgf-m, 57.9 ft-lb)
REMOVAL, Crankshaft Pulley.> CAUTION:
3) Remove the belt cover. <Ref. to ME-48, RE- Do not confuse the right and left side camshaft
MOVAL, Belt Cover.> sprockets during installation. The camshaft
4) Remove the timing belt assembly. <Ref. to ME- sprocket No. 2 is identified by a projection used
49, REMOVAL, Timing Belt Assembly.> to monitor camshaft position sensor.
5) Remove the camshaft position sensor. <Ref. to
FU-33, REMOVAL, Camshaft Position Sensor.> or
<Ref. to FU(w/oOBD)-32, REMOVAL, Camshaft
Position Sensor.>
6) Remove the camshaft sprocket No. 2. To lock
the camshaft, use ST.
ST 18231AA010 CAMSHAFT SPROCKET
WRENCH
NOTE:
Also the CAMSHAFT SPROCKET WRENCH
(499207100) can be used. B2M2599A
2) Install the camshaft sprocket No. 2. To lock cam-

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

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

FU-33, INSTALLATION, Camshaft Position Sen-
sor.> or <Ref. to FU(w/oOBD)-32, INSTALLATION,
Camshaft Position Sensor.>
B2M2599A 4) Install the timing belt assembly. <Ref. to ME-50,
INSTALLATION, Timing Belt Assembly.>
ME-54
CAMSHAFT SPROCKET
MECHANICAL

TION, 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 camshaft sprocket notch for sensor
for damage and contamination of foreign matter.
ME-55
CRANKSHAFT SPROCKET
MECHANICAL
17.Crankshaft Sprocket B: INSTALLATION

1) Install the crankshaft sprocket.
A: REMOVAL
V-belt.>
MOVAL, Belt Cover.>
4) Remove the timing belt assembly. <Ref. to ME-
49, REMOVAL, Timing Belt Assembly.>
5) Remove the camshaft sprocket. <Ref. to ME-54,
REMOVAL, Camshaft Sprocket.> S2M0414
6) Remove the crankshaft sprocket.
2) Install the camshaft sprocket. <Ref. to ME-54,
INSTALLATION, Camshaft Sprocket.>
3) Install the timing belt assembly. <Ref. to ME-50,
TION, V-belt.>
S2M0414 C: INSPECTION
scratches.
et and key.
3) Check the crankshaft sprocket notch for sensor
for damage and contamination of foreign matter.
ME-56
VALVE ROCKER ASSEMBLY
MECHANICAL
18.Valve Rocker Assembly (3) Tighten the bolts (a) through (d) to specified
torque.
A: REMOVAL
Tightening torque:
25 N·m (2.5 kgf-m, 18.1 ft-lb)
V-belt.>
MOVAL, Belt Cover.>
REMOVAL, Camshaft Sprocket.>
6) Disconnect the PCV hose and remove rocker
cover.
B2M2605A
7) Removal of valve rocker assembly
(1) Remove the bolts (a) through (h) in alpha- 2) Adjust the valve clearances. <Ref. to ME-32,
betical sequence. ADJUSTMENT, Valve Clearance.>
CAUTION: 3) Install the rocker cover and connect PCV hose.
Leave two or three threads of bolts (g and h) en- 4) Install the camshaft sprocket. <Ref. to ME-54,
gaged to retain the valve rocker assembly. INSTALLATION, Camshaft Sprocket.>
TION, V-belt.>
C: DISASSEMBLY
1) Remove the bolts which secure rocker shaft.
B2M2605F 2) Extract the rocker shaft. Remove the valve rock-
(2) Remove the valve rocker assembly. 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
B2M2606 supports in assembly order and insert valve rocker
shaft.
B: INSTALLATION
1) Installation of valve rocker assembly Tightening torque (Shaft supports installing
(1) Temporarily tighten the bolts (a) through (d) bolts):
equally as shown in the figure. 5 N·m (0.5 kgf-m, 3.6 ft-lb)
CAUTION: CAUTION:
Do not allow the valve rocker assembly to Valve rocker arms, rocker shaft and shaft sup-
gouge knock pins. ports have identification marks. Ensure the
parts with same markings are properly assem-
(2) Tighten the bolts (e) through (h) to specified bled.
torque.
3) Install the valve rocker shaft securing bolts.
ME-57
VALVE ROCKER ASSEMBLY
MECHANICAL
E: INSPECTION 4) If oil clearance exceeds the limit, replace the

rocker shaft support or shaft, whichever shows
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 cam or valve contact surface of valve rocker
Standard
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.
B2M0073
2) If oil clearance exceeds the limit, replace the

valve rocker arm or shaft, whichever shows greater
amount of wear.
Rocker arm inside diameter:
22.020 — 22.041 mm (0.8669 — 0.8678 in)
Rocker shaft diameter:
21.987 — 22.000 mm (0.8656 — 0.8661 in)
3) Measure the inside diameter of rocker shaft 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-58
CAMSHAFT
MECHANICAL
19.Camshaft (1) Remove the bolts (a) through (b) in alpha-

betical sequence.
A: REMOVAL
1) Remove the V-belt. <Ref. to ME-44, INSTALLA-
TION, V-belt.>
MOVAL, Belt Cover.>
REMOVAL, Camshaft Sprocket.> B2M2612B
6) Remove the crankshaft sprocket. <Ref. to ME- (2) Equally loosen the bolts (c) through (j) all the
56, REMOVAL, Crankshaft Sprocket.> way in alphabetical sequence.
7) Remove the belt cover No. 2 (LH).
8) Remove the belt cover No. 2 (RH).
CAUTION:
Do not damage or lose the seal rubber when re-
moving belt covers.
B2M2612C
(3) Remove the bolts (k) through (p) in alpha-

betical sequence using ST.
ST 499497000 TORX PLUS
B2M2601
9) Remove the tensioner bracket.
B2M2612D
(4) Remove the camshaft cap.

H2M2380
10) Remove the camshaft position sensor support.

(LH side only)
11) Remove the oil level gauge guide. (LH side
only)
12) Remove the valve rocker assembly. <Ref. to
ME-57, REMOVAL, Valve Rocker Assembly.>
13) Remove the camshaft cap.
B2M2613
14) Remove the camshaft.

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

in alphabetical sequence. B2M2621C
B2M2612E
ME-60
CAMSHAFT
MECHANICAL
(6) Tighten the bolts (o) through (v) in alphabet- 6) Install the rocker cover and connect PCV hose.
ical sequence. 7) Install the oil level gauge guide. (LH side only)
Tightening torque: 8) Install the camshaft position sensor support. (LH
side only)
10 N·m (1.0 kgf-m, 7.2 ft-lb)
9) Install the tensioner bracket.
Tightening torque:
25 N·m (2.5 kgf-m, 18.1 ft-lb)
B2M2621D
(7) Tighten the bolts (w) through (x) in alphabet-

ical sequence.
H2M2380
Tightening torque:
10 N·m (1.0 kgf-m, 7.2 ft-lb) 10) Install the belt cover No. 2 (RH).
Tightening torque:
5 N·m (0.5 kgf-m, 3.6 ft-lb)
11) Install the belt cover No. 2 (LH).
Tightening torque:
5 N·m (0.5 kgf-m, 3.6 ft-lb)
B2M2621E
3) Apply a coat of grease to oil seal lips, and then

install the oil seal (A) on camshaft using ST1 and
ST2.
NOTE:
Use a new oil seal. B2M2601
ST1 499597000 OIL SEAL GUIDE 12) Install the crankshaft sprocket. <Ref. to ME-56,
ST2 499587500 OIL SEAL INSTALLER INSTALLATION, Crankshaft Sprocket.>
14) Install the timing belt assembly. <Ref. to ME-
50, INSTALLATION, Timing Belt Assembly.>
INSTALLATION, Crankshaft Pulley.>
TION, V-belt.>
S2M1864A
4) Install the plug using ST.

ST 499587700 CAMSHAFT OIL SEAL IN-
STALLER
5) Adjust the valve clearance. <Ref. to ME-32, AD-
JUSTMENT, Valve Clearance.>
ME-61
CAMSHAFT
MECHANICAL
C: INSPECTION Model Item Unit: mm (in)

39.485 — 39.585
1. CAMSHAFT Intake
STD
(1.5545 — 1.5585)
1) Measure the bend, and repair or replace if nec- Limit 39.385 (1.5506)
2500 cc
essary. 39.257 — 39.357
STD
Exhaust (1.5455 — 1.5495)
Limit:
Limit 39.157 (1.5416)
0.025 mm (0.0010 in)
Cam base circle diameter A:
IN: 34.00 mm (1.3386 in)
EX: 34.00 mm (1.3386 in)
B2M2617
2) Check the journal for damage and wear. Re-

place if faulty.
B2M1209A
3) Measure the outside diameter of camshaft jour-
nal and inside diameter of cylinder head journal, 2. CAMSHAFT SUPPORT
and determine the difference between two (= oil
clearance). If the oil clearance exceeds specifica- Measure the thrust clearance of camshaft with dial
tions, replace the camshaft or cylinder head as gauge. If the clearance exceeds the limit, replace
necessary. the camshaft support.
Unit: mm (in) Standard:

Clear- Standard 0.055 — 0.090 (0.0022 — 0.0035)
0.030 — 0.090 mm (0.0012 — 0.0035 in)
ance at Limit:
journal Limit 0.10 (0.0039)
0.10 mm (0.0039 in)
31.928 — 31.945 (1.2570 —
Camshaft journal O.D.
1.2577)
32.000 — 32.018 (1.2598 —
Journal hole I.D.
1.2605)
4) Check the cam face condition; remove the minor

faults by grinding with oil stone. Measure the cam
height H; replace if the limit has been exceeded.
Cam height: H
Model Item Unit: mm (in)
B2M2618
39.378 — 39.478
STD
Intake (1.5503 — 1.5542)
Limit 39.278 (1.5464)
1600 cc
39.565 — 39.665
STD
Exhaust (1.5577 — 1.5616)
Limit 39.465 (1.5537)
38.732 — 38.832
STD
Intake (1.5249 — 1.528885)
Limit 39.632 (1.5209)
2000 cc
39.257 — 39.357
STD
Exhaust (1.5455 — 1.5495)
Limit 39.157 (1.5416)
ME-62
CYLINDER HEAD ASSEMBLY
MECHANICAL
20.Cylinder Head Assembly 13) Remove the cylinder head gasket.

CAUTION:
A: REMOVAL Do not scratch the mating surface of cylinder
1) Remove the V-belt. <Ref. to ME-44, REMOVAL, head and cylinder block.
V-belt.>
14) Similarly, remove the right side cylinder head.
REMOVAL, Crankshaft Pulley.> B: INSTALLATION
3) Remove the belt cover. <Ref. to ME-48, RE- 1) Install the cylinder head and gaskets on cylinder
MOVAL, Belt Cover.> block.
4) Remove the timing belt assembly. <Ref. to ME- CAUTION:
49, REMOVAL, Timing Belt Assembly.> • Use new cylinder head gaskets.
5) Remove the camshaft sprocket. <Ref. to ME-54, • Be careful not to scratch the mating surface
REMOVAL, Camshaft Sprocket.> of cylinder block and cylinder head.
6) Remove the intake manifold. <Ref. to FU-17,
REMOVAL, Intake Manifold.> or <Ref. to FU(w/ 2) Tighten the cylinder head bolts.
oOBD)-17, REMOVAL, Intake Manifold.> (1) Apply a coat of engine oil to the washers and
7) Remove the bolt which installs A/C compressor bolt threads.
bracket on cylinder head. (2) Tighten all bolts to 29 N·m (3.0 kgf-m, 22 ft-
8) Remove the valve rocker assembly. <Ref. to lb) in alphabetical sequence.
ME-57, REMOVAL, Valve Rocker Assembly.> Then tighten all bolts to 69 N·m (7.0 kgf-m, 51 ft-
9) Remove the camshaft. <Ref. to ME-59, RE- lb) in alphabetical sequence.
MOVAL, Camshaft.> (3) Back off all bolts by 180° first; back them off
10) Remove the cylinder head bolts in alphabetical by 180° again.
sequence shown in the figure. (4) Tighten the bolts (a) and (b) to 34 N·m (3.5
kgf-m, 25 ft-lb).
CAUTION: (5) Tighten the bolts (c), (d), (e) and (f) to 15
Leave the bolts (a) and (c) engaged by three or N·m (1.5 kgf-m, 11 ft-lb).
four threads to prevent cylinder head from fall- (6) Tighten all bolts by 80 to 90° in alphabetical
ing. sequence.
CAUTION:
Do not tighten bolts more than 90°°.
(7) Further tighten all bolts by 80 to 90° in al-
phabetical sequence shown in figure below.
CAUTION:
Ensure that the total “re-tightening angle” [in
the former two steps], do not exceed 180°°.
S2M1589A
11) While tapping the cylinder head with a plastic

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

TION, Camshaft.>
4) Install the valve rocker assembly. <Ref. to ME-
57, INSTALLATION, Valve Rocker Assembly.>
5) Install the A/C compressor bracket on cylinder
head.
S2M1589A
ME-63
MECHANICAL
6) Install the intake manifold. <Ref. to FU-19, IN-

STALLATION, Intake Manifold.> or <Ref. to FU(w/
oOBD)-20, INSTALLATION, Intake Manifold.>
TION, V-belt.>
C: DISASSEMBLY
1) Place the cylinder head on ST.
ST 498267800 CYLINDER HEAD TABLE
2) Set the ST on valve spring. Compress the valve
spring, and then remove the valve spring retainer
key. Remove each valve and valve spring.
ST 499718000 VALVE SPRING REMOVER
CAUTION:
• Mark each valve to prevent confusion.
• Use extreme care not to damage the lips of in-
take valve oil seals and exhaust valve oil seals.
B2M2630A
ME-64
MECHANICAL
D: ASSEMBLY
B2M2629B
(1) Valve (6) Retainer (11) Plug

(2) Valve guide (7) Retainer key (12) Camshaft cap
(3) Valve spring seat (8) Spark plug gasket (13) Valve rocker ASSY
(4) Oil seal (9) Camshaft
(5) Valve spring (10) Oil seal
1) Installation of valve spring and valve (4) Set the ST on valve spring.
(1) Place the cylinder head on ST. ST 499718000 VALVE SPRING REMOVER
(2) Coat the stem of each valve with engine oil
and insert 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 B2M2630A
head.
ME-65
MECHANICAL
(5) Compress the valve spring, and then fit the 2. INTAKE AND EXHAUST VALVE OIL
valve spring retainer key. SEAL
Replace the oil seal with new one, if lip is damaged
or spring out of place, or when the surfaces of in-
take valve and valve seat are reconditioned or in-
take valve guide is replaced. Use pliers to pinch
and remove oil seal from valve.
1) Place the cylinder head on ST1.
2) Press-fit oil seal to the specified dimension indi-
cated in the figure using ST2.
CAUTION:
B2M2634B • Apply engine oil to oil seal before press-fit-
ting.
(A) Retainer • When press-fitting oil seal, do not use ham-
(B) Painted face mer or strike in.
• Differentiate between intake valve oil seal
(6) After installing, tap the valve spring retainers and exhaust valve oil seal by noting their differ-
lightly with wooden hammer for better seating. ence in color.
E: INSPECTION ST1 498267800 CYLINDER HEAD TABLE
ST2 498857100 VALVE OIL SEAL GUIDE
1. VALVE SPRING
Color of rubber part:
1) Check the valve springs for damage, free length, Intake [Black]
and tension. Replace the valve spring if it is not to
Exhaust [Brown]
the specifications presented below.
2) To measure the squareness of valve spring, Color of spring part:
stand the spring on a surface plate and measure its Intake [Silver]
deflection at the top using a try square. Exhaust [Silver]
214 — 246 N
(21.8 — 25.1 kgf, 48.1 — 55.3 lb)/
Tension/spring 45.0 mm (1.772 in)
height 526 — 582 N
(53.6 — 59.3 kgf, 118.3 — 130.8 lb)/
34.7 mm (1.366 in)
B2M2633A
F: ADJUSTMENT
1. CYLINDER HEAD
1) Make sure that no crack or other damage exists.
In addition to visual inspection, inspect important
areas by means of red lead check.
Also make sure that gasket installing surface
G2M0154 shows no trace of gas and water leaks.
2) Place the cylinder head on ST.
ME-66
MECHANICAL
3) Measure the warping of the cylinder head sur- 2. VALVE SEAT

face that mates with crankcase using a straight
Inspect the intake and exhaust valve seats, and
edge and thickness gauge.
then correct the contact surfaces with valve seat
If the warping exceeds 0.05 mm (0.0020 in), re-
cutter if they are defective or when valve guides are
grind the surface with a surface grinder.
replaced.
Warping limit:
Valve seat width: W
0.05 mm (0.0020 in)
Intake
Grinding limit: Standard 1.0 mm (0.039 in)
0.1 mm (0.004 in) Limit 1.7 mm (0.067 in)
Exhaust
Standard height of cylinder head:
Standard 1.4 mm (0.055 in)
97.5 mm (3.839 in)
Limit 2.1 mm (0.083 in)
CAUTION:
Uneven torque for the cylinder head bolts can
cause warping. When reassembling, pay spe-
cial attention to the torque so as to tighten
evenly.
G2M0149
S2M1817A
(A) Straight edge

(B) Thickness gauge
B2M0074
ME-67
MECHANICAL
3. VALVE GUIDE (2) Insert the ST2 into valve guide and press it
down to remove valve guide.
1) Check the clearance between valve guide and
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
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 G2M0150
0.15 mm (0.0059 in)
(3) Turn the cylinder head upside down and
place ST as shown in the figure.
Intake side:
ST 499767700 VALVE GUIDE ADJUSTER
Exhaust side:
ST 499767800 VALVE GUIDE ADJUSTER
B2M0387A
B2M0077D
(A) Valve guide
(4) Before installing new oversize valve guide,

make sure that neither scratches nor damages
B2M0076B
exist on the inside surface of 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 ST1 with the
combustion chamber upward so that valve
guides enter the holes in ST1.
ME-68
MECHANICAL
(5) Put new valve guide, coated with sufficient (7) Ream the inside of valve guide with ST.
oil, in the cylinder, and then insert the ST1 into Gently rotate the reamer clockwise while press-
valve guide. Press in until the valve guide upper ing it lightly into valve guide, and return it also ro-
end is flush with the upper surface of ST2. tating clockwise. After reaming, clean the valve
ST1 499767200 VALVE GUIDE REMOVER guide to remove chips.
Intake side: CAUTION:
ST2 499767700 VALVE GUIDE ADJUSTER • Apply engine oil to the reamer when reaming.
Exhaust side: • If the inner surface of the valve guide is torn,
ST2 499767800 VALVE GUIDE ADJUSTER 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.
ST 499767400 VALVE GUIDE REAMER
B2M2632A
(6) Check the valve guide protrusion.

Valve guide protrusion: L
Intake
20.0 — 20.5 mm (0.787 — 0.807 in) B2M0078
Exhaust
16.5 — 17.0 mm (0.650 — 0.669 in) (8) Recheck the contact condition between
valve and valve seat after replacing valve guide.
B2M0077C
(A) Valve guide
ME-69
MECHANICAL
4. INTAKE AND EXHAUST VALVE

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

seat surface and lap the valve and seat surface.
<Ref. to ME-67, VALVE SEAT, ADJUSTMENT,
Cylinder Head Assembly.> Install a new intake
valve oil seal after lapping.
ME-70
CYLINDER BLOCK
MECHANICAL
21.Cylinder Block 12) Remove the bolts (a) and (b) to remove cylin-
der head.
A: REMOVAL
NOTE:
Before conducting this procedure, drain the engine
oil completely if applicable.
1) Remove the intake manifold. <Ref. to FU-17,
REMOVAL, Intake Manifold.> or <Ref. to FU(w/
oOBD)-17, REMOVAL, Intake Manifold.>
V-belt.>
3) Remove the crankshaft pulley. <Ref. to ME-46, B2M2628A
4) Remove the belt cover. <Ref. to ME-48, RE- 13) Remove the cylinder head gasket.
MOVAL, Belt Cover.> CAUTION:
5) Remove the timing belt assembly. <Ref. to ME- Do not scratch the mating surface of cylinder
49, REMOVAL, Timing Belt Assembly.> head and cylinder block.
6) Remove the camshaft sprocket. <Ref. to ME-54, 14) Similarly, remove the right side cylinder head.
REMOVAL, Camshaft Sprocket.> 15) Remove the clutch housing cover (MT vehicles
7) Remove the crankshaft sprocket. <Ref. to ME- only).
46, REMOVAL, Crankshaft Pulley.> 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 the 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 cylinder head from falling.
S2M1818C
• AT MODEL
B2M2628A
11) While tapping the cylinder head with a plastic

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

ST2 499057000 TORX PLUS (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 then remove
the oil pan.
CAUTION:
Do not use a screwdriver or similar tool in place
of oil pan cutter.
B2M3347A
17) Remove the oil separator cover.

18) Remove the water by-pass pipe for heater.
19) Remove the water pump.
20) Remove the oil pump from cylinder block.
Use a flat-bladed screwdriver as shown in the fig-
ure when removing oil pump.
CAUTION:
Be careful not to scratch the mating surface of S2M1820
cylinder block and oil pump.
22) Remove the oil strainer stay.
23) Remove the oil strainer.
24) Remove the baffle plate.
25) Remove the oil filter using ST.
S2M1819
B2M2611A
26) Remove the water pipe.
B2M2638
ME-72
CYLINDER BLOCK
MECHANICAL
S2M1590B
(1) Service hole plug (3) Circlip (5) Service hole cover
(2) Gasket (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 hexagon wrench [14 mm (0.55 tons to bottom dead center position, and then re-
in)]. move the piston circlip through service hole of #1
and #2 cylinders.
B2M2620
G2M0165
ME-73
CYLINDER BLOCK
MECHANICAL
29) Draw out the piston pin from #1 and #2 pistons 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, and then remove the
cylinder block connecting bolts.
34) Separate the cylinder blocks (RH) and (LH).
CAUTION:
When separating the cylinder block, do not al-
low the connecting rod to fall and damage the
cylinder block.
G2M0166
B2M2408A
(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- wooden bar or hammer handle.
ing rod. CAUTION:
37) Remove the crankshaft bearings from cylinder Do not confuse the combination of piston and
block using hammer handle. cylinder.
CAUTION:
Do not confuse the combination of crankshaft
bearings. Press bearing at the end opposite to
locking lip.
ME-74
CYLINDER BLOCK
MECHANICAL
B: INSTALLATION
B2M2407A
(1) Crankshaft bearing (4) Rear oil seal Tightening torque: N·m (kgf-m, ft-lb)
(2) Crankshaft T1: 25 (2.5, 18.1)
(3) Cylinder block T2: 47 (4.8, 34.7)
CAUTION: CAUTION:
Remove oil in the mating surface of bearing and Do not allow fluid packing to jut into O-ring
cylinder block before installation. Also apply a grooves, oil passages, bearing grooves, etc.
coat of engine oil to crankshaft pins.
1) Position the crankshaft on #2 and #4 cylinder
block.
2) Apply fluid packing to the mating surface of #1
and #3 cylinder block, and position it on #2 and #4
cylinder block.
Fluid packing:
THREE BOND 1215 or equivalent
S2M1826A
ME-75
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
B2M0088D S2M1827A
4) Tighten the 10 mm cylinder block connecting

(A) Rear oil seal
bolts in alphabetical sequence.
(B) Fly wheel 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.
8) Position the second ring gap at 180° on the re-
verse side for top ring gap.
• 1600 cc MODEL
B2M0088D
5) Tighten the 8 mm and 6 mm cylinder block con-

necting bolts in alphabetical sequence shown in the
figure. H2M3248
Tightening torque: • 2000 cc MODEL

(A) — (G): 25 N·m (2.5 kgf-m, 18.1 ft-lb)
180˚
(H): 6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
B0SH
B2M4617A
B2M0089F
ME-76
CYLINDER BLOCK
MECHANICAL
• 2500 cc MODEL 10) Position the lower rail gap at (D) in the figure.
• 1600 cc MODEL
180˚
(D)
B5SH
B2M4618A
EN1379
9) Position the expander gap at (C) in the figure.
• 1600 cc MODEL • 2000 cc MODEL
25˚
B0SH
(C) EN1378 B2M4621A
• 2000 cc MODEL • 2500 cc MODEL
25˚
B0SH
B5SH
B2M4619A B2M4622A
• 2500 cc MODEL NOTE:

Align the lower rail stopper (F) to the lateral hole (E)
on the piston.
B5SH
B2M4620A
B2M4601A
ME-77
CYLINDER BLOCK
MECHANICAL
11) Position the upper rail gap at (G) in the figure. 12) Install circlip.
• 1600 cc MODEL Install circlips in the piston holes located opposite
service holes in cylinder block, when positioning all
pistons in the corresponding cylinders.
(G) NOTE:
Use new circlips.
EN1380
• 2000 cc MODEL
B2M1403A
30˚ CAUTION:
Piston front mark faces towards the front of the
engine.
B0SH
• 1600 cc MODEL
B2M4623A
• 2500 cc MODEL
30˚
EN1497
B5SH • 2000 cc MODEL
B2M4624A
CAUTION:
• Ensure ring gaps do not face the same direc-
tion.
B0SH
• Ensure ring gaps are not within the piston
skirt area.
B2M4625A
ME-78
CYLINDER BLOCK
MECHANICAL
• 2500 cc MODEL
B5SH
B2M4626A
(A) Front mark
B2M1322J
(1) Piston (4) Gasket Tightening torque: N·m (kgf-m, ft-lb)

(2) Piston pin (5) Service hole plug T: 69 (7.0, 50.6)
(3) Circlip
13) Installing piston ST2 498747300 PISTON GUIDE (2500 cc
(1) Turn the cylinder block so that #1 and #2 cyl- model)
inders face upward.
(2) Using the ST1, turn the crankshaft so that
#1 and #2 connecting rods are set at bottom
dead center.
ST1 499987500 CRANKSHAFT SOCKET
(3) Apply a coat of engine oil to pistons and cyl-
inders, and then insert the pistons in their cylin-
ders using ST2.
ST2 498747000 PISTON GUIDE (1600 cc
model)
ST2 398744300 PISTON GUIDE (2000 cc S2M0306A
model)
ME-79
CYLINDER BLOCK
MECHANICAL
14) Installing piston pin (5) Install the service hole plug and gasket.
(1) Insert the ST3 into service hole to align pis- NOTE:
ton pin hole with connecting rod small end. Use a new gasket.
CAUTION:
Apply a coat of engine oil to the ST3 before in-
sertion.
ST3 499017100 PISTON PIN GUIDE
B2M2620
G2M0189
(2) Apply a coat of engine oil to the piston pin,

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

plug.
Fluid packing:
B2M2625
ME-80
CYLINDER BLOCK
MECHANICAL
B2M1323K
(1) 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 the matching surfaces,
inders face upward. Using the same procedures then and install the oil pan.
as used for #1 and #2 cylinders, install the pis-
Fluid packing:
tons and piston pins.
15) Install the water pipe.
S2M1833A
B2M2638
16) Install the baffle plate.

Tightening torque:
6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
17) Install the oil strainer and O-ring
Tightening torque:
10 N·m (1.0 kgf-m, 7 ft-lb)
18) Install the oil strainer stay.
ME-81
CYLINDER BLOCK
MECHANICAL
20) Apply fluid packing to the matching surfaces, ST1 498497100 CRANKSHAFT STOPPER
and then install the oil separator cover. ST2 499057000 TORX PLUS
Fluid packing:
B2M3347A
22) Install the housing cover.

S2M1834A 23) Installation of oil pump
(1) Discard the front oil seal after removal. Re-
21) Install the flywheel or drive plate. place with a new one using the ST.
To lock the crankshaft, use ST. ST 499587100 OIL SEAL INSTALLER
ST 498497100 CRANKSHAFT STOPPER
Tightening torque:
72 N·m (7.3 kgf-m, 52.8 ft-lb)
S2M0235
(2) Apply fluid packing to the matching surface

of oil pump.
B2M3361A
Fluid packing:
B2M3393A
NOTE: S2M0739A
Use the ST to remove flywheel (MT vehicles only)

for 2500 cc model. (A) O-ring
(3) Apply a coat of engine oil to the inside of oil

seal.
ME-82
CYLINDER BLOCK
MECHANICAL
26) Install the oil filter using ST.

S2M0118B
(4) Install the oil pump on cylinder block. Be

B2M2611A
careful not to damage the oil seal during instal-
lation. 27) Tighten the cylinder head bolts.
Tightening torque: (1) Apply a coat of engine oil to the washers and
6.4 N·m (0.65 kgf-m, 4.7 ft-lb) bolt threads.
(2) Tighten all bolts to 29 N·m (3.0 kgf-m, 22 ft-
CAUTION: lb) in alphabetical sequence.
• Do not forget to the install the O-ring and seal Then tighten all bolts to 69 N·m (7.0 kgf-m, 51 ft-
when installing oil pump. lb) in alphabetical sequence.
• Align flat surface of oil pump's inner rotor (3) Back off all bolts by 180° first; back them off
with crankshaft before installation. by 180° again.
24) Install the water pump and gasket. (4) Tighten the bolts (a) and (b) to 34 N·m (3.5
Tightening torque: kgf-m, 25 ft-lb).
First; 12 N·m (1.2 kgf-m, 8.7 ft-lb) (5) Tighten the bolts (c), (d), (e) and (f) to 15
Second; 12 N·m (1.2 kgf-m, 8.7 ft-lb) N·m (1.5 kgf-m, 11 ft-lb).
(6) Tighten all bolts by 80 to 90° in alphabetical
CAUTION: sequence.
• Be sure to use a new gasket.
• When installing the water pump, tighten the CAUTION:
bolts in two stages in alphabetical sequence as Do not tighten bolts more than 90°°.
shown in the figure. (7) Further tighten all bolts by 80 to 90° in al-
phabetical sequence.
CAUTION:
Ensure that the total “re-tightening angle” [in
the former two steps], do not exceed 180°°.
H2M1568B
25) Install the water by-pass pipe for heater.
B2M2628B
28) Install the oil level gauge guide, and then tight-
en the attaching bolt (left side only).
29) Install the rocker cover.
30) Install the crankshaft sprocket. <Ref. to ME-56,
INSTALLATION, Crankshaft Sprocket.>
ME-83
CYLINDER BLOCK
MECHANICAL
32) Install the timing belt assembly. <Ref. to ME-

50, INSTALLATION, Timing Belt Assembly.>
35) Install the generator and A/C compressor
brackets on cylinder head.
TION, V-belt.>
37) Install the intake manifold. <Ref. to FU-19, IN-
STALLATION, Intake Manifold.> or <Ref. to FU(w/
oOBD)-20, INSTALLATION, Intake Manifold.>
ME-84
CYLINDER BLOCK
MECHANICAL
C: DISASSEMBLY
B2M1320I
(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 good order
to prevent confusion.
5) Remove the circlip.
ME-85
CYLINDER BLOCK
MECHANICAL
D: ASSEMBLY
B2M1320J
(1) Connecting rod bearing (5) Second ring Tightening torque: N·m (kgf-m, ft-lb)
(2) Connecting rod (6) Top ring T: 44.6 (4.55, 32.9)
(3) Connecting rod cap (7) Circlip
(4) Oil ring
1) Install 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 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- 2. CYLINDER AND PISTON
ply oil on the threads. 1) The cylinder bore size is stamped on cylinder
4) Install the expander, lower rail and upper rail in block's front upper surface.
this order by hand. Then install the second ring and
CAUTION:
top ring with a piston ring expander.
Measurement should be performed at a temper-
ature 20°°C (68°°F).
NOTE:
Standard sized pistons are classified into two
grades, “A” and “B”. These grades should be used
as a guide line in selecting a standard piston.
ME-86
CYLINDER BLOCK
MECHANICAL
Standard diameter: 2) How to measure the inner diameter of each cyl-

1600 cc MODEL inder
A: 87.905 — 87.915 mm (3.4608 — 3.4612 Measure the inner diameter of each cylinder in both
in) the thrust and piston pin directions at the heights
B: 87.895 — 87.905 mm (3.4604 — 3.4608 shown in the figure, using a cylinder bore gauge.
in) CAUTION:
2000 cc MODEL Measurement should be performed at a temper-
A: 92.005 — 92.015 mm (3.6222 — 3.6226 ature 20°°C (68°°F).
in)
B: 91.995 — 92.005 mm (3.6218 — 3.6222 Taper:
in) Standard
2500 cc MODEL 0.015 mm (0.0006 in)
A: 99.505 — 99.515 mm (3.9175 — 3.9179 Limit
in) 0.050 mm (0.0020 in)
B: 99.495 — 99.505 mm (3.9171 — 3.9175 Out-of-roundness:
in) Standard
0.010 mm (0.0004 in)
Limit
0.050 mm (0.0020 in)
H2M1732C
(A) Main journal size mark

(B) Cylinder block RH-LH combination mark
S2M1821A
(C) #1 cylinder bore size mark
(D) #2 cylinder bore size mark (A) Piston pin direction
(E) #3 cylinder bore size mark (B) Thrust direction
(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-87
CYLINDER BLOCK
MECHANICAL
4) How to measure the outer diameter of each pis-

ton
Measure the outer diameter of each piston at the
height shown in the figure. (Thrust direction)
CAUTION:
ature of 20°°C (68°°F).
Piston grade point H:
1600 cc and 2000 cc MODEL
40.0 mm (1.575 in) B2M1305A
2500 cc MODEL
5) Calculate the clearance between cylinder and
37.0 mm (1.457 in) piston.
Piston outer diameter: CAUTION:
1600 cc MODEL Measurement should be performed at a temper-
Standard ature of 20°°C (68°°F).
A: 87.885 — 87.895 mm
(3.4600 — 3.4604 in) Cylinder to piston clearance at 20°C (68°F):
B: 87.875 — 87.885 mm Standard
(3.4596 — 3.4699 in) 0.010 — 0.030 mm (0.0004 — 0.0012 in)
0.25 mm (0.0098 in) oversize Limit
88.125 — 88.135 mm 0.050 mm (0.0020 in)
(3.4695 — 3.4699 in) 6) Boring and honing
0.50 mm (0.0197 in) oversize (1) If the value of taper, out-of-roundness, or
88.375 — 88.385 mm cylinder-to-piston clearance measured exceeds
(3.4793 — 3.4797 in) the specified limit or if there is any damage on
2000 cc MODEL the cylinder wall, rebore it to use an oversize pis-
Standard ton.
A: 91.985 — 91.995 mm CAUTION:
(3.6214 — 3.6218 in) When any of the cylinders needs reboring, all
B: 91.975 — 91.985 mm other cylinders must be bored at the same time,
(3.6211 — 3.6214 in) and use oversize pistons. Do not perform bor-
0.25 mm (0.0098 in) oversize ing on one cylinder only, nor use an oversize
92.225 — 92.235 mm piston for one cylinder only.
(3.6309 — 3.6313 in) (2) If the cylinder inner diameter exceeds the
0.50 mm (0.0197 in) oversize limit after boring and honing, replace the crank-
92.475 — 92.485 mm case.
(3.6407 — 3.6411 in) CAUTION:
2500 cc MODEL Immediately after reboring, the cylinder diame-
Standard ter may differ from its real diameter due to tem-
A: 99.485 — 99.495 mm perature rise. Thus, pay attention to this when
(3.9167 — 3.9171 in) measuring the cylinder diameter.
B: 99.475 — 99.485 mm
Limit of cylinder enlarging (boring):
(3.9163 — 3.9167 in)
0.5 mm (0.020 in)
0.25 mm (0.0098 in) oversize
99.725 — 99.735 mm
(3.9262 — 3.9266 in)
0.50 mm (0.0197 in) oversize
99.975 — 99.985 mm
(3.9360 — 3.9364 in)
ME-88
CYLINDER BLOCK
MECHANICAL
3. PISTON AND PISTON PIN 5) Check the piston pin circlip for distortion, cracks
and wear.
1) Check the pistons and piston pins for damage,
cracks, and wear and the piston ring grooves for 4. PISTON RING
wear and damage. Replace if defective.
1) If the piston ring is broken, damaged, or worn, or
2) Measure the piston-to-cylinder clearance at
if its tension is insufficient, or when the piston is re-
each cylinder. <Ref. to ME-86, CYLINDER AND
placed, replace the piston ring with a new one of
PISTON, INSPECTION, Cylinder Block.> If any of
the same size as the piston.
the clearances is not to specification, replace the
piston or bore the cylinder to use an oversize pis- CAUTION:
ton. • Marks are shown on the end of top and sec-
3) Make the sure that piston pin can be inserted ond rings. When installing the rings to piston,
into piston pin hole with a thumb at 20°C (68°F). face these marks upward.
Replace if defective. • Oil ring is composed of upper rail, expander
and lower rail. Be careful of the rail direction
Standard clearance between piston pin and when installing oil ring to the pisiton.
hole in piston:
Standard
0.004 — 0.008 mm (0.0002 — 0.0003 in)
Limit
0.020 mm (0.0008 in)
B2M1401
B2M4595A
(A) Upper rail

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

burr (A). If necessary, remove the burr from groove
so that piston pin can lightly move.
B2M0420C
ME-89
CYLINDER BLOCK
MECHANICAL
2) Squarely place the piston ring and oil ring in cyl- 5. CONNECTING ROD
inder, and then measure the piston ring gap with a
1) Replace the connecting rod, if the large or small
thickness gauge.
end thrust surface is damaged.
Unit: mm (in) 2) Check for bend or twist using a connecting rod
Standard Limit aligner. Replace the connecting rod if the bend or
0.20 — 0.35 twist exceeds the limit.
Top ring 1.0 (0.039)
(0.0079 — 0.0138)
Limit of bend or twist per 100 mm (3.94 in) in
Piston Second 0.35 — 0.50 length:
1.0 (0.039)
ring gap ring (0.0138 — 0.0197)
0.10 mm (0.0039 in)
Oil ring 0.20 — 0.50
1.5 (0.059)
rail (0.0079 — 0.0197)
S2M1823
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.
Unit: mm (in)
Standard Limit B2M1184B
0.055 — 0.090
Clearance Top ring (0.0022 — 0.15 (0.0059) (A) Thickness gauge
between pis-
0.0035) (B) Connecting rod
ton ring and
piston ring 0.030 — 0.070
Second 3) Install the connecting rod fitted with bearing to
groove (0.0012 — 0.15 (0.0059)
ring crankshaft, and then measure the side clearance
0.0028)
(thrust clearance). Replace the connecting rod if
the side clearance exceeds the specified limit.
Connecting rod side clearance:
Standard
0.070 — 0.330 mm (0.0028 — 0.0130 in)
Limit
0.4 mm (0.016 in)
B2M1402
EN0335
ME-90
CYLINDER BLOCK
MECHANICAL
4) Inspect the connecting rod bearing for scar, Connecting rod oil clearance:
peeling, seizure, melting, wear, etc.
• 2500 cc MODEL
5) Measure the oil clearance on individual connect-
Standard
ing rod bearings by means of plastigauge. If any oil
0.012 — 0.037 mm (0.0005 — 0.0015 in)
clearance is not within specification, replace the
defective bearing with a new one of standard size Limit
or undersize as necessary. (See the table below.) 0.050 mm (0.0020 in)
Connecting rod oil clearance: Unit: mm (in)

Bearing size
• 1600 cc MODEL Outer diameter of
Bearing (Thickness at cen-
Standard crank pin
ter)
0.010 — 0.038 mm (0.0004 — 0.0015 in) 1.490 — 1.502 51.984 — 52.000
Limit Standard
(0.0587 — 0.0591) (2.0466 — 2.0472)
0.05 mm (0.0020 in) 0.03
1.504 — 1.512 51.954 — 51.970
(0.0012)
Unit: mm (in) (0.0592 — 0.0595) (2.0454 — 2.0461)
undersize
Bearing size 0.05
Outer diameter of 1.514 — 1.522 51.934 — 51.950
Bearing (Thickness at cen- (0.0020)
crank pin (0.0596 — 0.0599) (2.0446 — 2.0453)
ter) undersize
1.492 — 1.501 47.954 — 48.000 0.25
Standard 1.614 — 1.622 51.734 — 51.750
(0.0587 — 0.0591) (4.8879 — 1.8898) (0.0098)
0.03 (0.0635 — 0.0639) (2.0368 — 2.0374)
1.510 — 1.513 47.954 — 47.970 undersize
(0.0012)
(0.0594 — 0.0596) (1.8879 — 1.8886)
undersize 6) Inspect the bushing at connecting rod small end,
0.05 and replace if worn or damaged. Also measure the
1.520 — 1.523 47.934 — 47.950
(0.0020) piston pin clearance at connecting rod small end.
(0.0598 — 0.0600) (1.8872 — 1.8878)
undersize
Clearance between piston pin and bushing:
0.25
(0.0098)
1.620 — 1.623 47.734 — 47.750 Standard
(0.0638 — 0.0639) (1.8793 — 1.8799) 0 — 0.022 mm (0 — 0.0009 in)
undersize
Limit
Connecting rod oil clearance: 0.030 mm (0.0012 in)
• 2000 cc MODEL
Standard
0.010 — 0.038 mm (0.0004 — 0.0015 in)
Limit
0.05 mm (0.0020 in)
Unit: mm (in)
Bearing size
Outer diameter of
crank pin
ter)
1.492 — 1.501 51.984 — 52.000 B2M0085
Standard
(0.0587 — 0.0591) (2.0466 — 2.0472)
0.03
1.510 — 1.513 51.954 — 51.970
(0.0012)
(0.0594 — 0.0596) (2.0454 — 2.0461)
undersize
0.05
1.520 — 1.523 51.934 — 51.950
(0.0020)
(0.0598 — 0.0600) (2.0446 — 2.0453)
undersize
0.25
1.620 — 1.623 51.734 — 51.750
(0.0098)
(0.0638 — 0.0639) (2.0368 — 2.0374)
undersize
EN0337
ME-91
CYLINDER BLOCK
MECHANICAL
7) Replacement procedure is as follows.

(1) Remove the bushing from connecting rod
with ST and press.
(2) Press the bushing with ST after applying oil
on the periphery of bushing.
ST 499037100 CONNECTING ROD BUSH-
ING REMOVER AND IN-
STALLER
G2M0177
(3) Make two 3 mm (0.12 in) holes in bushing.

Ream the inside of bushing.
(4) After the completion of reaming, clean the
bushing to remove chips.
ME-92
CYLINDER BLOCK
MECHANICAL
6. CRANKSHAFT AND CRANKSHAFT 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 then
1) Clean the crankshaft completely and check for replace or recondition the crankshaft as necessary.
cracks by means of red lead check etc., and re- When grinding the crank journal or crank pin, finish
place if defective. them to specified dimensions according to the un-
2) Measure the crankshaft bend, and correct or re- dersize bearing 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 the
#1 and #5 crankshaft bearing on cylinder block, 0.020 mm (0.0008 in) or less
position the crankshaft on these bearings and Taper limit
measure the crankshaft bend using a dial 0.07 mm (0.0028 in)
gauge. Grinding limit
0.250 mm (0.0098 in)
Crankshaft bend limit:
0.035 mm (0.0014 in)
G2M0179
EN0339
Unit: mm (in)
Crank journal diameter Crank pin diameter
#1, #3 #2, #4, #5 1600 cc 2000 cc 2500 cc
Journal 59.992 — 60.008 59.992 — 60.008 47.984 — 48.000 51.984 — 52.000 51.984 — 52.000
O.D. (2.3619 — 2.3625) (2.3619 — 2.3625) (1.8891 — 1.8898) (2.0466 — 2.0472) (2.0466 — 2.0472)
Standard Bearing
size 1.998 — 2.011 2.000 — 2.013 1.492 — 1.510 1.492 — 1.501 1.490 — 1.502
(Thickness (0.0787 — 0.0792) (0.0787 — 0.0793) (0.0587 — 0.0594) (0.0587 — 0.0591) (0.0587 — 0.0591)
at center)
Journal 59.962 — 59.978 59.962 — 59.978 47.954 — 47.970 51.954 — 51.970 51.954 — 51.970
O.D. (2.3607 — 2.3613) (2.3607 — 2.3613) (1.8879 — 1.8886) (2.0454 — 2.0461) (2.0454 — 2.0461)
0.03
(0.0012) Bearing
undersize size 2.017 — 2.020 2.019 — 2.022 1.510 — 1.513 1.510 — 1.513 1.504 — 1.512
(Thickness (0.0794 — 0.0795) (0.0795 — 0.0796) (0.0594 — 0.0596) (0.0594 — 0.0596) (0.0592 — 0.0595)
at center)
Journal 59.942 — 59.958 59.942 — 59.958 47.934 — 47.950 51.934 — 51.950 51.934 — 51.950
O.D. (2.3599 — 2.3605) (2.3599 — 2.3605) (1.8872 — 1.8878) (2.0446 — 2.0453) (2.0446 — 2.0453)
0.05
(0.0020) Bearing
undersize size 2.027 — 2.030 2.029 — 2.032 1.520 — 1.523 1.520 — 1.523 1.514 — 1.522
(Thickness (0.0798 — 0.0799) (0.0799 — 0.0800) (0.0598 — 0.0600) (0.0598 — 0.0600) (0.0596 — 0.0599)
at center)
Journal 59.742 — 59.758 59.742 — 59.758 47.734 — 47.750 51.734 — 51.750 51.734 — 51.750
O.D. (2.3520 — 2.3527) (2.3520 — 2.3527) (1.8793 — 1.8799) (2.0368 — 2.0374) (2.0368 — 2.0374)
0.25
(0.0098) Bearing
undersize size 2.127 — 2.130 2.129 — 2.132 1.620 — 1.623 1.620 — 1.623 1.614 — 1.622
(Thickness (0.0837 — 0.0839) (0.0838 — 0.0839) (0.0638 — 0.0639) (0.0638 — 0.0639) (0.0635 — 0.0639)
at center)
O.D. : Outer Diameter
ME-93
CYLINDER BLOCK
MECHANICAL
4) Measure the thrust clearance of crankshaft at

center bearing. If the clearance exceeds the limit,
replace bearing.
Crankshaft thrust clearance:
Standard
0.030 — 0.115 mm (0.0012 — 0.0045 in)
Limit
0.25 mm (0.0098 in)
EN0341
5) Inspect the individual crankshaft bearings for

signs of flaking, seizure, melting, and wear.
6) Measure the oil clearance on each crankshaft
bearing by means of plastigauge. If the measure-
ment is not within the specification, replace the de-
fective bearing with an undersize one, and then
replace or recondition the crankshaft as necessary.
Unit: mm (in)
Crankshaft oil clearance
0.010 — 0.030 (0.0004 —
Standard
0.0012)
Limit 0.040 (0.0016)
ME-94
ENGINE TROUBLE IN GENERAL
MECHANICAL
22.Engine Trouble in General

A: INSPECTION
NOTE:
“RANK” shown in the chart refer to the possibility of reason for the trouble in order (“Very often” to “Rarely”)
A — Very often
B — Sometimes
C — Rarely
TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE 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
• Defective starter B
• Battery • Poor terminal connection A
• Run-down battery A
• Defective charging system B
• Friction • Seizure of crankshaft and connecting rod bearing C
• Seized camshaft C
• Seized or stuck piston and cylinder C
2) Initial combustion does • Starter • Defective starter C
not occur. • Engine control system <Ref. to EN-2, Basic Diagnostic Procedure.> or <Ref. to EN(w/ A
• Fuel line • Defective fuel pump and relay A
• Lack of or insufficient fuel B
• Belt • Defective B
• Defective timing B
• Compression • Incorrect valve clearance C
• Loosened spark plugs or defective gasket C
• Loosened cylinder head bolts or defective gasket 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-95
MECHANICAL

3) Initial combustion occur. • Engine control system <Ref. to EN-2, Basic Diagnostic Procedure.> or <Ref. to EN(w/ A
• Intake system • Defective intake manifold gasket B
• Defective throttle body gasket B
• Fuel line • Defective fuel pump and relay C
• Clogged fuel line C
4) Engine stalls after initial • Engine control system <Ref. to EN-2, Basic Diagnostic Procedure.> or <Ref. to EN(w/ A
combustion. oOBD)-2, Basic Diagnostic Procedure.>
• Intake system • Loosened or cracked intake duct B
• Loosened or cracked PCV hose C
• Loosened or cracked vacuum hose C
• Defective intake manifold gasket B
• Dirty air cleaner element C
• Fuel line • Clogged fuel line C
ME-96
MECHANICAL

2. Rough idle and engine • Engine control system <Ref. to EN-2, Basic Diagnostic Procedure.> or <Ref. to EN(w/ A
stall oOBD)-2, Basic Diagnostic Procedure.>
• Intake system • Loosened or cracked intake duct A
• Loosened or cracked PCV hose A
• Loosened or cracked vacuum hose A
• Defective PCV valve C
• Loosened oil filler cap B
• Belt • Defective timing C
• Compression • Incorrect valve clearance B
• Loosened spark plugs or defective gasket B
• Loosened cylinder head bolts or defective gasket B
• Improper valve seating B
• Worn or stuck piston rings, cylinder and piston B
• Incorrect valve timing A
• Lubrication system • Incorrect oil pressure B
• Defective rocker cover gasket C
• Cooling system • Overheating C
• Others • Malfunction of evaporative emission control system A
• Stuck or damaged throttle valve B
• Accelerator cable out of adjustment C
ME-97
MECHANICAL

3. Low output, hesitation and • Engine control system <Ref. to EN-2, Basic Diagnostic Procedure.> or <Ref. to EN(w/ A
poor acceleration oOBD)-2, Basic Diagnostic Procedure.>
• Loosened or cracked vacuum hose B
• Defective PCV valve B
• Dirty air cleaner element A
• Fuel line • Defective fuel pump and relay B
• Clogged fuel line B
• Lack of or insufficient fuel C
• Belt • Defective timing B
• Over cooling C
4. Surging • Engine control system <Ref. to EN-2, Basic Diagnostic Procedure.> or <Ref. to EN(w/ A
• Dirty air cleaner element B
• Worn or broken valve spring C
• Cooling system • Overheating B
• Others • Malfunction of evaporative emission control system C
ME-98
MECHANICAL

5. Engine does not return to • Engine control system <Ref. to EN-2, Basic Diagnostic Procedure.> or <Ref. to EN(w/ A
idle. oOBD)-2, Basic Diagnostic Procedure.>
• Intake system • Loosened or cracked vacuum hose A
• Others • Stuck or damaged throttle valve A
• Accelerator cable out of adjustment B
6. Dieseling (Run-on) • Engine control system <Ref. to EN-2, Basic Diagnostic Procedure.> or <Ref. to EN(w/ A
• Others • Malfunction of evaporative emission control system B
7. After burning in exhaust • Engine control system <Ref. to EN-2, Basic Diagnostic Procedure.> or <Ref. to EN(w/ A
system oOBD)-2, Basic Diagnostic Procedure.>
• Intake system • Loosened or cracked intake duct C
• Loosened oil filler cap C
• Lubrication system • Incorrect oil pressure C
• Cooling system • Over cooling C
8. Knocking • Engine control system <Ref. to EN-2, Basic Diagnostic Procedure.> or <Ref. to EN(w/ A
• Intake system • Loosened oil filler cap B
• Cooling system • Overheating A
9. Excessive engine oil con- • Intake system • Loosened or cracked PCV hose A
sumption • Defective PCV valve B
• Compression • Defective valve stem A
• Worn or stuck piston rings, cylinder and piston A
• Lubrication system • Loosened oil pump attaching bolts and defective B
gasket
• Defective oil filter seal B
• Defective crankshaft oil seal B
• Defective rocker cover gasket B
• Loosened oil drain plug or defective gasket B
• Loosened oil pan fitting bolts or defective oil pan B
ME-99
MECHANICAL

10. Excessive fuel consump- • Engine control system <Ref. to EN-2, Basic Diagnostic Procedure.> or <Ref. to EN(w/ A
tion oOBD)-2, Basic Diagnostic Procedure.>
• Intake system • Dirty air cleaner element A
• Others • Accelerator cable out of adjustment B
ME-100
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 spring
• Worn crankshaft main bearing
Oil pressure is low.
• Worn connecting rod bearing (big end)
Heavy and dull clank
• Loose flywheel mounting bolts
Oil pressure is normal.
• Damaged engine mounting
• Ignition timing advanced
High-pitched clank (Spark Sound is noticeable when • Accumulation of carbon inside combustion chamber
knock) accelerating with an overload. • Wrong spark plug
• Improper gasoline
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
Squeaky sound — • Insufficient generator lubrication
Rubbing sound — • Defective generator brush and rotor contact
Gear scream when starting • Defective ignition starter switch
—
engine • Worn gear and starter pinion
Sound like polishing glass with • Loose drive belt
—
a dry cloth • Defective water pump shaft
• Loss of compression
Hissing sound — • Air leakage in air intake system, hoses, connections or mani-
folds
• Loose timing belt
Timing belt noise —
• Belt contacting case/adjacent part
Valve tappet noise — • Incorrect valve clearance
NOTE*:
When disconnecting fuel injector connector, Malfunction Indicator Light (CHECK ENGINE light) illuminates and trouble code is
stored in ECM memory.
Therefore, carry out the CLEAR MEMORY MODE <Ref. to EN-49, OPERATION, Clear Memory Mode.> or <Ref. to EN(w/
oOBD)-30, OPERATION, Clear Memory Mode.> and INSPECTION MODE <Ref. to EN-42, OPERATION, Inspection Mode.> or
<Ref. to EN(w/oOBD)-28, OPERATION, Inspection Mode.> after connecting fuel injector connector.
ME-101
ENGINE NOISE
MECHANICAL
ME-102
EXHAUST
EX
Page
2. Front Exhaust Pipe......................................................................................7
3. Center Exhaust Pipe .................................................................................10
4. Rear Exhaust Pipe ....................................................................................11
5. Muffler .......................................................................................................12
GENERAL DESCRIPTION
EXHAUST
A: COMPONENT
1. 1600 CC
(16)
(15)
(13)
(14)
T7 (16)
(11)
(10)
(12)
(9)
(16)
T1 T4
(27)
T6 T2
(26) T2
(17) (28)
(22) (18)
T4
(25)
T2 (24)
(23)
(8) T2
(3)
T3
(31)
(1) (30)
(2) T6
(3)
(19)
T1
(21) (29)
(4)
(7) T5
T2 (20)
T5 (31)
(6)
(5)
T5
EN1372
EX-2
GENERAL DESCRIPTION
EXHAUST
(1) Upper front exhaust pipe cover (13) Gasket (27) Rear oxygen sensor
CTR (14) Self-locking nut (28) Upper rear catalytic converter
(2) Lower front exhaust pipe cover (15) Muffler cover
CTR (16) Cushion rubber (29) Lower rear catalytic converter
(3) Clamp (17) Lower clamp cover
(4) Upper front exhaust pipe cover LH (18) Upper center exhaust pipe cover (30) Rear catalytic converter
(5) Lower front exhaust pipe cover LH (19) Lower center exhaust pipe cover (31) Gasket
(6) Front exhaust pipe (20) Protector
(7) Lower front exhaust pipe cover (21) Gasket Tightening torque: N·m (kgf-m, ft-lb)
RH (22) Front oxygen (A/F) sensor T1: 8 (0.8, 5.8)
(8) Upper front exhaust pipe cover (23) Front catalytic converter T2: 13 (1.3, 9.4)
RH (24) Center exhaust pipe T3: 18 (1.8, 13.0)
(9) Gasket (25) Lower front catalytic converter T4: 21 (2.1, 15.2)
(10) Spring cover T5: 30 (3.1, 22.4)
(11) Chamber (26) Upper front catalytic converter T6: 35 (3.6, 26.0)
(12) Rear exhaust pipe cover T7: 48 (4.9, 35.4)
EX-3
GENERAL DESCRIPTION
EXHAUST
2. 2000 CC AND 2500 CC
(16)
(15)
(13)
(14)
T2
T7 (16)
(11)
(10)
(17)
(9)
(16)
(12)
T1 T4
(28)
T6
T2
(27) T2
(18) (29)
(23) (19)
T4
(26)
T2 (25)
(24)
(8) T2
(3) T3
(32)
(1) (31)
(2) T6
(3)
(20)
T1
(22) (30)
(4)
(7) T5
T2 (21)
T5 (32)
(6)
(5)
T5
EN1373
EX-4
GENERAL DESCRIPTION
EXHAUST
(1) Upper front exhaust pipe cover (14) Self-locking nut (29) Upper rear catalytic converter
CTR (15) Muffler cover
(2) Lower front exhaust pipe cover (16) Cushion rubber (30) Lower rear catalytic converter
CTR (17) Rear exhaust pipe cover
(3) Clamp (18) Lower clamp (31) Rear catalytic converter
(4) Upper front exhaust pipe cover LH (19) Upper center exhaust pipe cover (32) Gasket
(5) Lower front exhaust pipe cover LH (20) Lower center exhaust pipe cover
(6) Front exhaust pipe (21) Protector Tightening torque: N·m (kgf-m, ft-lb)
(7) Lower front exhaust pipe cover (22) Gasket T1: 8 (0.8, 5.8)
RH (23) Front oxygen (A/F) sensor T2: 13 (1.3, 9.4)
(8) Upper front exhaust pipe cover (24) Front catalytic converter T3: 18 (1.8, 13.0)
RH (25) Center exhaust pipe T4: 21 (2.1, 15.2)
(9) Gasket (26) Lower front catalytic converter T5: 30 (3.1, 22.4)
(10) Spring cover T6: 35 (3.6, 26.0)
(11) Chamber (27) Upper front catalytic converter T7: 48 (4.9, 35.4)
(12) Rear exhaust pipe cover cover
(13) Gasket (28) Rear oxygen sensor
EX-5
GENERAL DESCRIPTION
EXHAUST
B: CAUTION
tion.
points.
cable from battery.
EX-6
FRONT EXHAUST PIPE
EXHAUST
2. Front Exhaust Pipe 5) Separate the front and center exhaust pipe as-
sembly from rear exhaust pipe.
A: REMOVAL WARNING:
1) Disconnect the ground cable from battery. Be careful, the exhaust pipe is hot.
G6M0095
B2M3109
2) Disconnect the front oxygen (A/F) sensor con-
nector. 6) Remove the under cover.
7) Remove the nuts which hold front exhaust pipe
CAUTION:
Be careful not to pull down the front and center
exhaust pipe assembly.
B2M4243
3) Disconnect the rear oxygen sensor connector.
B2M3200
8) Remove the bolt which installs front and center

exhaust pipe assembly to hanger bracket.
B2M4244
B2M3111
EX-7
FRONT EXHAUST PIPE
EXHAUST
9) Remove the front and center exhaust pipe as- 4) Temporarily tighten the bolt which installs front
sembly from vehicle. and center exhaust pipe assembly to hanger brack-
CAUTION: et.
• Be careful not to let the front and center ex-
haust pipe assembly fall off when removing as
it is quite heavy.
• After removing the front and center exhaust
pipe assembly, do not apply excessive pulling
force on the rear exhaust pipe.
10) Separate the front exhaust pipe from center ex-
haust pipe.
B2M3111
5) Tighten the nuts which hold front exhaust pipe

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

rear oxygen sensor. <Ref. to FU-47, REMOVAL,
Front Oxygen (A/F) Sensor.> and <Ref. to FU-49,
REMOVAL, Rear Oxygen Sensor.> .
B: INSTALLATION
1) Install the front oxygen (A/F) sensor and the rear
B2M3200
oxygen sensor. <Ref. to FU-47, INSTALLATION,
Front Oxygen (A/F) Sensor.> and <Ref. to FU-49, 6) Install the under cover.
INSTALLATION, Rear Oxygen Sensor.> . 7) Tighten the bolts which install front and center
2) Install the front exhaust pipe to center exhaust exhaust pipe assembly to rear exhaust pipe.
pipe.
Tightening torque:
NOTE: 18 N·m (1.8 kgf-m, 13.0 ft-lb)
Replace the gaskets with new ones.
Tightening torque:
30 N·m (3.1 kgf-m, 22.4 ft-lb)
B2M3109
S2M0923

bly to vehicle.
EX-8
FRONT EXHAUST PIPE
EXHAUST
8) Tighten the bolt which holds front and center ex- C: INSPECTION
haust pipe assembly to hanger bracket. 1) Make sure there are no exhaust leaks from con-
Tightening torque: nections and welds.
35 N·m (3.6 kgf-m, 26.0 ft-lb) 2) Make sure there are no holes or rusting.
B2M3111

10) Connect the rear oxygen sensor connector.
B2M4244
11) Connect the front oxygen (A/F) sensor connec-

tor.
B2M4243
G6M0095
EX-9
CENTER EXHAUST PIPE
EXHAUST
3. Center Exhaust Pipe

A: REMOVAL
After removing the center and front exhaust pipes
as one unit, separate them. Refer to the procedure
for removing the front exhaust pipe. <Ref. to EX-7,
REMOVAL, Front Exhaust Pipe.>
B: INSTALLATION
Install the center exhaust pipe and front exhaust
pipe as one unit. Refer to the procedure for install-
ing the front exhaust pipe. <Ref. to EX-8, INSTAL-
LATION, Front Exhaust Pipe.>
C: INSPECTION
nections and welds.
EX-10
REAR EXHAUST PIPE
EXHAUST
4. Rear Exhaust Pipe 2) Install the rear exhaust pipe bracket to cushion
rubber.
A: REMOVAL
1) Separate the rear exhaust pipe from center ex-
haust pipe.
CAUTION:
Be careful, the exhaust pipe is hot.
S2M0560
NOTE:
3) Install the rear exhaust pipe to muffler.
B2M3109 Tightening torque:
48 N·m (4.9 kgf-m, 35.4 ft-lb)
2) Separate the rear exhaust pipe from muffler.
CAUTION:
Be careful not to pull down the rear exhaust
pipe.
G2M0382
4) Install the rear exhaust pipe to center exhaust

pipe.
G2M0382 Tightening torque:
18 N·m (1.8 kgf-m, 13.0 ft-lb)
3) Apply a coat of SUBARU CRC to mating area of
the cushion rubbers in advance.
4) Remove the rear exhaust pipe bracket from the
cushion rubber.
B2M3109
C: INSPECTION
nections and welds.
S2M0560 2) Make sure there are no holes or rusting.
3) Make sure the cushion rubber is not worn or
B: INSTALLATION cracked.
EX-11
MUFFLER
EXHAUST
5. Muffler B: INSTALLATION
A: REMOVAL
1) Separate the muffler from rear exhaust pipe. NOTE:
CAUTION:
Be careful, the exhaust pipe is hot. Tightening torque:
48 N·m (4.9 kgf-m, 35.4 ft-lb)
G2M0382
G2M0382
the cushion rubbers in advance. C: INSPECTION
SUBARU CRC (Part No. 004301003) 1) Make sure there are no exhaust leaks from con-
nections and welds.
cracked.
G2M0385
3) Remove the front, right and left cushion rubber,

and detach the muffler assembly.
EX-12
COOLING
CO
Page
2. Radiator Main Fan System........................................................................10
3. Radiator Sub Fan System .........................................................................18
4. Engine Coolant..........................................................................................26
5. Water Pump ..............................................................................................28
6. Thermostat ................................................................................................37
7. Radiator.....................................................................................................39
8. Radiator Cap .............................................................................................47
9. Radiator Main Fan and Fan Motor ............................................................48
10. Radiator Sub Fan and Fan Motor..............................................................50
11. Reservoir Tank..........................................................................................52
12. Coolant Filler Tank ....................................................................................53
13. Engine Cooling System Trouble in General ..............................................54
GENERAL DESCRIPTION
COOLING
A: SPECIFICATIONS
Model Non-turbo Turbo
Cooling system Electric fan + Forced engine coolant circulation system
1.6 L AT: Approx. 7.3
(7.71, 6.42)
1.6 L MT: Approx. 7.4 AT: Approx. 7.6
(7.82, 6.51) (8.03, 6.69)
Total engine coolant capacity 2 (US qt, Imp qt)
2.0 and 2.5 L AT: Approx. 6.9 MT: Approx. 7.7
(7.29, 6.07) (8.14, 6.78)
2.0 and 2.5 L MT: Approx. 7
(7.4, 6.2)
Type Centrifugal impeller type
Discharge 20 2 (5.3 US gal, 4.4 Imp gal)/min.
Discharge perfor- Pump speed—total engine
760 rpm — 0.3 mAq (1.0 ftAq)
mance I coolant head
Engine coolant temperature 85°C (185°F)
Discharge 100 2 (26.4 US gal, 22.0 Imp gal)/min.
3,000 rpm — 5.0 mAq (16.4 ftAq)
mance II coolant head
Water pump Discharge 200 2 (52.8 US gal, 44.0 Imp gal)/min.
6,000 rpm — 23.0 mAq (75.5 ftAq)
mance III coolant head
Impeller diameter 76 mm (2.99 in)
Number of impeller vanes 8
Pump pulley diameter 60 mm (2.36 in)
Clearance between Standard 0.5 — 0.7 mm (0.020 — 0.028 in)
impeller and case Limit 1.0 mm (0.039 in)
“Thrust” runout of impeller end 0.5 mm (0.020 in)
Type Wax pellet type
Starts to open 76 — 80°C (169 — 176°F)
Thermostat Fully opened 91°C (196°F)
Valve lift 9.0 mm (0.354 in) or more
Valve bore 35 mm (1.38 in)
Main fan 70 W 120 W
Motor
Sub fan 70 W 120 W
Radiator fan
320 mm (11.81 in) × 5 (main fan)
Fan diameter × Blade
320 mm (11.81 in) × 7 (sub fan)
Type Down flow, pressure type
AT: 691.5 × 340 × 16
mm
691.5 × 340 × 16 mm (27.22 × 13.39 × 0.63 in)
Core dimensions
(27.22 × 13.39 × 0.63 in) MT: 691.5 × 340 × 27
mm
Radiator (27.22 × 13.39 × 1.06 in)
Above: 108±15 kPa
(1.1±0.15 kg/cm2, 16±2 psi)
Pressure range in which cap valve is open
Below: −1.0 to −4.9 kPa
(−0.01 to −0.05 kg/cm2, −0.1 to −0.7 psi)
Fins Corrugated fin type
Reservoir
Capacity 0.5 2 (0.5 US qt, 0.4 Imp qt)
tank
CO-2
GENERAL DESCRIPTION
COOLING
B: COMPONENT
1. WATER PUMP
• NON-TURBO MODEL
H2M2354A
(1) Water pump ASSY (5) Gasket Tightening torque: N·m (kgf-m, ft-lb)
(2) Gasket (6) Thermostat cover T1: First 12 (1.2, 8.7)
(3) Heater by-pass hose Second 12 (1.2, 8.7)
(4) Thermostat T2: 6.4 (0.65, 4.7)
CO-3
GENERAL DESCRIPTION
COOLING
• TURBO MODEL
H2M1785B
(1) Thermostat cover (6) Heater 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
(8)
(6) (5)
T5
(10) (12)
(7)
T5
T3 (5)
T5
(15)
(4)
T1
(3)
(9)
(11) (13)
(24)
T4
T1 (16)
(17) T2
(2)
T4 (16)
(14)
(18)
(21) (16)
T2
(16)
(1)
(16)
(23) (19)
(20)
(16)
(5)
(22)
EN0068
(1) Radiator lower cushion (14) Radiator main fan (22) Radiator outlet hose
(2) Radiator (15) Radiator main fan motor (23) Radiator lower bracket
(3) Radiator upper cushion (16) ATF hose clamp (AT vehicles (24) Radiator drain plug
(4) Radiator upper bracket only)
(5) Clamp (17) ATF inlet hose A (AT vehicles Tightening torque: N·m (kgf-m, ft-lb)
(6) Radiator inlet hose only) T1: 4.4 (0.45, 3.3)
(7) Engine coolant reservoir tank cap (18) ATF outlet hose A (AT vehicles T2: 12 (1.2, 8.7)
(8) Over flow hose only) T3: 18 (1.8, 13.0)
(9) Engine coolant reservoir tank (19) ATF pipe (AT vehicles only) T4: 3.4 (0.35, 2.5)
(10) Radiator sub fan shroud (20) ATF inlet hose B (AT vehicles T5: 4.9 (0.50, 3.6)
(11) Radiator sub fan only)
(12) Radiator sub fan motor (21) ATF outlet hose B (AT vehicles
(13) Radiator main fan shroud only)
CO-5
GENERAL DESCRIPTION
COOLING
• TURBO MODEL
(21)
(20)
(19)
(5)
(5)
(6) (5)
T4
T4
(11)
(10) (7)
(8) T4
T2 (5)
(13)
(16)
(4)
T1
(3)
(9)
(2)
(12) (14)
(18)
T3
(5) T1
T3
(15)
(17)
(1)
(5)
(22)
EN0069
(1) Radiator lower cushion (10) Over flow pipe (19) Engine coolant filler tank
(2) Radiator (11) Radiator sub fan shroud (20) Engine coolant filler tank cap
(3) Radiator upper cushion (12) Radiator sub fan (21) Engine coolant hose
(4) Radiator upper bracket (13) Radiator sub fan motor (22) Radiator lower bracket
(5) Clamp (14) Radiator main fan shroud Tightening torque: N·m (kgf-m, ft-lb)
(6) Radiator inlet hose (15) Radiator main fan T1: 4.4 (0.45, 3.3)
(7) Engine coolant reservoir tank cap (16) Radiator main fan motor T2: 18 (1.8, 13.0)
(8) Over flow hose (17) Radiator outlet hose T3: 3.4 (0.35, 2.5)
(9) Engine coolant reservoir tank (18) Radiator drain plug T4: 4.9 (0.50, 3.6)
CO-6
GENERAL DESCRIPTION
COOLING
C: CAUTION
tion.
part in the vehicle is hot after running.
points.
cable from battery.
CO-7
GENERAL DESCRIPTION
COOLING
D: PREPARATION TOOL
1. NON-TURBO MODEL
499977100 CRANK PULLEY Used for stopping crankshaft pulley when
WRENCH loosening and tightening crankshaft pulley
bolts. (2500 cc model)
B2M3870
bolts. (1600 cc and 2000 cc model)
B2M4157
18231AA010 CAMSHAFT • Used for removing and installing camshaft
(Newly adopted SPROCKET sprocket.
tool) WRENCH • Also the CAMSHAFT SPROCKET
WRENCH (499207100) can be used.
NOTE:
For common use with turbo model, this ST is
changed and registered as a newly adopted
tool. Though the previous ST also can be
used.
B2M3859
CO-8
GENERAL DESCRIPTION
COOLING
2. TURBO MODEL
bolts.
B2M4157
18231AA010 CAMSHAFT Used for removing and installing camshaft
(Newly adopted SPROCKET sprocket. (Intake)
tool) WRENCH
B2M3859
SPROCKET sprocket. (Exhaust)
WRENCH
B2M4158
CO-9
RADIATOR MAIN FAN SYSTEM
COOLING
2. Radiator Main Fan System

A: SCHEMATIC
1. NON-TURBO MODEL
BATTERY
SBF-1
IGNITION
B72
SWITCH
SBF-4 No.17
AIR CONDITIONING No.18 AIR CONDITIONING

RELAY HOLDER RELAY HOLDER
1 3
F27 20A F27 20A
2 4
26 18
MAIN SUB
28 20
F66 FAN F29 FAN
RELAY 27 19 RELAY
25 17
MAIN FAN SUB FAN

MOTOR MOTOR
2 F45 2
1
2
1 1
B62
F17 F16
1 LHD :2
RHD :7
2 LHD :12
RHD :17
12
3
B134 ECM
F16
LHD: F45 RHD: F45
F17
1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8
2 1 12 13 14 15 16 17 18 19 20 21 22 23 24 9 10 11 12 13 14 15 16 17 18
B134
F27 F29 F66
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
1 2 5 6 9 13 14 17 21 22 25 29
24 25 26 27 28 29 30 31 32 33 34 35
7 10 15 18 23 26
3 4 8 11 12 16 19 20 24 27 28 30
EN1413
CO-10
COOLING
2. TURBO MODEL
BATTERY
SBF-1
IGNITION
B72 SWITCH
SBF-4 No.18
LHD : 2 No.17
*1 RHD : 7
LHD : 12
*2 RHD : 17
17
B137 ECM
28 * 12
*
B62 F45
17
19
20
18
24
22
21
23
25
27
28
26
8
6
5
7
2
1
4
3
30A
30A
1
3
2
1
3
2
F16 F17
SUB FAN SUB FAN MAIN FAN MAIN FAN

RELAY2 RELAY1 RELAY2 RELAY1
M M
E E F29 F28 F30 F66 F27
SUB FAN MAIN FAN
MOTOR MOTOR AIR CONDITIONING RELAY HOLDER
B72 (BLUE) F27 F28 F29 F30 F66 B137 F45 F16
1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 10 11 F17
1 2 1 2 5 6 9 13 14 17 21 22 25 29
3 4 7 10 15 18 23 26 10 11 12 13 14 15 16 17 18 19 20 21 12 13 14 15 16 17 18 19 20 21 22 23 24
3 4 8 11 12 16 19 20 24 27 28 30 22 23 24 25 26 27 28 29 30 31 (LHD) 3 2 1
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18
(RHD)
EN0260
CO-11
COOLING
B: INSPECTION
1. NON-TURBO MODEL
DETECTING CONDITION:
• Engine coolant temperature is above 95°C (203°F).
• Vehicle speed is below 19 km/h (12 MPH).
TROUBLE SYMPTOM:
• Radiator main fan does not rotate under the above conditions.
Step Check Yes No

1 CHECK POWER SUPPLY TO MAIN FAN MO- Is the voltage more than 10 V? Go to step 2. Go to step 5.
TOR.
CAUTION:
Be careful not to overheat the engine during
repair.
1)Turn the ignition switch to OFF.
2)Disconnect the connector from main fan
motor.
3)Start the engine, and warm it up until engine
coolant temperature increases over 95°C
(203°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. 2 (+) — Chassis ground (−):
2 CHECK GROUND CIRCUIT OF MAIN FAN Is the resistance less than 5 Go to step 3. Repair the open
MOTOR. Ω? 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:
3 CHECK POOR CONTACT. Is there poor contact in main Repair the poor Go to step 4.
Check poor contact in main fan motor connec- fan motor connector? contact in main fan
tor. motor connector.
4 CHECK MAIN FAN MOTOR. Does 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. 2, and ground (−) terminal to termi- motor connector. new one.
nal No. 1 of main fan motor connector.
5 CHECK POWER SUPPLY TO MAIN FAN RE- Is the voltage more than 10 V? Go to step 6. Go to step 7.
LAY.
2)Remove the main fan relay from A/C relay
holder.
3)Measure the voltage between main fan relay
terminal and chassis ground.
6 CHECK POWER SUPPLY TO MAIN FAN RE- Is the voltage more than 10 V? Go to step 10. Go to step 9.
LAY.
1)Turn the ignition switch to ON.
2)Measure the voltage between main fan relay
CO-12
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 A/C relay holder.
2)Check the condition of fuse.
8 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 main fan relay box connector and
ground. terminal. 20 A fuse terminal.
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 the condition of fuse. relay and ignition
switch.
10 CHECK MAIN FAN RELAY. Is the resistance more than 1 Go to step 11. Replace the main
1)Turn the ignition switch to OFF. MΩ? 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 Ω? 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 Ω? 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.
(F17) No. 2 — (F66) No. 25:
RELAY AND ECM. Ω? circuit in harness
2)Disconnect the connector from ECM. relay and ECM.
3)Measure the resistance of harness between
main fan relay connector and ECM connector.
(F66) No. 27 — (B134) No. 3:
14 CHECK POOR CONTACT. Is there poor contact in con- Repair the poor Contact with your
Check poor contact in connector between main nector between main fan motor contact connector. Subaru distributor
fan and ECM. and ECM? service.
NOTE:
Inspection by your Subaru distributor is required,
because probable cause is deterioration of multiple
parts.
CO-13
COOLING
2. TURBO MODEL
• A/C compressor is rotated.
TROUBLE SYMPTOM:
• Radiator main fan does not rotate under the above conditions.
• Radiator main fan does not rotate at high speed when the following conditions are both met:
(1) Engine coolant temperature is above 90°C (194°F)
(2) A/C is ON
Step Check Yes No

1 CHECK OPERATION OF RADIATOR. Does the main radiator fan Go to step 2. Go to step 3.
1)Run the engine at idle. (Vehicle stationary) rotate?
2)Turn the A/C switch to OFF.
3)Warm the engine coolant temperature over
96°C (205°F).
2 CHECK OPERATION OF RADIATOR. Does the main radiator fan Radiator main fan Go to step 17.
1)Turn the A/C switch ON at condition of step rotate faster when A/C com- system is okay.
1. pressor is operated?
TOR.
CAUTION:
repair.
motor.
(205°F).
ON.
4 CHECK GROUND CIRCUIT OF MAIN FAN Is the resistance less than 5 Go to step 5. Repair the open
2)Measure the resistance between main fan motor connector
CO-14
COOLING
Step Check Yes No

7 CHECK POWER SUPPLY TO MAIN FAN Is the voltage more than 10 V? Go to step 8. Go to step 9.
RELAY1.
2)Remove the main fan relay1 from A/C relay
holder.
relay1 terminal and chassis ground.
RELAY1.
switch.
2)Remove the main fan relay1.
3)Measure the resistance of main fan relay1.
Terminal
No. 26 — No. 25:
No. 28 of main fan relay1.
Terminal
No. 26 — No. 25:
terminal. terminal.
(F17) No. 3 — (F66) No. 25:
(F66) No. 28 — (B137) No. 17:
CO-15
COOLING
Step Check Yes No

TOR.
CAUTION:
repair.
motor.
(205°F).
4)Turn the A/C switch ON.
5)Measure the voltage while A/C compressor
is rotating.
RELAY2.
2)Remove the main fan relay2 from A/C relay
holder.
RELAY2.
switch.
CO-16
COOLING
Step Check Yes No

Terminal
No. 23 — No. 24:
No. 22 of main fan relay1.
Terminal
No. 23 — No. 24:
terminal. terminal.
(F17) No. 2 — (F66) No. 24:
(F30) No. 21 — (B134) No. 28:
NOTE:
parts.
CO-17
RADIATOR SUB FAN SYSTEM
COOLING
3. Radiator Sub Fan System

A: SCHEMATIC
1. NON-TURBO MODEL
BATTERY
SBF-1
IGNITION
B72
SWITCH
SBF-4 No.17

1 3
F27 20A F27 20A
2 4
26 18
MAIN SUB
28 20
F66 FAN F29 FAN
RELAY 27 19 RELAY
25 17
MAIN FAN SUB FAN

MOTOR MOTOR
2 F45 2
1
2
1 1
B62
F17 F16
1 LHD :2
RHD :7
2 LHD :12
RHD :17
12
3
B134 ECM
F16
LHD: F45 RHD: F45
F17
1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8
2 1 12 13 14 15 16 17 18 19 20 21 22 23 24 9 10 11 12 13 14 15 16 17 18
B134
F27 F29 F66
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
1 2 5 6 9 13 14 17 21 22 25 29
24 25 26 27 28 29 30 31 32 33 34 35
7 10 15 18 23 26
3 4 8 11 12 16 19 20 24 27 28 30
EN1413
CO-18
COOLING
2. TURBO MODEL
BATTERY
SBF-1
IGNITION
B72 SWITCH
SBF-4 No.18
LHD : 2 No.17
*1 RHD : 7
LHD : 12
*2 RHD : 17
17
B137 ECM
28 * 12
*
B62 F45
17
19
20
18
24
22
21
23
25
27
28
26
8
6
5
7
2
1
4
3
30A
30A
1
3
2
1
3
2
F16 F17

M M
E E F29 F28 F30 F66 F27
SUB FAN MAIN FAN
B72 (BLUE) F27 F28 F29 F30 F66 B137 F45 F16
1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 10 11 F17
1 2 1 2 5 6 9 13 14 17 21 22 25 29
3 4 7 10 15 18 23 26 10 11 12 13 14 15 16 17 18 19 20 21 12 13 14 15 16 17 18 19 20 21 22 23 24
3 4 8 11 12 16 19 20 24 27 28 30 22 23 24 25 26 27 28 29 30 31 (LHD) 3 2 1
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18
(RHD)
EN0260
CO-19
COOLING
B: INSPECTION
1. NON-TURBO MODEL
NOTE:
System for A/C equipped vehicles only.
Condition (1):
• Engine coolant temperature is below 95°C (203°F).
• A/C switch is turned ON.
Condition (2):
• A/C switch is turned OFF.
TROUBLE SYMPTOM:
• Radiator sub fan does not rotate under conditions (1) and (2) above.
Step Check Yes No

1 CHECK POWER SUPPLY TO SUB FAN MO- Is the voltage more than 10 V? Go to step 2. Go to step 5.
TOR.
CAUTION:
repair.
2)Disconnect the connector from sub fan motor
and main fan motor.
(212°F).
ON.
5)Measure the voltage between sub fan motor
connector and chassis ground.
2 CHECK GROUND CIRCUIT OF SUB FAN Is the resistance less than 5 Go to step 3. Repair the open
1)Turn the ignition switch to OFF. between sub fan
2)Measure the resistance between sub fan motor connector
3 CHECK POOR CONTACT. Is there poor contact in sub fan Repair the poor Go to step 4.
Check poor contact in sub fan motor connec- motor connector? contact in sub fan
4 CHECK SUB FAN MOTOR. Does the sub fan rotate? Repair the poor Replace the sub
Connect the battery positive (+) terminal to ter- contact in sub fan fan motor with a
nal No. 1 of sub fan motor connector.
5 CHECK POWER SUPPLY TO SUB FAN RE- Is the voltage more than 10 V? Go to step 6. Go to step 7.
LAY.
2)Remove the sub fan relay from A/C relay
holder.
3)Measure the voltage between sub fan relay
CO-20
COOLING
Step Check Yes No

6 CHECK POWER SUPPLY TO SUB FAN RE- Is the voltage more than 10 V? Go to step 10. Go to step 9.
LAY.
2)Measure the voltage between sub fan relay
relay holder 20 A fuse terminal and chassis and sub fan relay box connector and
2)Remove the fuse No. 17 from joint box. between sub fan
switch.
10 CHECK SUB FAN RELAY. Is the resistance more than 1 Go to step 11. Replace the sub
2)Measure the resistance of sub fan relay.
Terminal
No. 17 — No. 18:
11 CHECK SUB FAN RELAY. Is the resistance less than 1 Go to step 12. Replace the sub
No. 19 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 Ω? 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.
(F16) No. 2 — (F29) No. 17:
LAY AND ECM. Ω? circuit in harness
sub fan relay connector and ECM connector.
(F29) No. 19 — (B134) No. 12:
Check poor contact in connector between sub nector between sub fan motor contact connector. Subaru distributor
NOTE:
parts.
CO-21
COOLING
2. TURBO MODEL
• A/C compressor is rotated.
TROUBLE SYMPTOM:
• Radiator sub fan does not rotate under the above conditions.
• Radiator sub fan does not rotate at high speed when the following conditions are both met:
(1) Engine coolant temperature is above 90°C (194°F)
(2) A/C is ON
Step Check Yes No

1 CHECK OPERATION OF RADIATOR. Does the radiator sub fan Go to step 2. Go to step 3.
1)Run the engine at idle. (Vehicle stationary) rotate?
3)Warm the engine coolant temperature over
96°C (205°F).
2 CHECK OPERATION OF RADIATOR. Does the radiator sub fan Radiator main fan Go to step 17.
1)Turn the A/C switch ON at condition of step rotate faster when A/C com- system is okay.
1. pressor is operated?
TOR.
CAUTION:
repair.
2)Disconnect the connector from sub fan
motor.
(205°F).
ON.
4 CHECK GROUND CIRCUIT OF SUB FAN Is the resistance less than 5 Go to step 5. Repair the open
2)Measure the resistance between sub fan motor connector
6 CHECK MAIN FAN MOTOR. Does the main fan rotate? Repair the poor Replace the sub
CO-22
COOLING
Step Check Yes No

7 CHECK POWER SUPPLY TO SUB FAN Is the voltage more than 10 V? Go to step 8. Go to step 9.
RELAY1.
2)Remove the sub fan relay1 from A/C relay
holder.
3)Measure the voltage between sub fan relay1
RELAY1.
Measure the voltage of harness between A/C between 30 A fuse between sub fuse
switch.
3)Measure the resistance of sub fan relay1.
Terminal
No. 7 — No. 8:
13 CHECK SUB FAN RELAY. Is the resistance less than 1 Go to step 14. Replace the sub
No. 5 of sub fan relay1.
Terminal
No. 7 — No. 8:
sub fan motor connector and sub fan relay ter- and sub fan relay
minal. terminal.
(F16) No. 3 — (F28) No. 8:
(F28) No. 6 — (B137) No. 17:
CO-23
COOLING
Step Check Yes No

TOR.
CAUTION:
repair.
2)Disconnect the connector from sub fan
motor.
(205°F).
4)Turn the A/C switch ON.
5)Measure the voltage while A/C compressor
is rotating.
19 CHECK SUB FAN MOTOR. Does the main fan rotate? Repair the poor Replace the sub
RELAY2.
2)Remove the sub fan relay2 from A/C relay
holder.
RELAY2.
Measure the voltage of harness between A/C between 30 A fuse between sub fuse
switch.
CO-24
COOLING
Step Check Yes No

2)Remove the sub fan relay2.
Terminal
No. 18 — No. 17:
26 CHECK MAIN FAN RELAY. Is the resistance less than 1 Go to step 27. Replace the sub
No. 20 of sub fan relay2.
Terminal
No. 18 — No. 17:
sub fan motor connector and sub fan relay2 and sub fan relay
terminal. terminal.
(F16) No. 2 — (F29) No. 17:
(F29) No. 19 — (B137) No. 28:
NOTE:
parts.
CO-25
ENGINE COOLANT
COOLING
4. Engine Coolant 2. FILLING OF ENGINE COOLANT

A: REPLACEMENT 1) Fill engine coolant into the radiator up to filler
neck position.
1. DRAINING OF ENGINE COOLANT Coolant capacity (fill up to “FULL” level):
1) Lift-up the vehicle. 1.6 L AT model
2) Remove the under cover. Approx. 7.3 2(7.71 US qt, 6.42 Imp qt)
3) Remove the drain cock to drain engine coolant 1.6 L MT model
into container. Approx. 7.4 2 (7.82 US qt, 6.51 Imp qt)
NOTE: Non-turbo 2.0 L and 2.5 L AT model
Remove the radiator cap so that engine coolant will Approx. 6.9 2 (7.29 US qt, 6.07 Imp qt)
drain faster. Non-turbo 2.0 L and 2.5 L MT model
Approx. 7 2 (7.4 US qt, 6.2 Imp qt)
Turbo AT model
Turbo MT model
CAUTION:
The SUBARU Genuine Coolant containing anti-
freeze and anti-rust agents is especially made
for SUBARU engine, which has an aluminum
crankcase. Always use SUBARU Genuine Cool-
EN0073
ant, since other coolant may cause corrosion.
2) Fill engine coolant into the reservoir tank up to
upper level.
S2M0552A
3) Warm-up the engine completely for more than 5

minutes at 2,000 to 3,000 rpm.
4) If the engine coolant level drops in radiator, add
engine coolant to filler neck position.
5) If the engine coolant level drops from upper level
of reservoir tank, add engine coolant to upper level.
6) Attach the radiator cap and reservoir tank cap
properly.
CO-26
ENGINE COOLANT
COOLING
B: INSPECTION 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-
tion, and read the scale on the vertical axis of the
graph at height A. The quantity of coolant to be
drained is 2.12 (2.2 US qt, 1.8 Imp qt). Drain 2.1 2
(2.2 US qt, 1.8 Imp qt) of coolant from the cooling
system and add 2.12 (2.2 US qt, 1.8 Imp qt) of the
undiluted solution of SUBARU coolant.
If a coolant concentration of 50% is needed, drain
all the coolant and refill with the undiluted solution
only.
B2M3128A
B2M3129A
CO-27
WATER PUMP
COOLING
5. Water Pump 7) Disconnect the radiator outlet hose and heater

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

9) Remove the air intake duct.
G6M0095

5) Drain the engine coolant completely.
<Ref. to CO-26, DRAINING OF ENGINE COOL-
ANT, REPLACEMENT, Engine Coolant.>
6) Disconnect the connectors from radiator main
fan motor (A) and sub fan motor (B).
EN0063
(A) • 2500 cc MODEL
EN0077
(B)
B6M1224
10) Disconnect the over flow hose.
EN0078
B2M2925
CO-28
WATER PUMP
COOLING
11) Remove the reservoir tank. 17) Remove the camshaft sprocket (LH) by using
ST.
WRENCH
NOTE:
(499207100) can be used.
B2M2926
12) Remove the radiator main fan and sub fan as-
semblies. <Ref. to CO-48, REMOVAL, Radiator
Main Fan and Fan Motor.> and <Ref. to CO-50,
REMOVAL, Radiator Sub Fan and Fan Motor.>
13) Remove the V-belts.
<Ref. to ME-44, REMOVAL, V-belt.> B2M2039A
14) Remove the timing belt.
<Ref. to ME-49, TIMING BELT, REMOVAL, Timing
Belt Assembly.>
15) Remove the automatic belt tension adjuster.
B2M2040

H2M2375
16) Remove the belt idler No. 2.
H2M2380
20) Disconnect the heater hose from water pump.

S2M0024 21) Remove the water pump.
B2M3894
CO-29
WATER PUMP
COOLING
2. TURBO MODEL 7) Remove the bolt which installs water by-pass

pipe of oil cooler onto oil pump.
WARNING:
The radiator is pressurized. Wait until the en-
gine cools down before working on the radia-
tor.
S2M0027
8) Disconnect the radiator outlet hose (A) and heat-

er hose (B) from water pump.
9) Disconnect the water by-pass hose (C) and oil
cooler hose (D).
G6M0095

5) Drain the engine coolant completely. <Ref. to
CO-26, DRAINING OF ENGINE COOLANT, RE-
PLACEMENT, Engine Coolant.>
6) Disconnect the connectors of radiator main fan
motor (A) and sub fan motor (B).
S2M1159A
(A) 10) Lower the vehicle.

12) Remove the reservoir tank.
EN0077
(B)
S2M0931
13) Remove the radiator main fan and sub fan as-
semblies. <Ref. to CO-48, REMOVAL, Radiator
Main Fan and Fan Motor.> and <Ref. to CO-50,
REMOVAL, Radiator Sub Fan and Fan Motor.>
14) Remove the V-belts. <Ref. to ME(TURBO)-44,
EN0078
REMOVAL, V-belt.>
15) Remove the timing belt. <Ref. to ME(TURBO)-
16) Remove the automatic belt tension adjuster
(A).
17) Remove the belt idler (B).
CO-30
WATER PUMP
COOLING
18) Remove the belt idler No. 2 (C). 22) Remove the tensioner bracket.
S2M1160A S2M1163
19) Remove the camshaft position sensor. <Ref. to 23) Disconnect the heater hose from water pump.
FU(TURBO)-31, REMOVAL, Camshaft Position 24) Remove the water pump.
Sensor.>
20) Remove the camshaft sprockets (LH) by using
ST.
WRENCH (Intake)
WRENCH (Exhaust)
S2M1829
B: INSTALLATION
ST
1. NON-TURBO MODEL
1) Install water pump onto cylinder head (LH).
NOTE:
EN1320 • Replace the gasket with a new one.
21) Remove the belt cover No. 2 (LH). • When installing the water pump, tighten bolts in
two stages in alphabetical sequence as shown in
the figure.
Tightening torque:
First:
12 N·m (1.2 kgf-m, 8.7 ft-lb)
Second:
12 N·m (1.2 kgf-m, 8.7 ft-lb)
S2M1162
S2M0760A
CO-31
WATER PUMP
COOLING
2) Install the belt cover No. 2 (LH). 5) Install the belt idler No. 2.
Tightening torque: Tightening torque:
5 N·m (0.5 kgf-m, 3.6 ft-lb) 39 N·m (4.0 kgf-m, 28.9 ft-lb)
B2M2040 S2M0024
3) Install the tensioner bracket. 6) Install the automatic belt tension adjuster which
tension rod is holded with pin. <Ref. to ME-50, AU-
Tightening torque:
TOMATIC BELT TENSION ADJUSTER ASSEM-
25 N·m (2.5 kgf-m, 18.1 ft-lb)
BLY AND BELT IDLER, INSTALLATION, Timing
Belt Assembly.>
7) Install the timing belt. <Ref. to ME-51, TIMING
BELT, INSTALLATION, Timing Belt Assembly.>
8) Install the V-belts. <Ref. to ME-44, INSTALLA-
TION, V-belt.>
9) Install the radiator main fan and sub fan motor
assemblies. <Ref. to CO-49, INSTALLATION, Ra-
diator Main Fan and Fan Motor.> and <Ref. to CO-
50, INSTALLATION, Radiator Sub Fan and Fan
Motor.>
H2M2380
10) Install the reservoir tank.
4) Install the camshaft sprockets (LH) by using ST.
WRENCH
NOTE:
(499207100) can be used.
Tightening torque:
78 N·m (8.0 kgf-m, 57.9 ft-lb)
B2M2926
11) Connect the over flow hose.
B2M2039A
B2M2925
CO-32
WATER PUMP
COOLING
12) Install air intake duct. 15) Connect the connectors to radiator main fan
• 1600 cc and 2000 cc MODEL motor (A) and sub fan motor (B).
(A)
EN0063 EN0077
• 2500 cc MODEL
(B)
EN0078
B6M1224
13) Lift-up the vehicle. 17) Lower the vehicle.
14) Connect the radiator outlet hose and heater 18) Connect the battery ground cable to battery.
hose to water pump.
G6M0095
EN0112
19) Fill engine coolant. <Ref. to CO-26, FILLING
OF ENGINE COOLANT, REPLACEMENT, Engine
Coolant.>
CO-33
WATER PUMP
COOLING
2. TURBO MODEL 4) Install the camshaft sprockets (LH) by using ST.

1) Install the water pump onto cylinder head (LH).
WRENCH (Intake)
NOTE: ST 499207400 CAMSHAFT SPROCKET
• Replace the gasket with a new one. WRENCH (Exhaust)
• When installing the water pump, tighten bolts in
two stages in alphabetical sequence as shown in Tightening torque:
the figure. 98 N·m (10.0 kgf-m, 72.4 ft-lb)
Tightening torque:
First:
12 N·m (1.2 kgf-m, 8.7 ft-lb)
Second:
12 N·m (1.2 kgf-m, 8.7 ft-lb)
ST
EN1320
5) Install the camshaft position sensor. <Ref. to

FU(TURBO)-31, INSTALLATION, Camshaft Posi-
tion Sensor.>
6) Install the belt idler No. 2 (C).
H2M1846C 7) Install the belt idler (B).
8) Install the automatic belt tension adjuster (A)
2) Install the belt cover No. 2 (LH). which has a tension rod held by a pin. <Ref. to
Tightening torque: ME(TURBO)-50, AUTOMATIC BELT TENSION
5 N·m (0.5 kgf-m, 3.6 ft-lb) ADJUSTER ASSEMBLY AND BELT IDLER, IN-
STALLATION, Timing Belt Assembly.>
Tightening torque:
39.4 N·m (4.0 kgf-m, 28.9 ft-lb)
S2M1162

Tightening torque: S2M1160A
25 N·m (2.5 kgf-m, 18.1 ft-lb)
9) Install the timing belt. <Ref. to ME(TURBO)-51,
TIMING BELT, INSTALLATION, Timing Belt As-
sembly.>
10) Install the V-belts. <Ref. to ME(TURBO)-45,
INSTALLATION, V-belt.>
11) Install the radiator main fan and sub fan motor
assemblies. <Ref. to CO-49, INSTALLATION, Ra-
diator Main Fan and Fan Motor.> and <Ref. to CO-
50, INSTALLATION, Radiator Sub Fan and Fan
Motor.>
S2M1163
CO-34
WATER PUMP
COOLING
12) Install the reservoir tank. 18) Connect the connectors to radiator main fan
(A)
S2M0931
EN0077
13) Connect the over flow hose.
15) Connect the radiator outlet hose (A) and heater (B)
hose (B) to water pump.
16) Connect the water by-pass hose (C) and oil
cooler hose (D).
EN0078

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

onto oil pump.
G6M0095

Coolant.>
S2M0027
CO-35
WATER PUMP
COOLING
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 the impeller runout
in thrust direction while rotating the pulley.
“Thrust” runout limit:
0.5 mm (0.020 in)
G2M0211
4) Check the clearance between impeller and

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

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

pull out the thermostat.
A: REMOVAL
G2M0214
B: INSTALLATION
1) Install the thermostat in the water pump, and
then install the thermostat cover together with a
gasket.
EN0073 NOTE:
4) Disconnect the radiator outlet hose from thermo- • When reinstalling the thermostat, use a new gas-
stat cover. ket.
• Non-turbo MODEL • The thermostat must be installed with the jiggle
pin (A) facing to front side.
• At this time, set the jiggle pin of thermostat for
front side.
Tightening torque:
6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
EN0112
5) Disconnect the radiator outlet hose.

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

ENGINE COOLANT, REPLACEMENT, Engine
Coolant.>
EN0107
CO-37
THERMOSTAT
COOLING
C: INSPECTION
Replace the thermostat if the valve does not close
completely at an ambient temperature or if the 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 (169 — 176°F)
Fully opens:
91°C (196°F)
H2M2357A
(A) Thermometer
(B) Thermostat
CO-38
RADIATOR
COOLING
7. Radiator 5) Disconnect the radiator outlet hose from thermo-

stat cover.
A: REMOVAL
1. NON-TURBO MODEL
EN0112
6) Disconnect the ATF cooler hoses from radiator.

(AT vehicles only)
G6M0095

EN0102
(A)
EN0077
(B)
EN0063
• 2500 cc MODEL
EN0078
B6M1224
CO-39
RADIATOR
COOLING
9) Disconnect the over flow hose. 13) Detach the power steering hose from the clip
on the radiator.
B2M2925
B2M2932
14) While slightly lifting the radiator, slide it to left.
15) Lift the radiator up and away from vehicle.
B2M2926
11) Disconnect the radiator inlet hose from engine.

B2M2933
B2M2930
12) Remove the radiator upper brackets.
B2M2931
CO-40
RADIATOR
COOLING
2. TURBO MODEL 7) Disconnect the oil cooler hoses from oil cooler
pipes. (if equipped)
WARNING:
The radiator is pressurized. Wait until the en-
tor.
S2M1743
8) Disconnect the radiator outlet hose from thermo-

stat cover.
G6M0095

EN0107
(A)
EN0077
EN0108
(B)
EN0078
S2M0931
CO-41
RADIATOR
COOLING
13) Remove the V-belt covers. B: INSTALLATION

1. NON-TURBO MODEL
1) Attach the radiator mounting cushions to holes
on the vehicle.
EN0048
14) Disconnect the radiator inlet hose (A) and wa-

ter tank hose (B) from radiator.
B2M2934
(A) 2) Install the radiator while fitting radiator pins to

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

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

17) Lift the radiator up and away from vehicle.
CO-42
RADIATOR
COOLING
4) Attach the power steering hose to radiator. • 2500 cc MODEL
B2M2932 B6M1224
5) Connect the radiator inlet hose. 8) Lift-up the vehicle.

9) Connect the ATF cooler hoses. (AT vehicles
only)
B2M2930
6) Install the reservoir tank. EN0102

Tightening torque:
10) Connect the connectors to radiator main fan
4.9 N·m (0.50 kgf-m, 3.6 ft-lb)
(A)
B2M2926 EN0077
7) Install the air intake duct.

• 1600 cc and 2000 cc MODEL (B)
EN0078
EN0063
CO-43
RADIATOR
COOLING
11) Connect the radiator outlet hose. 2) Install the radiator brackets, and then tighten the
bolts.
Tightening torque:
18 N·m (1.8 kgf-m, 13.0 ft-lb)
EN0112

14) Connect the battery ground cable to battery. EN0035
3) Connect the radiator inlet hose (A) and water

tank hose (B).
(A)
G6M0095

OF ENGINE COOLANT, REPLACEMENT, Engine EN0109
Coolant.>
16) Check the ATF level. <Ref. to AT-9, INSPEC-
TION, Automatic Transmission Fluid.>
2. TURBO MODEL
1) Attach the radiator mounting cushions to holes
on the vehicle.
(B)
EN0110
4) Install the reservoir tank.

Tightening torque:
4.9 N·m (0.50 kgf-m, 3.6 ft-lb)
B2M2934
S2M0934
CO-44
RADIATOR
COOLING
5) Connect the over flow hose. 12) Install the V-belt covers.
7) Connect the connectors to radiator main fan mo-
tor (A) and sub fan motor (B).
(A)
EN0048
13) Install the air intake duct.

EN0077
(B)
EN0108
EN0078
8) Connect the oil cooler hoses. (if equipped)
G6M0095

S2M1743
9) Connect the radiator outlet hose. Coolant.>
EN0107

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

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

stops. Radiator cap is functioning properly if it holds
the service limit pressure for 5 to 6 seconds.
Standard pressure:
93 — 123 kPa (0.95 — 1.25 kg/cm2, 14 — 18
psi)
Service limit pressure:
83 kPa (0.85 kg/cm2, 12 psi)
CAUTION:
Be sure to remove foreign matter and rust from
the cap in advance otherwise, results of pres-
sure test will be incorrect.
CO-47
RADIATOR MAIN FAN AND FAN MOTOR
COOLING
9. Radiator Main Fan and Fan • Turbo MODEL (includes Non-turbo 2500 cc
MODEL)
Motor
A: REMOVAL
EN0108
G6M0095

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

EN0077

• Non-turbo MODEL (except 2500 cc MODEL)
B2M2926
10) Remove the radiator main fan motor assembly.
EN0063
B2M2927
CO-48
RADIATOR MAIN FAN AND FAN MOTOR
COOLING
B: INSTALLATION 2) Remove the nut which holds fan itself onto fan
Install in the reverse order of removal. 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.
Tightening torque:
4.9 N·m (0.50 kgf-m, 3.6 ft-lb)
EN0120
3) Remove the bolts which install fan motor onto

shroud.
B2M2927
Tightening torque:
4.9 N·m (0.50 kgf-m, 3.6 ft-lb)
EN0121
D: ASSEMBLY
Assemble in the reverse order of disassembly.
Tightening torque:
4.4 N·m (0.45 kgf-m, 3.3 ft-lb)
B2M2926
C: DISASSEMBLY
1) Remove the clip which holds motor connector
onto shroud.
EN0121
Tightening torque:
3.4 N·m (0.35 kgf-m, 2.5 ft-lb)
S2M0937
EN0120
CO-49
RADIATOR SUB FAN AND FAN MOTOR
COOLING
10.Radiator Sub Fan and Fan • Turbo MODEL (includes Non-turbo 2500 cc
MODEL)
Motor
A: REMOVAL
EN0108
7) Remove the bolts which hold sub fan shroud to

radiator.
G6M0095 8) Remove the over flow pipe. (Turbo model)
2) Lift-up the vehicle. 9) Remove the radiator sub fan shroud through the
3) Remove the under cover. under side of vehicle.
4) Disconnect the connector of sub fan motor (B).
(B)
B2M2937
EN0078 B: INSTALLATION
5) Lower the vehicle. Install in the reverse order of removal.
6) Remove the air intake duct. Tightening torque:
• Non-turbo MODEL (except 2500 cc MODEL) 4.9 N·m (0.50 kgf-m, 3.6 ft-lb)
EN0063
B2M2937
CO-50
RADIATOR SUB FAN AND FAN MOTOR
COOLING
C: DISASSEMBLY D: ASSEMBLY
1) Remove the clip which holds motor harness onto Assemble in the reverse order of disassembly.
shroud.
Tightening torque:
4.4 N·m (0.45 kgf-m, 3.3 ft-lb)
S2M0937
2) Remove the nut which holds fan itself onto fan EN0121
motor and shroud assembly.
Tightening torque:
3.4 N·m (0.35 kgf-m, 2.5 ft-lb)
EN0123
3) Remove the bolts which install fan motor onto EN0123

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

A: REMOVAL
Tightening torque:
WARNING: T1: 19 N·m (1.9 kgf-m, 13.7 ft-lb)
The radiator is pressurized. Wait until the en- T2: 21 N·m (2.1 kgf-m, 15.2 ft-lb)
tor.
1) Drain the coolant about 3.0 2 (3.2 US qt, 2.6
lmp qt). <Ref. to CO-26, DRAINING OF ENGINE
COOLANT, REPLACEMENT, Engine Coolant.>
2) Remove the air cleaner upper cover and air in-
take boot. <Ref. to IN(TURBO)-7, REMOVAL, Air
T1
Cleaner.>
4) Disconnect the engine coolant hoses from cool-
ant filler tank.
T2
EN0125
EN0127
5) Remove the bolts and nut which install coolant
filler tank. 2) Fill engine coolant. <Ref. to CO-26, FILLING OF
6) Disconnect the engine coolant hose which con- ENGINE COOLANT, REPLACEMENT, Engine
nects under side of coolant filler tank. Coolant.>
7) Remove the coolant filler tank.
EN0126
CO-53
ENGINE COOLING SYSTEM TROUBLE IN GENERAL
COOLING
13.Engine Cooling System Trouble in General

A: INSPECTION
Trouble Possible cause Corrective action
Replenish the engine coolant, inspect for leakage, and
a. Insufficient engine coolant
repair.
b. Loose timing belt Repair or replace the timing belt tensioner.
c. Oil on drive belt Replace.
d. Malfunction of thermostat Replace.
e. Malfunction of water pump Replace.
f. Clogged engine coolant passage Clean.
Inspect and repair the ignition control system.
<Ref. to EN-2, Basic Diagnostic Procedure.> or <Ref. to
g. Improper ignition timing EN(w/oOBD)-2, Basic Diagnostic Procedure.> or <Ref.
to EN(TURBO)-2, PROCEDURE, Basic Diagnostic Pro-
cedure.>
h. Clogged or leaking radiator Clean or repair, or replace.
Over-heating i. Improper engine oil in engine coolant Replace the engine coolant.
Inspect and repair the fuel injection system.
<Ref. to EN-2, Basic Diagnostic Procedure.> or <Ref. to
j. Air/fuel mixture ratio too lean EN(w/oOBD)-2, Basic Diagnostic Procedure.> or <Ref.
to EN(TURBO)-2, PROCEDURE, Basic Diagnostic Pro-
cedure.>
k. Excessive back pressure in exhaust system Clean or replace.
l. Insufficient clearance between piston and cylinder Adjust or replace.
m. Slipping clutch Repair or replace.
n. Dragging brake Adjust.
o. Improper transmission oil Replace.
p. Defective thermostat Replace.
Inspect the radiator fan relay, engine coolant tempera-
q. Malfunction of electric fan
ture sensor or radiator motor and replace there.
a. Atmospheric temperature extremely low Partly cover the radiator front area.
Over-cooling
b. Defective thermostat Replace.
a. Loosened or damaged connecting units on hoses Repair or replace.
b. Leakage from water pump Replace.
c. Leakage from water pipe Repair or replace.
Engine coolant
d. Leakage around cylinder head gasket Retighten the cylinder head bolts or replace gasket.
leaks.
e. Damaged or cracked cylinder head and crankcase Repair or replace.
f. Damaged or cracked thermostat case Repair or replace.
g. Leakage from radiator Repair or replace.
a. Defective drive belt Replace.
b. Defective radiator fan Replace.
Noise
c. Defective water pump bearing Replace the water pump.
d. Defective water pump mechanical seal Replace the water pump.
CO-54
LUBRICATION
LU
Page
2. Oil Pressure System ...................................................................................7
3. Engine Oil..................................................................................................10
4. Oil Pump ...................................................................................................12
5. Oil Pan and Strainer..................................................................................16
6. Oil Pressure Switch...................................................................................21
7. Engine Oil Cooler ......................................................................................22
8. Engine Oil Filter.........................................................................................24
9. Engine Lubrication System Trouble in General.........................................25
GENERAL DESCRIPTION
LUBRICATION
A: SPECIFICATIONS
Lubrication method Forced lubrication
Pump type Trochoid type
Inner rotor 9
Number of teeth
Outer rotor 10
Outer rotor diameter × thickness 78 × 7 mm (3.07 × 0.28 in)
STANDARD 0.04 — 0.14 mm (0.0016 — 0.0055 in)
Tip clearance between inner and outer rotor
LIMIT 0.18 mm (0.0071 in)
Side clearance between inner rotor and pump STANDARD 0.02 — 0.07 mm (0.0008 — 0.0028 in)
Oil pump case LIMIT 0.12 mm (0.0047 in)
Case clearance between outer rotor and pump STANDARD 0.10 — 0.175 mm (0.0039 — 0.0069 in)
case LIMIT 0.20 mm (0.0079 in)
- pressure 98 kPa (1.0 kg/cm2, 14 psi)
600 rpm Discharge
Capacity at - quantity 3.2 2 (3.4 US qt, 2.8 Imp qt)/min.
80°C (176°F) - pressure 294 kPa (3.0 kg/cm2, 43 psi)
5,000 rpm Discharge
- quantity 32.6 2 (8.6 US gal, 7.2 Imp gal)/min.
Relief valve operation pressure 490 kPa (5.0 kg/cm2, 71 psi)
Type Full-flow filter type
Filtration area 1,000 cm2 (155 sq in)
Oil filter By-pass valve opening pressure 157 kPa (1.6 kg/cm2, 23 psi)
Outer diameter × width 80 × 70 mm (3.15 × 2.76 in)
Oil filter to engine thread size M 20 × 1.5
Relief valve (on rocker shaft) operation pressure 69 kPa (0.7kg/cm2, 10 psi)
Type Immersed contact point type
Oil pressure Working voltage — wattage 12 V — 3.4 W or less
switch Warning light activation pressure 14.7 kPa (0.15 kg/cm2, 2.1 psi)
Proof pressure More than 981 kPa (10 kg/cm2, 142 psi)
Non-Turbo model 4.0 2 (4.2 US qt, 3.5 Imp qt)
Oil capacity (at replacement)
Turbo model 4.5 2 (4.8 US qt, 4.0 Imp qt)
LU-2
GENERAL DESCRIPTION
LUBRICATION
B: COMPONENT
1. NON-TURBO MODEL
EN1491
(1) Plug (14) Oil filler duct (27) Gasket

(2) 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 (4.5, 32.5)
(9) Oil pump cover (22) O-ring T6: 6.4 (0.65, 4.7)
(10) Oil filter (23) Oil pan T7: 25 (2.5, 18.1)
(11) O-ring (24) Oil level gauge T8: 44 (4.5, 32.5)
(12) Oil pump ASSY (25) Drain plug
(13) Oil pressure switch (26) Metal gasket
LU-3
GENERAL DESCRIPTION
LUBRICATION
2. TURBO MODEL
T8 (16)
(17)
T7
(15)
(18)
T3
(14)
(19)
T3
(20)
(29)
(9) T6
T2 T3
(8) (21)
(13)
(7) (23)
(6) (12) (22)
(24)
(26)
T7
(5) (11) T4
(2) T10
(4)
T5 T1 T1
(3)
(1) (10)
T9 (28) (27) (25)
EN1492
(1) Plug (15) Oil pump ASSY (29) O-ring

(2) Gasket (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: 10 (1.0, 7.0)
(8) Outer rotor (22) Oil strainer T5: 44 (4.5, 32.5)
(9) Oil pump cover (23) Gasket T6: 69 (7.0, 50.9)
(10) Oil filter (24) Oil level gauge guide T7: 6.4 (0.65, 4.7)
(11) Connector (25) Oil pan T8: 25 (2.5, 18.1)
(12) Water by-pass pipe (26) Oil level gauge T9: 44 (4.5, 32.5)
(13) Oil cooler (27) Metal gasket T10: 54 (5.5, 40)
(14) O-ring (28) Drain plug
LU-4
GENERAL DESCRIPTION
LUBRICATION
C: CAUTION
tion.
points.
cable from battery.
LU-5
GENERAL DESCRIPTION
LUBRICATION
D: PREPARATION TOOL
bolt. (2500 cc model)
B2M3870
bolt. (1600 cc and 2000 cc model)
B2M4157
WRENCH
B2M3872
INSTALLER
B2M3875
LU-6
OIL PRESSURE SYSTEM
LUBRICATION
2. Oil Pressure System

A: SCHEMATIC
1. NON-TURBO MODEL
BATTERY
No.13 SBF-4 SBF-1
4 1
IGNITION
B72 SWITCH
LHD RHD
AT MT
B36 B38 B36
23
22
4
i1 i3 i1
AT MT
LHD RHD
A7
COMBINATION
METER
WARNING LIGHT
OIL PRESSURE
A: i10
B: i11
B2
i2
LHD : 23
RHD : 14
B37
B21
5
E2
E11
OIL PRESSURE
SWITCH
B72 A: i10 B: i11 B21 i2
1 2 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11
3 4 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 5 6 7 8 12 13 14 15 16 17 18 19 20 21 22 23 24
9 10 11 12 (LHD)
13 14 15 16
LHD: B36 RHD: 17 18 19 20
RHD: i1 i3
1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10 10 11 12 13 14 15 16 17 18 19 20 21
12 13 14 15 16 17 18 19 20 21 22 23 24 7 8 9 10 11 12 13 14 11 12 13 14 15 16 17 18 19 20 21 22 22 23 24 25 26 27 28 29 30 31 32
(RHD)
EN1381
LU-7
OIL PRESSURE SYSTEM
LUBRICATION
2. TURBO MODEL
BATTERY
No.13 SBF-4 SBF-1
4 1
IGNITION
B72 SWITCH
LHD RHD
AT MT
B36 B38 B36
23
22
4
i1 i3 i1
AT MT
LHD RHD
A7
COMBINATION
METER
WARNING LIGHT
OIL PRESSURE
A: i10
B: i11
B2
RHD
LHD
i2
23
B37
B209 i2
14
I1
SMJ
B76 B37
F61 B21
14
14
E2 E2
E11 E11
OIL PRESSURE OIL PRESSURE

SWITCH SWITCH
B72 A: i10 B: i11 i2 B209
1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 A1 K2 A3 K4 A5
1 2 1 2 3 4 5 6 7 8 9 10
12 13 14 15 16 17 18 19 20 21 22 23 24 B1 L2 L4 B5
3 4 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
C1 M2 C3 M4 C5
(LHD) D1 N2 N4 D5
E1 E5
LHD: B36 RHD: F61
i3
1 2 3 4 5 6 7 8 9
F1 F5
1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9 10 B21 10 11 12 13 14 15 16 17 18 19 20 21
G1 Q2 Q4 G5
12 13 14 15 16 17 18 19 20 21 22 23 24 11 12 13 14 15 16 17 18 19 20 21 22 22 23 24 25 26 27 28 29 30 31 32
H1 R2 H3 R4 H5
1 2 3 4 (RHD) I1 S2 S4 I5
RHD: i1 5 6 7 8 J1 T2 J3 T4 J5
9 10 11 12
1 2 3 4 5 6 13 14 15 16
7 8 9 10 11 12 13 14 17 18 19 20
EN1382
LU-8
OIL PRESSURE SYSTEM
LUBRICATION
B: INSPECTION
Step Check Yes No
1 CHECK COMBINATION METER. Does the warning lights go on? Go to step 2. Repair or replace
1)Turn the ignition switch to ON. (engine OFF) the combination
2)Check other warning lights. meter. <Ref. to
IDI-5, INSPEC-
TION, Combina-
tion 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.
2)Disconnect the connector from oil pressure
switch.
3)Turn the ignition switch ON.
4)Measure the voltage of harness between the
combination meter connector and chassis
ground.
(E11) No. 1 (+) — Chassis ground (-):
3 CHECK COMBINATION METER. Is the resistance less than 10 Replace the har- Repair or replace
1)Turn the ignition switch to OFF. Ω? ness connector the combination
2)Remove the combination meter. between combina- meter and the oil
3)Measure the resistance of combination tion meter and oil pressure switch
meter. pressure switch. warning light bulb.
Terminal
No. A7 — No. B2:
LU-9
ENGINE OIL
LUBRICATION
3. Engine Oil B: REPLACEMENT

1) Drain the engine oil by loosening the engine oil
A: INSPECTION drain plug.
1) Park the vehicle on a level surface. • Non-Turbo MODEL
3) Reinsert the level gauge all the way. Be sure that
the level gauge is correctly inserted and in the
proper orientation.
4) Remove it again and note the reading. If the en-
gine oil level is below the “L” line, add oil to bring (A)
the level up to “F” line.
5) After turning off the engine, wait a few minutes (B)
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- EN0009
gine oil level may show in the range between the
“F” line and notch mark. This is caused by thermal • Turbo MODEL
expansion of the engine oil.
7) To prevent overfilling the engine oil, do not add
oil above the “F” line when the engine is cold.
(A)
(B)
EN0010
(A) Gasket
B2M3883A (B) Drain plug
2) Open the engine oil filler cap for quick draining of

the engine oil.
B2M3883A
3) Replace the drain plug gasket.
LU-10
ENGINE OIL
LUBRICATION
4) Tighten the engine oil drain plug after draining Engine oil capacity: (Turbo model)
engine oil. Upper level
Tightening torque: 4.5 2 (4.8 US qt, 4.0 Imp qt)
44 N·m (4.5 kgf-m, 32.5 ft-lb) Lower level
3.5 2 (3.7 US qt, 3.1 Imp qt)
• Non-Turbo MODEL
(A)
(B)
EN0009 B2M3885A
• Turbo MODEL The proper viscosity helps vehicle get good cold
and hot starting by reducing viscous friction and
thus increasing cranking speed.
CAUTION:
When replenishing oil, it does not matter if the
(A) oil to be added is a different brand from that in
the engine; however, use oil having the API
(B)
classification and SAE viscosity No. designat-
ed by SUBARU.
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: SL or SJ or SH
(B) Drain plug SAE Viscosity No.: 30, 40, 10W-50, 20W-40, 20W-
50.
5) Fill engine oil through the filler pipe up to upper
point on level gauge. Make sure that the vehicle is 6) Close the engine oil filler cap.
placed level when checking oil level. Use the en- 7) Start the engine and warm it up for a time.
gine oil of proper quality and viscosity, selected in 8) After the engine stops, recheck the oil level. If
accordance with the table in figure. necessary, add engine oil up to the upper level on
level gauge.
Recommended oil
API classification
SL or SJ or SH with the words “Energy Con-
serving or Energy conserving II”, CCMC
specification G4 or G5, ACEA specification
A1, A2 or A3, or New API mark displayed on
the container (If it is impossible to get SL or
SJ or SH grade, you may use SG grade.)
Engine oil capacity: (Non-Turbo model)
Upper level
4.0 2 (4.2 US qt, 3.5 Imp qt) B2M3883A
Lower level
3.0 2 (3.2 US qt, 2.6 Imp qt)
LU-11
OIL PUMP
LUBRICATION
4. Oil Pump 7) Remove the crankshaft position sensor.
A: REMOVAL
B2M1252
8) Remove the V-belts. <Ref. to ME-44, REMOV-

AL, V-belt.> or <Ref. to ME(TURBO)-44, REMOV-
G6M0095
AL, V-belt.>
2) Lift-up the vehicle. 9) Remove the rear side V-belt tensioner.
4) Remove the bolts which install water pipe of oil
cooler to oil pump. (Turbo model)
S2M0113
10) Remove the crankshaft pulley by using ST.

1600 cc and 2000 cc model:
S2M0027
5) Remove the water pipe and hoses between oil WRENCH
cooler and water pump. (Turbo model) 2500 cc model:
WRENCH
S2M0112
6) Remove the radiator. <Ref. to CO-39, REMOV-

S2M0114
AL, Radiator.>
11) Remove the water pump. <Ref. to CO-28, RE-
MOVAL, Water Pump.>
LU-12
OIL PUMP
LUBRICATION
12) Remove the timing belt guide. (MT vehicles B: INSTALLATION

only) Install in the reverse order of removal.
Do the following:
1) Apply fluid packing to the matching surfaces of
oil pump.
Fluid packing:
S2M0115
13) Remove the crankshaft sprocket.
S2M0739B
2) Replace the O-ring (A) with a new one.

3) Apply a coat of engine oil to the inside of oil seal.
S2M0116
14) Remove the bolts which install oil pump onto

cylinder block.
S2M0118B
4) Be careful not to scratch the oil seal when install-

ing oil pump on cylinder block.
5) Position the oil pump, aligning the notched area
with crankshaft, and push the oil pump straight.
CAUTION:
S2M0117
Make sure the oil seal lip is not folded.
15) Remove the oil pump by using flat bladed 6) Install the oil pump.
screwdriver.
Tightening torque:
CAUTION: 6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
Be careful not to scratch the mating surfaces of
S2M0740B
S2M1819
LU-13
OIL PUMP
LUBRICATION
Remove the screws which secure oil pump cover 1) Install the front oil seal by using ST.
and disassemble oil pump. Inscribe alignment ST 499587100 OIL SEAL INSTALLER
marks on the inner and outer rotors so that they can NOTE:
be replaced in their original positions during reas- Use a new oil seal.
sembly.
CAUTION:
Before removing the relief valve, loosen the
plug when removing oil pump from cylinder
block.
S2M0235A
2) Apply a coat of engine oil to the inner and outer

rotors.
3) Install the inner and outer rotors in their original
positions.
4) Install the oil relief valve and relief valve spring
and plug.
NOTE:
Use a new gasket.
5) Install the oil pump cover.
Tightening torque:
T1: 5 N·m (0.5 kgf-m, 3.6 ft-lb)
T2: 44 N·m (4.5 kgf-m, 32.5 ft-lb)
S2M0735A
(A) Oil seal

(B) Pump case
(C) Inner rotor
(D) Outer rotor
(E) Pump cover
(F) Relief valve
(G) Relief valve spring
(H) Plug
(I) Gasket
S2M0735B
LU-14
OIL PUMP
LUBRICATION
E: INSPECTION 3. SIDE CLEARANCE

1. TIP CLEARANCE Measure the clearance between the oil pump inner
rotor and pump cover. If clearance exceeds the lim-
Measure the tip clearance of rotors. If clearance ex- it, replace the rotor or pump body.
ceeds the limit, replace the rotors as a matched set.
Side clearance:
Tip clearance: Standard
Standard 0.02 — 0.07 mm (0.0008 — 0.0028 in)
0.04 — 0.14 mm (0.0016 — 0.0055 in) Limit
Limit 0.12 mm (0.0047 in)
0.18 mm (0.0071 in)
S2M0738
S2M0736
4. OIL RELIEF VALVE
2. CASE CLEARANCE
Check the valve for fitting condition and damage,
Measure the clearance between the outer rotor and and the relief valve spring for damage and deterio-
cylinder block rotor housing. If clearance exceeds ration. Replace the parts if defective.
the limit, replace the rotor.
Relief valve spring:
Case clearance: Free length
0.10 — 0.175 mm (0.0039 — 0.0069 in) Installed length
Limit 54.7 mm (2.154 in)
0.20 mm (0.0079 in) Load when installed
77.08 N (7.86 kgf, 17.33 lb)
5. OIL PUMP CASE
Check the oil pump case for worn shaft hole,
clogged oil passage, worn rotor chamber, cracks,
and other faults.
6. OIL SEAL
Check the oil seal lips for deformation, hardening,
wear, etc. and replace if defective.
S2M0737
LU-15
OIL PAN AND STRAINER
LUBRICATION
5. Oil Pan and Strainer 8) Remove the pitching stopper.
A: REMOVAL
1) Set the vehicle on lift arms.
2) Remove the front wheels.
H3M1839

• Non-Turbo MODEL
G6M0095
4) Remove the air intake duct and air cleaner case.

(Non-Turbo model)
5) Disconnect the connector from mass air flow
sensor. (Turbo model)
B2M2931
• Turbo MODEL
EN0031
6) Remove the air intake boot and air cleaner upper

cover. (Turbo model)
EN0035
10) Support the engine with a lifting device and

wire ropes.
EN0032
7) Remove the intercooler (Turbo model) <Ref. to

IN(TURBO)-10, REMOVAL, Intercooler.>
G2M0297

CAUTION:
At this time, raise up the wire ropes.
LU-16
LUBRICATION
13) Drain the engine oil. 17) Insert the oil pan cutter blade between the cyl-
Set a container under the vehicle, and remove the inder block-to-oil pan clearance.
drain plug from oil pan. CAUTION:
• Non-Turbo MODEL Do not use a screwdriver or similar tool in place
of oil pan cutter.
• Non-Turbo MODEL
(A)
(B)
EN0009
• Turbo MODEL
EN0040
• Turbo MODEL
(A)
(B)
EN0010
(A) Gasket EN0041

(B) Drain plug
14) Remove the front and center exhaust pipes.
(Non-Turbo model) <Ref. to EX-7, REMOVAL,
Front Exhaust Pipe.> or <Ref. to EX(w/oOBD)-9,
REMOVAL, Front Exhaust Pipe.>
rubber onto front crossmember.
S2M0238
S2M1831
16) Remove the bolts which install oil pan on cylin-

der block while raising up engine.
S2M0309
LU-17
LUBRICATION
B: INSTALLATION 4) Tighten the bolts which install the oil pan onto
engine 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)
EN0040
• Turbo MODEL
S2M0309
2) Install the oil strainer onto baffle plate.

NOTE:
Replace the O-ring with a new one.
Tightening torque:
10 N·m (1.0 kgf-m, 7.2 ft-lb)
EN0041
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, 50.9 ft-lb)
S2M0238
3) Apply fluid packing to the mating surfaces and

install oil pan.
Fluid packing:
S2M1831
S2M1833A
LU-18
LUBRICATION
7) Install the front and center exhaust pipes. (Non- 12) Install the radiator upper brackets.
Turbo model) • Non-Turbo MODEL
<Ref. to EX-8, INSTALLATION, Front Exhaust
Pipe.> or <Ref. to EX(w/oOBD)-10, INSTALLA-
TION, Front Exhaust Pipe.>
NOTE:
Always use new gaskets.
B2M2931
• Turbo MODEL
B2M3200

CAUTION:
At this time, lower the lifting device and release
steel cables.
EN0035
10) Remove the lifting device and steel cables.
13) Install the air intake duct and air cleaner case.
(Non-Turbo model)
<Ref. to IN-6, INSTALLATION, Air Cleaner Case.>
and <Ref. to IN-7, INSTALLATION, Air Intake
Duct.>
14) Install the intercooler. (Turbo model) <Ref. to
IN(TURBO)-11, INSTALLATION, Intercooler.>
15) Install the air intake boot and air cleaner upper
cover. (Turbo model)
G2M0297
11) Install the pitching stopper.

Tightening torque:
T1: 50 N·m (5.1 kgf-m, 36.9 ft-lb)
T2: 58 N·m (5.9 kgf-m, 42.8 ft-lb)
EN0032
H3M1839A
LU-19
LUBRICATION
16) Connect the connector to mass air flow sensor.

(Turbo model)
EN0031
17) Install the front wheels.

G6M0095
19) Fill engine oil. <Ref. to LU-10, INSPECTION,

Engine Oil.>
C: INSPECTION
By visual check make sure the oil pan, oil strainer,
oil strainer stay and baffle plate are not damaged.
LU-20
OIL PRESSURE SWITCH
LUBRICATION
6. Oil Pressure Switch B: INSTALLATION

1) Apply fluid packing to the oil pressure switch
A: REMOVAL threads.
1) Remove the generator from bracket. <Ref. to
SC-14, REMOVAL, Generator.> Fluid packing:
2) Disconnect the terminal from oil pressure switch. THREE BOND 1215 or equivalent
G2M0091 S2M0124B
3) Remove the oil pressure switch. 2) Install the oil pressure switch onto engine block.
Tightening torque:
25 N·m (2.5 kgf-m, 18.1 ft-lb)
S2M0119
S2M0119
3) Connect the terminal of oil pressure switch.
G2M0091
4) Install the generator on bracket. <Ref. to SC-14,

INSTALLATION, Generator.>
C: INSPECTION
Make sure oil does not leak or seep from where the
oil pressure switch is installed.
LU-21
ENGINE OIL COOLER
LUBRICATION
7. Engine Oil Cooler 7) Remove the connector and remove oil cooler.
A: REMOVAL
3) Drain the engine oil.
Set a container under the vehicle, and remove the
drain plug from oil pan.
(A)
(B)
EN0010
(A) Gasket
(B) Drain plug
S2M1835A
4) Drain the engine coolant.
5) Remove the water by-pass pipe between oil
cooler and water pump. (A) O-ring
(B) Oil cooler
(C) Connector
S2M0112
6) Remove the engine oil filter. <Ref. to LU-24, RE-

MOVAL, Engine Oil Filter.>
LU-22
ENGINE OIL COOLER
LUBRICATION
1) Install in the reverse order of removal. 1) Check that the coolant passages are not
clogged using air blow method.
Tightening torque:
2) Check the mating surfaces of cylinder block, O-
T: 54 N·m (5.5 kgf-m, 40 ft-lb)
ring groove and oil filter for damage.
NOTE:
Always use a new O-ring.
G2M0784
LU-23
ENGINE OIL FILTER
LUBRICATION
8. Engine Oil Filter

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

A: INSPECTION
Before performing diagnostics, make sure that the engine oil level is correct and no oil leakage exists.
Trouble Possible cause Corrective action
1) Oil pressure switch Cracked diaphragm or oil leakage within switch Replace.
failure Broken spring or seized contacts Replace.
Clogged oil filter Replace.
Malfunction of oil by-pass valve of oil filter Clean or replace.
Malfunction of oil relief valve of oil pump Clean or replace.
1. Warning light remains 2) Low oil pressure Clogged oil passage Clean.
on. Excessive tip clearance and side clearance of oil
Replace.
pump rotor and gear
Clogged oil strainer or broken pipe Clean or replace.
Insufficient engine oil Replenish.
3) No oil pressure Broken pipe of oil strainer Replace.
Stuck oil pump rotor Replace.
1) Burn-out bulb Replace.
2. Warning light does
2) Poor contact of switch contact points Replace.
not go on.
3) Disconnection of wiring Repair.
1) Poor contact at terminals Repair.
2) Defective wiring harness Repair.
3. Warning light flickers
momentarily. Check for the same
3) Low oil pressure possible causes as
listed in 1.—2).
LU-25
ENGINE LUBRICATION SYSTEM TROUBLE IN GENERAL
LUBRICATION
LU-26
SPEED CONTROL SYSTEMS
SP
Page
2. Accelerator Pedal........................................................................................4
3. Accelerator Control Cable ...........................................................................9
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. LHD MODEL
B2M4176A
(1) Accelerator bracket (7) Accelerator pedal lever (13) Kick-down switch (AT model)
(2) Stopper (8) Spring pin
(3) Bushing (9) Accelerator pedal Tightening torque: N·m (kgf-m, ft-lb)
(4) Clip (10) Accelerator stopper T: 18 (1.8, 13.0)
(5) Accelerator spring (11) Accelerator plate
(6) Accelerator pedal spring (12) Clip
SP-2
GENERAL DESCRIPTION
2. RHD MODEL
EN1493
(1) Accelerator bracket (6) Spring pin (11) Kick-down switch (AT model).
(2) Stopper (7) Accelerator spring
(3) Accelerator pedal lever (8) Bushing Tightening torque: N·m (kgf-m, ft-lb)
(4) Accelerator pedal spring (9) Clip T: 18 (1.8, 13.0)
(5) Accelerator pedal (10) Accelerator stopper
C: CAUTION
• Wear work clothing, including a cap, protective
goggles, and protective shoes during operation.
• Remove contamination, including dirt and corro-
sion, before removal, installation or disassembly.
tect them from dust and dirt.
points.
cable from battery.
SP-3
ACCELERATOR PEDAL
2. Accelerator Pedal • RHD SOHC MODEL

(C)
A: REMOVAL (B)
2) Remove the lock nut from accelerator cable (E)
bracket. (E)
3) Separate the accelerator cable from bracket.
4) Remove the accelerator cable end from throttle (D)
(E)
cam. (A)
5) Disconnect the accelerator cable from throttle
body. (E)
EN0921
CAUTION:
Be careful not to kink the accelerator cable. • LHD DOHC turbo MODEL
• SOHC MODEL
(D)
(E)
(A)
(A) (E)
(B)
(C)
(E)
(E) EN0922
(B) (C) (D) EN0918
• RHD DOHC turbo MODEL
• DOHC turbo MODEL (E) (C)
(B)
(A) (C)
(D) (A)
(B) (E)
(D)
EN0923
EN0919
(A) Toe board
(A) Lock nut (B) Accelerator cable
(B) Accelerator cable bracket (C) To accelerator pedal
(C) Accelerator cable (D) Brake booster
(D) Throttle cam (E) Clip
6) Remove the clip inside engine compartment. 7) Remove the instrument panel lower cover from
• LHD SOHC MODEL instrument panel, and connector.
8) Disconnect the connector from kick-down
switch. (AT model)
(A) 9) Remove the brake and clutch pedal bracket.
(LHD MT model) <Ref. to BR-65, REMOVAL,
(D) Brake Pedal.>
(C)
(E) (E)
(B)
EN0920
SP-4
ACCELERATOR PEDAL
10) Remove the accelerator pedal connecting bolt 13) Disconnect the accelerator cable bushing from
from accelerator pedal bracket. accelerator pedal lever.
• LHD MODEL
B4M1741B
EN0924
(A) Slot type screwdriver
• RHD MODEL
14) Disconnect the accelerator cable stopper (A)
from bracket.
EN0925
11) Disconnect the grommet from toe board.

B4M1742B
NOTE:
From the inside compartment, push the grommet 15) Separate the accelerator cable and bracket.
(A) into hole. B: INSTALLATION
CAUTION:
• If the cable clamp is damaged, replace it with
a new one.
• Never fail to cover the outer cable end with
boot.
• Be careful not to kink the accelerator cable.
• Always use new clevis pins.
B4M1740C
12) Pull out the cable from toe board hole.
SP-5
ACCELERATOR PEDAL
C: DISASSEMBLY • RHD MODEL

1) Remove the clip, and then remove the accelera-
tor pedal from bracket.
2) Pull out the spring pin, and then remove the ac-
celerator pedal from accelerator pedal lever.
• LHD MODEL
EN1494
(A) Accelerator bracket

(B) Stopper
(C) Bushing
EN0926 (D) Clip
(E) Accelerator spring
(A) Accelerator bracket (F) Accelerator pedal spring
(B) Stopper (G) Accelerator pedal lever
(C) Bushing (H) Spring pin
(D) Clip (I) Accelerator pedal
(E) Accelerator spring (J) Kick-down switch (AT model)
(F) Accelerator pedal spring
(G) Accelerator pedal lever D: ASSEMBLY
(H) Spring pin Assemble in the reverse order of disassembly.
(I) Accelerator pedal CAUTION:
(J) Kick-down switch (AT model) Clean and apply grease to the portions indicat-
ed in the figure.
Grease:
Nigtight — LYW No.2 or equivalent
SP-6
ACCELERATOR PEDAL
E: INSPECTION F: ADJUSTMENT
1) Check the pedal stroke and free play by operat-
1. ACCELERATOR PEDAL ing accelerator pedal by hand.
Lightly move the pedal pad in lateral direction to en- If it is not within specified value, adjust it by turning
sure that pedal deflection is in specified range. the nut connecting the accelerator cable to throttle
CAUTION: body.
If excessive deflection is noted, replace the Free play at pedal pad: L
bushing and clip with new ones. 1 — 4 mm (0.04 — 0.16 in)
Deflection of accelerator pedal: Stroke at pedal pad: A
Service limit 52 — 57 mm (2.05 — 2.24 in)
5.0 mm (0.197 in) or less
G4M0333
2. KICK-DOWN SWITCH
If the kick-down switch does not operate properly
(or if it does not stop at the specified position), re-
place with a new one.
Specified position: A
2+1.5/0 mm (0.079 +0.059/0 in)
B4M1739A
(A) Accelerator pedal

(B) Accelerator pedal bracket
Accelerator cable lock nut tightening torque:

12 N·m (1.2 kgf-m, 9 ft-lb)
B4M0155A
SP-7
ACCELERATOR PEDAL
2) Check to ensure the kick-down switch operates

at the specified value in relation to the stroke of the
accelerator pedal.
If it is not within specified value, adjust it by adjust-
ing the position of kick-down switch.
CAUTION:
Be careful not to rotate the kick-down switch.
Kick-down switch stroke: A
48±1 mm (1.89±0.04 in)
Kick-down switch tightening torque:
12 N·m (1.2 kgf-m, 9 ft-lb)
B4M1758C
(A) Kick down switch
SP-8
ACCELERATOR CONTROL CABLE
3. Accelerator Control Cable

A: REMOVAL
1) Remove the accelerator pedal. <Ref. to SP-4,
REMOVAL, Accelerator Pedal.>
2) Separate the accelerator cable and accelerator
pedal.
B: INSTALLATION
CAUTION:
a new one.
boot.
• Do not apply grease to the throttle cable on
engine side.
2) Adjustment after pedal installation. <Ref. to SP-
5, INSTALLATION, Accelerator Pedal.>
C: INSPECTION
1) Make sure the inner cable is not twisted or
frayed.
2) Make sure the outer cable is not cracked.
SP-9
ACCELERATOR CONTROL CABLE
SP-10
IGNITION
IG
Page
2. Spark Plug...................................................................................................5
3. Ignition Coil and Ignitor Assembly...............................................................8
4. Spark Plug Cord........................................................................................10
GENERAL DESCRIPTION
IGNITION
A: SPECIFICATIONS
Item Designation
1600 cc CM12—100C
Model 2000 cc and
FH0137
2500 cc
1600 cc HITACHI
Manufacturer 2000 cc and
DIAMOND
2500 cc
Ignition coil
1600 cc 0.7 Ω±10%
and ignitor
assembly Primary coil resistance 2000 cc and
0.73 Ω±10%
2500 cc
1600 cc 13.0 kΩ±20%
Secondary coil resis-
tance 2000 cc and
12.8 kΩ±15%
2500 cc
Insulation resistance between primary
More than 100 MΩ
terminal and case
CHAMPION: RC8YC4
1600 cc
NGK: BKR6E-11 (Alternate)
Type and manufacturer
2000 cc and CHAMPION: RC10YC4
Spark plug
2500 cc NGK: BKR5E-11 (Alternate)
Thread size mm 14, P = 1.25
Spark gap mm (in) 1.0 — 1.1 (0.039 — 0.043)
IG-2
GENERAL DESCRIPTION
IGNITION
B: COMPONENT
1. 1600 CC MODEL
T1
(3)
(2)
(2)
(1)
T2
(4)
(4)
T2
EN1039
S6M0329B
(1) Spark plug (4) Spark plug cord (#2, #4) Tightening torque: N·m (kgf-m, ft-lb)
(2) Spark plug cord (#1, #3) T1: 6.4 (0.65, 4.7)
(3) Ignition coil and ignitor ASSY T2: 21 (2.1, 15.2)
IG-3
GENERAL DESCRIPTION
IGNITION
2. 2000 CC AND 2500 CC MODEL
S6M0329B
(2) Spark plug cord (#1, #3) T1: 21 (2.1, 15.2)
(3) Ignition coil and ignitor ASSY T2: 6.4 (0.65, 4.7)
C: CAUTION • Be sure to tighten fasteners including bolts and

• Wear working clothing, including a cap, protec- nuts to the specified torque.
tive goggles, and protective shoes during opera- • Place shop jacks or safety stands at the specified
tion. points.
• Remove contamination including dirt and corro- • Before disconnecting electrical connectors of
sion before removal, installation or disassembly. sensors or units, be sure to disconnect the ground
• Keep the disassembled parts in order and pro- cable from battery.
IG-4
SPARK PLUG
IGNITION
2. Spark Plug 2. LH SIDE

A: REMOVAL 1) Disconnect the ground cable from battery.
CAUTION:
All spark plugs installed on an engine, must be
of the same heat range.
Spark plug
CHAMPION: RC8YC4
1600 cc
2000 cc
CHAMPION: RC10YC4
and
2500 cc
G6M0095
1. RH SIDE 2) Disconnect the washer motor connector.

B6M0562
G6M0095 3) Disconnect the rear window glass washer hose

2) Remove the resonator chamber. <Ref. to IN-8, from washer motor, then plug connection with a
REMOVAL, Resonator Chamber.> suitable cap.
3) Remove the spark plug cords by pulling boot, not 4) Remove the two bolts which hold washer tank,
the cord itself. then take the tank away from the working area.
B2M2023
B2M4127
4) Remove the spark plugs with spark plug sock- 5) Remove the spark plugs cord by pulling boot, not
ets. the cord itself.
B2M4286 B2M4287
IG-5
SPARK PLUG
IGNITION
6) Remove the spark plugs with spark plug sock- C: INSPECTION

ets. Check the electrodes and inner and outer porcelain
of plugs, noting the type of deposits and the degree
of electrode erosion.
B2M4288
B: INSTALLATION S6M0420A
1. RH SIDE
(A) Electrode gap
(B) Carbon accumulation or wear
Tightening torque (Spark plug): (C) Cracks
21 N·m (2.1 kgf-m, 15.2 ft-lb) (D) Damage
CAUTION: (E) Damaged gasket
The above torque should be only applied to
new spark plugs without oil on their threads. 1) Normal:
In case their threads are lubricated, the torque Brown to grayish-tan deposits and slight electrode
should be reduced by approx. 1/3 of the speci- wear indicates correct spark plug heat range.
fied torque in order to avoid over-stressing.
2. LH SIDE
Tightening torque (Spark plug):
21 N·m (2.1 kgf-m, 15.2 ft-lb)
CAUTION:
new spark plugs without oil on their threads.
G6M0087
In case their threads are lubricated, the torque
should be reduced by approx. 1/3 of the speci- 2) Carbon fouled:
fied torque in order to avoid over-stressing. 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.
G6M0088
IG-6
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)
G6M0089 S6M0412B
4) Overheating: NOTE:
White or light gray insulator with black or gray Replace with a new spark plug if this area (A) is
brown spots and bluish burnt electrodes indicates worn to “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 spark
plugs.
IG-7
IGNITION COIL AND IGNITOR ASSEMBLY
IGNITION
3. Ignition Coil and Ignitor As- 4) Remove the ignition coil and ignitor assembly.
• 1600 cc MODEL
sembly
A: REMOVAL
EN1044
G6M0095
2) Disconnect the spark plug cords from ignition

coil and ignitor assembly.
• 1600 cc MODEL
B6M0930
B: INSTALLATION
Tightening torque:
EN1040 6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
• 2000 cc and 2500 cc MODEL CAUTION:
Be sure to connect wires to their proper posi-
tions. Failure to do so will damage unit.
• 1600 cc MODEL
S6M0373
3) Disconnect the connector from ignition coil and

ignitor assembly. EN1044
IG-8
IGNITION
• 2000 cc and 2500 cc MODEL Specified resistance: (2000 cc and 2500 cc)
[Primary side]
Between terminal No. 1 and No. 2
0.73 Ω±10%
0.73 Ω±10%
B6M0930
4 3 2 1
C: INSPECTION
Using the accurate tester, inspect the following
items, and replace if defective.
1) Primary resistance
2) Secondary coil resistance EN1041
CAUTION: [Secondary side]

If the resistance is extremely low, this indicates Between (A) and (B)
the presence of a short-circuit. 12.8 kΩ±15%
Specified resistance:(1600 cc) Between (C) and (D)
12.8 kΩ±15%
[Primary side]
Between terminal No. 1 and No. 4 (C)
0.7 Ω±10% (A)
0.7 Ω±10%
(D)
(B)
4 3 2 1 EN1043
3) Insulation between primary terminal and case:

100 MΩ or more.
EN1041
[Secondary side]
Between (A) and (B)
13.0 kΩ±20%
Between (C) and (D)
13.0 kΩ±20%
(C) (D)
(A) (B)
EN1042
IG-9
SPARK PLUG CORD
IGNITION
4. Spark Plug Cord

A: INSPECTION
Check for:
1) Damage to cords, deformation, burning or rust
formation of terminals
2) Resistance values of cords
Resistance value:
#1 cord: 5.6 — 10.6 kΩ
#2 cord: 7.3 — 13.7 kΩ
#3 cord: 5.9 — 11.1 kΩ
#4 cord: 7.3 — 13.7 kΩ
S6M0337
IG-10
STARTING/CHARGING SYSTEMS
SC
Page
2. Starter .........................................................................................................5
3. Generator ..................................................................................................14
4. Battery.......................................................................................................20
GENERAL DESCRIPTION
A: SPECIFICATIONS
Item Designation
Type Reduction type
Vehicle type MT vehicles AT vehicles
Model M000T83981 M001T86381
Manufacturer Mitsubishi Electric
Voltage and output 12 V — 1.0 kW 12 V — 1.4 kW
Direction of rotation Counterclockwise (when observed from pinion)
Number of pinion teeth 8 9
Voltage 11 V
No-load charac-
Starter Current 90 A or less
teristics
Rotating speed 2,800 rpm or more 2,400 rpm or more
Voltage 7.5 V 7.7 V
Load character- Current 300 A 400 A
istics Torque 8.6 N (0.88 kgf, 1.93 lb) or more 16.0 N (1.63 kgf, 3.60 lb) or more
Rotating speed 920 rpm or more 740 rpm or more
Voltage 4V 3.5 V
Lock character-
Current 650 A or less 940 A or less
istics
Torque 14.7 N (1.50 kgf, 3.30 lb) or more 28.9 N (2.95 kgf, 6.50 lb) or more
Rotating-field three-phase type, Voltage regulator built-in type, with load
Type
response control system
Model A2TB2891
Manufacturer Mitsubishi Electric
Voltage and output 12 V — 90 A
Polarity on ground side Negative
Generator
Rotating direction Clockwise (when observed from pulley side)
Armature connection 3-phase Y-type
1,500 rpm — 36 A or more
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)]
SC-2
GENERAL DESCRIPTION
B: COMPONENT
1. STARTER
H6M0492C
(1) Sleeve bearing (7) Internal gear ASSY (13) Armature

(2) Front bracket (8) Shaft ASSY (14) Brush holder
(3) Lever set (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-3
GENERAL DESCRIPTION
2. GENERATOR
H6M0493C
(1) Pulley (5) Rotor (9) Brush

(2) Front cover (6) Bearing (10) Rectifier
(3) Ball bearing (7) Stator coil (11) Rear cover
(4) Bearing retainer (8) IC regulator with brush (12) Terminal

• Wear working clothing, including a cap, protec- part in the vehicle is hot after running.
SC-4
STARTER
2. Starter • AT vehicles
A: REMOVAL
EN0370
5) Disconnect the connector and terminal from

starter.
G6M0095
2) Remove the air cleaner case. (Non-Turbo Mod-

el)
S6M0002A
(A) Terminal
B6M1221 (B) Connector
3) Remove the intercooler. (Turbo Model) <Ref. to 6) Remove the starter from transmission.
4) Remove the air cleaner case stay. (Non-Turbo
Model)
• MT vehicles
EN1007
EN0369
SC-5
STARTER
B: INSTALLATION 2) Remove the bolts which hold switch assembly,

Install in the reverse order of removal. and then remove the switch assembly, plunger and
plunger spring from starter as a unit.
Tightening torque:
50 N·m (5.1 kgf-m, 37 ft-lb) CAUTION:
Be careful because the pinion gap adjustment
washer may sometimes be used on the mount-
ing surface of switch assembly.
EN1007
C: DISASSEMBLY
B2M4455A
1. STARTER ASSEMBLY
1) Loosen the nut which holds terminal M of switch (A) Switch ASSY
assembly, and then disconnect the connector. (B) Plunger
3) Remove both through-bolts and brush holder

screws, and then detach the rear bracket and brush
holder.
CAUTION:
Before removal, confirm the attachment loca-
tions of brush holder and rear bracket.
B2M4454A
(A) Terminal M
(B) Terminal B
(C) Terminal S
H6M0494B
(A) Brush holder

(B) Rear bracket
SC-6
STARTER
4) Remove the armature and yoke. The ball used 6) Remove the shaft assembly and overrunning
as a bearing will then be removed from the end of clutch as a unit.
armature. CAUTION:
CAUTION: Before removal, confirm the following:
Be sure to mark an alignment mark on the yoke • Lever direction
and front bracket before removing yoke. • Internal gear assembly position
H6M0495D B2M4458B
(A) Armature (A) Lever

(B) Ball (B) Shaft ASSY
(C) Yoke (C) Overrunning clutch
(D) Front bracket (D) Internal gear ASSY
5) Remove the packing A, three planetary gears,

packing B and plate.
CAUTION:
Before removal, confirm the inserting location
of packing A.
B2M4793A
(A) Packing A
(B) Planetary gear
(C) Plate
(D) Packing B
SC-7
STARTER
7) Remove the overrunning clutch from shaft as- 2. BRUSH HOLDER

sembly as follows:
Slightly open the metal fitting holding the insulating
(1) Remove the stopper from ring by lightly tap-
plate to brush holder. Remove the insulating plate.
ping the stopper with an appropriate tool (such
as a 14 mm (0.55 in) socket wrench). NOTE:
(2) Remove the ring, stopper and clutch from The brush and spring can be easily removed from
shaft. the brush holder at this time.
H6M0497B
(A) Brush holder

(B) Insulating plate
(C) Metal fitting
B2M4769A
(A) Socket wrench

(B) Ring
(C) Shaft
(D) Stopper
SC-8
STARTER
D: ASSEMBLY 3) When installing the yoke to the front bracket,

Assemble in the reverse order of disassembly. Do match bolt hole.
the following:
1) Carefully assemble all parts in the order of as-
sembly and occasionally inspect nothing has been
overlooked.
2) When installing the shaft assembly to front
bracket, be careful of the following.
• Lever direction
B2M4773A
(A) Bolt hole
4) When installing the rear bracket, match brush

holder and yoke's groove.
B2M4770
• Internal gear position
B2M4774
5) When installing the switch assembly, catch

plunger protrusion to lever edge.
6) Apply grease to the following parts during as-
B2M4771
sembly.
• Packing position • Front and rear bracket sleeve bearing
• Armature shaft gear
• Outer periphery of plunger
• Mating surface of plunger and lever
• Gear shaft splines
• Mating surface of lever and clutch
• Ball at the armature shaft end
• Internal and planetary gears
7) After assembling parts correctly, make sure the
starter operates properly.
B2M4772
SC-9
STARTER
E: INSPECTION 4) Armature short-circuit test

Check the armature for short-circuit by placing it on
1. ARMATURE growler tester. Hold a hacksaw blade against the
1) Check the commutator for any sign of burns of armature core while slowly rotating armature. A
rough surfaces or stepped wear. If wear is of a mi- short-circuited armature will cause the blade to vi-
nor nature, correct it by using sand paper. brate and to be attracted to core. If the hacksaw
2) Run-out test blade is attracted or vibrates, the armature, which
Check the commutator run-out, and then replace if is short-circuited, must be replaced or repaired.
it exceeds the limit.
Commutator run-out:
Standard
0.05 mm (0.0020 in)
Service limit
Less than 0.10 mm (0.0039 in)
S6M0402A
(A) Iron sheet

(B) Grower tester
5) Armature ground test

Using a circuit tester, touch one probe to the com-
B2M4460A mutator segment and the other to shaft. There
should be no continuity. If there is continuity, the ar-
(A) Dial gauge mature is grounded.
(B) V-block
Replace the armature if it is grounded.
3) Depth of segment mold

Check the depth of segment mold.
Depth of segment mold:
0.5 mm (0.020 in)
G6M0041
2. YOKE
Make sure the pole is set in position.
3. OVERRUNNING CLUTCH
S6M0401A
Inspect the teeth of pinion for wear and damage.
Replace if it is damaged. Rotate the pinion in direc-
(A) Depth of mold
tion of rotation (counterclockwise). It should rotate
(B) Segment smoothly. But in opposite direction, it should be
(C) Mold locked.
CAUTION:
Do not clean the overrunning clutch with oil to
prevent grease from flowing out.
SC-10
STARTER
4. BRUSH AND BRUSH HOLDER 5. SWITCH ASSEMBLY

1) Brush length Be sure there is continuity between the terminals S
Measure the brush length, and then replace if it ex- and M, and between terminal S and ground. Use a
ceeds the service limit. circuit tester (set in “ohm”).
Replace if abnormal wear or cracks are noticed. Also check to be sure there is no continuity be-
tween terminal M and B.
Brush length:
Standard Terminal / Specified resistance:
12.3 mm (0.484 in) S — M / Less than 1 Ω
Service limit S — Ground / Less than 1 Ω
7.0 mm (0.276 in) M — B / More than 1 M Ω
H6M0496B S6M0403
(A) Service limit line 6. SWITCH ASSEMBLY OPERATION

(B) Brush 1) Connect the terminal S of switch assembly to
positive terminal of battery with a lead wire, and
2) Brush movement starter body to ground terminal of battery. The pin-
Be sure the brush moves smoothly inside brush ion should be forced endwise on shaft.
holder.
3) Brush spring force CAUTION:
Measure the brush spring force with a spring scale. With the pinion forced endwise on shaft, starter
If it is less than the service limit, replace the brush motor can sometimes rotate because current
holder. flows, through pull-in coil, to motor. This is not
a problem.
Brush spring force: 2) Disconnect the connector from terminal M, and
Standard then connect the positive terminal of battery and
21.6 N (2.2 kgf, 4.9 lb) (when new) terminal M using a lead wire and ground terminal to
Service limit starter body.
5.9 N (0.6 kgf, 1.3 lb) In this test set up, the pinion should return to its
original position even when it is pulled out with a
screwdriver.
S6M0393A
(A) Terminal S
(B) Terminal M
SC-11
STARTER
7. PINION GAP 8. PERFORMANCE TEST

1) Measure the pinion gap while the pinion is pulled The starter should be submitted to performance
out as shown in the figure. tests whenever it has been overhauled, to assure
its satisfactory performance when installed on the
Pinion gap:
engine.
0.5 — 2.0 mm (0.020 — 0.079 in)
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.
S6M0394A
(A) Pinion
(B) Gap
(C) Stopper
S6M0395A
If the motor is running with the pinion forced end-
wise on shaft, disconnect the connector from termi-
(A) Variable resistance
nal M of switch assembly, and then connect
(B) Magnetic switch
terminal M to ground terminal (−) of battery with a
lead wire. Next, gently push the pinion back with (C) Starter body
your fingertips, and then measure the pinion gap. 1) No-load test
2) If the pinion gap is outside specified range, re- With switch on, adjust the variable resistance to ob-
move or add number of adjustment washers used tain 11 V, take the ammeter reading, and then mea-
on the mounting surface of switch assembly until sure the starter speed. Compare these values with
correct pinion gap is obtained. the specifications.
No-load test (Standard):
Voltage / Current
11 V / 90 A max.
Rotating speed
MT vehicles
2,800 rpm or more
AT vehicles
2,400 rpm or more
SC-12
STARTER
2) Load test
Apply the specified braking torque to starter. The
condition is satisfactory if the current draw and
starter speed are within the specifications.
Load test (Standard):
Voltage / Load
MT vehicles
7.5 V/8.6 N (0.88 kgf, 1.93 lb)
AT vehicles
7.7 V/16.0 N (1.63 kgf, 3.60 lb)
Current / Speed
MT vehicles
300 A/920 rpm or more
AT vehicles
400 A/740 rpm or more
3) Lock test
With the starter stalled, or not rotating, measure the
torque developed and current draw when the volt-
age is adjusted to the specified voltage.
Lock test (Standard):
Voltage / Current
MT vehicles
4 V/650 A or less
AT vehicles
3.5 V/940 A or less
Torque
MT vehicles
14.7 N (1.50 kgf, 3.30 lb) or more
AT vehicles
28.9 N (2.95 kgf, 6.50 lb) or more
SC-13
GENERATOR
3. Generator • Turbo Model
A: REMOVAL
EN0048
4) Remove the front side V-belt.

G6M0095
<Ref. to ME-44, FRONT SIDE BELT, REMOVAL,
V-belt.> or <Ref. to ME(TURBO)-44, FRONT SIDE
2) Disconnect the connector and terminal from BELT, REMOVAL, V-belt.>
generator. 5) Remove the bolts which install generator onto
• Non-Turbo Model bracket.
B2M3105 S6M0352
• Turbo Model B: INSTALLATION

CAUTION:
Check and adjust the V-belt tension. <Ref. to
ME-45, INSPECTION, V-belt.> or <Ref. to
ME(TURBO)-45, INSPECTION, V-belt.>
EN0046

• Non-Turbo Model
S6M0352
B2M3106
SC-14
GENERATOR
C: DISASSEMBLY
1) Heat the portion (A) of rear cover to 50°C
(122°F) with heater drier.
H6M0498B
(A) Front bracket

B6M0476B (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
stator core and front bracket. Pry them apart to dis- 4) Unsolder connection between rectifier and stator
assemble. coil to remove the stator coil.
CAUTION:
Finish the work rapidly (less than 3 seconds)
because the rectifier cannot withstand heat
very well.
G6M0065A
(A) Screwdriver
3) Hold the rotor with a vise and remove pulley nut.

G6M0068
5) Remove the screws which secure IC regulator to

rear cover, and then unsolder connection between
IC regulator and rectifier to remove the IC regula-
tor.
G6M0066
CAUTION:
When holding the rotor with vise, insert alumi-
num plates or wood pieces on the contact sur-
faces of vise to prevent rotor from damage.
G6M0069
SC-15
GENERATOR
6) Remove the brushes by unsoldering at pigtails. 2) Heat the bearing box in rear bracket [50 to 60°C
(122 to 140°F)], and then press the rear bearing
into rear bracket.
CAUTION:
Grease should not be applied to rear bearing.
Remove the oil completely if it is found on bear-
ing box.
3) After reassembly, turn the pulley by hand to
check that rotor turns smoothly.
E: INSPECTION
G6M0070
1. DIODE
7) Remove the nut and insulating bushing at termi-
nal B, and then remove the rectifier. CAUTION:
Never use a mega 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
positive side heat sink. The positive diode is in
good condition if resistance is 1 Ω or less only in the
direction from the diode lead to heat sink.
S6M0405A
(A) Ractifier
(B) Rear cover
(C) Nut
D: ASSEMBLY
To assemble, reverse order of disassembly.
1) Pulling up brush
Before assembling, press the brush down into S6M0406A
brush holder with your finger, and then secure in
that position by passing a [2 mm (0.08 in) dia. (A) Diode lead
length 4 to 5 cm (1.6 to 2.0 in)] wire (A) through the (B) Heat sink (Positive side)
hole shown in the figure.
CAUTION:
Be sure to remove the wire after reassembly.
S6M0411A
SC-16
GENERATOR
2) Checking negative diode 4) Insulation test

Check for continuity between the negative side Check the continuity between slip ring and rotor
heat sink and diode lead. The negative diode is in core or shaft. If resistance is 1 Ω or less, the rotor
good condition if resistance is 1 Ω or less only in the coil is grounded, and so replace the rotor assem-
direction from the heat sink to diode lead. bly.
S6M0407A G6M0076
5) Ball bearing (rear side)

(A) Diode lead
(1) Check the rear ball bearing. Replace if it is
(B) Heat sink (Negative side)
noisy or if the rotor does not turn smoothly.
2. ROTOR (2) The rear bearing can be removed by using
common bearing puller.
1) Slip ring surface
Inspect the slip rings for contamination or any
roughness of the sliding surface. Repair the slip
ring surface using a lathe or sand paper.
2) Slip ring outer diameter
Measure the slip ring outer diameter. If the slip ring
is worn replace rotor assembly.
Slip ring outer diameter:
Standard
22.7 mm (0.894 in)
G6M0077
Limit
22.1 mm (0.870 in) 3. STATOR
3) Continuity test 1) Continuity test
Check the resistance between slip rings using cir- Inspect the stator coil for continuity between each
cuit tester. end of the lead wires. If resistance is 1 M Ω or
If the resistance is not within specification, replace more, the lead wire is broken, and so replace the
the rotor assembly. stator assembly.
Specified resistance:
Approx. 2.7 — 3.2 Ω
G6M0078A
G6M0075 (A) Stator
SC-17
GENERATOR
2) Insulation test 2) Checking brush spring for proper pressure

Inspect the stator coil for continuity between stator Using a spring pressure indicator, push the brush
core and each end of lead wire. If resistance is 1 Ω into the brush holder until its tip protrudes 2 mm
or less, the stator coil is grounded, and so replace (0.08 in). Then measure the pressure of brush
the stator assembly. spring. If the pressure is less than 2.648 N (270 g,
9.52 oz), replace the brush spring with a new one.
The new spring must have a pressure of 4.609 to
5.786 N (470 to 590 g, 16.58 to 20.81 oz).
G6M0079
4. BRUSH
1) Measure the length of each brush. If wear ex- G6M0143
ceeds the service limit, replace the brush. Each

brush has the service limit mark (A) on it. 5. BEARING (FRONT SIDE)
1) Check the front ball bearing. If the resistance is
Brush length:
felt while rotating, or if abnormal noise is heard, re-
Standard
place the ball bearing.
18.5 mm (0.728 in)
2) Replacing front bearing
Service limit
(1) Remove the front bearing retainer.
5.0 mm (0.197 in)
(2) Closely install a fit tool on the bearing inner
race. Press the bearing down out of front brack-
et with a hand press or vise. A socket wrench
can serve as the tool.
H6M0499B
S6M0409A
(A) Front bracket

(B) Socket wrench
(3) Set a new bearing and closely install a fit

tool on the bearing outer race. Press the bearing
down into place with a hand press or vise. A
socket wrench can serve as the tool.
SC-18
GENERATOR
(4) Install the front bearing retainer.
S6M0410A
(A) Bearing
(B) Socket wrench
(C) Front bracket
SC-19
BATTERY
4. Battery C: INSPECTION
A: REMOVAL WARNING:
1) Disconnect the positive (+) cable after discon- • Electrolyte has toxicity; be careful handling
necting the ground (−) cable of battery. the fluid.
2) Remove the flange nuts from battery rods, and • Avoid contact with skin, eyes or clothing. Es-
then take off the battery holder. pecially at contact with eyes, blush 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.
B6M1506 • Do not let the battery fluid contact eyes, skin,
fabrics, or paint-work because battery fluid is
3) Remove the battery. corrosive acid.
B: INSTALLATION • To lessen the risk of sparks, remove rings,
Install in the reverse order of removal. metal watch-bands, and other metal jewelry.
Never allow metal tools to contact the positive
Tightening torque: battery terminal and anything connected to it
3.4 N·m (0.35 kgf-m, 2.5 ft-lb) while you are at the same time in contact with
NOTE: any other metallic portion of the vehicle be-
• Clean the battery cable terminals, and then apply cause a short circuit will be caused.
grease to retard formation of corrosion. 1. EXTERNAL PARTS:
• Connect the positive (+) cable of battery and then
the ground (−) cable of battery. Check for the existence of dirt or cracks on battery
case, top cover, vent plugs, and terminal posts. If
necessary, clean with water and wipe with a dry
cloth.
Apply a thin coat of grease on the terminal posts to
prevent corrosion.
2. ELECTROLYTE LEVEL:
Check the electrolyte level in each cell. If the level
is below MIN LEVEL, bring the level to MAX LEVEL
by pouring distilled water into the battery cell. Do
not fill beyond MAX LEVEL.
SC-20
BATTERY
3. SPECIFIC GRAVITY OF ELECTROLYTE: 1. JUDGMENT OF BATTERY IN CHARGED

1) Measure the specific gravity of electrolyte using CONDITION
a hydrometer and a thermometer. 1) Specific gravity of electrolyte is held at a specific
Specific gravity varies with temperature of electro- value in a range from 1.250 to 1.290 for more than
lyte so that it must be corrected at 20°C (68°F) us- one hour.
ing the following equation: 2) Voltage per battery cell is held at a specific value
S20 = St + 0.0007 × (t − 20) in a range from 2.5 to 2.8 volts for more than one
S20: Specific gravity corrected at electrolyte hour.
temperature of 20°C 2. CHECK HYDROMETER FOR STATE OF
St : Measured specific gravity CHARGE
t : Measured temperature (°C)
Determine whether or not battery must be Hydrometer
State of charge Required action
charged, according to corrected specific indicator
gravity. Green dot Above 65% Load test
Standard specific gravity: 1.220 — 1.290 [at Dark dot Below 65% Charge battery
20°C (68°F)] Replace battery*
Clear dot Low electrolyte
(If cranking complaint)
*: Check electrical system before replacement.
3. NORMAL CHARGING
Charge the battery at current value specified by
manufacturer or at approx. 1/10 of battery's am-
pere-hour rating.
4. QUICK CHARGING
Quick charging is a method in which the battery is
G6M0103
charged in a short period of time with a relatively
2) Measuring the specific gravity of the electrolyte large current by using a quick charger.
in battery will disclose the state of charge of bat- Since a large current flow raises electrolyte temper-
tery. The relation between specific gravity and state ature, the battery is subject to damage if large cur-
of charge is as shown in the figure. rent is used for prolonged time. For this reason, the
quick charging must be carried out within a current
D: MEASUREMENT range that will not increase the electrolyte temper-
WARNING: ature above 40°C (104°F).
• Do not bring an open flame close to the bat- It should be also remembered that the quick charg-
tery at this time. ing is a temporary means to bring battery voltage
CAUTION: up to a fair value and, as a rule, a battery should be
• Prior to charging, corroded terminals should charged slowly with a low current.
be cleaned with a brush and common baking CAUTION:
soda solution. • Observe the items in 1. NORMAL CHARGING.
• Be careful since the battery electrolyte over- • Never use more than 10 amperes when
flows while charging the battery. charging the battery because that will shorten
• Observe the instructions when handling bat- battery life.
tery charger.
• Before charging the battery on vehicle, dis-
connect battery ground terminal. Failure to fol-
low this rule may damage alternator's diodes or
other electrical units.
SC-21
BATTERY
SC-22
ENGINE (DIAGNOSTICS)
EN
Page
1. Basic Diagnostic Procedure ........................................................................2
2. Check List for Interview...............................................................................4
4. Electrical Components Location................................................................10
5. Engine Control Module (ECM) I/O Signal .................................................24
6. Engine Condition Data ..............................................................................27
7. Transmission Control Module (TCM) I/O Signal .......................................28
8. Data Link Connector .................................................................................31
9. OBD-II General Scan Tool ........................................................................32
10. Subaru Select Monitor...............................................................................34
11. Read Diagnostic Trouble Code (DTC) ......................................................41
12. Inspection Mode........................................................................................42
13. Drive Cycle................................................................................................47
14. Clear Memory Mode..................................................................................49
15. Compulsory Valve Operation Check Mode ...............................................50
16. Engine Malfunction Indicator Lamp (MIL) .................................................52
17. Diagnostics for Engine Starting Failure.....................................................62
18. List of Diagnostic Trouble Code (DTC) .....................................................83
19. Diagnostic Procedure with Diagnostic Trouble Code (DTC) .....................90
20. General Diagnostic Table........................................................................292
BASIC DIAGNOSTIC PROCEDURE
1. Basic Diagnostic Procedure

A: PROCEDURE
1. ENGINE
Step Check Yes No

1 CHECK ENGINE START FAILURE. Does 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. Engine Start Fail-
to EN-4, CHECK, Check List for Interview.> ure”. <Ref. to EN-
2)Start the engine. 62, Diagnostics for
Engine Starting
Failure.>
2 CHECK ILLUMINATION OF CHECK ENGINE Does the CHECK ENGINE Go to step 3. Inspection using
MALFUNCTION INDICATOR LAMP (MIL). malfunction indicator lamp illu- “General Diagnos-
minate? tics Table”. <Ref.
to EN-292,
INSPECTION,
General Diagnos-
tic Table.>
3 CHECK INDICATION OF DIAGNOSTIC Does the Subaru Select Moni- Record the DTC. Repair the related
TROUBLE CODE (DTC) ON DISPLAY. tor or OBD-II general scan tool Repair the trouble parts.
1)Turn the ignition switch to OFF. indicate DTC? cause. <Ref. to NOTE:
2)Connect the Subaru Select Monitor or OBD- EN-83, List of If a DTC is not
II general scan tool to data link connector. Diagnostic Trou- shown on display
3)Turn the ignition switch to ON and Subaru ble Code (DTC).> although the MIL il-
Select Monitor or OBD-II general scan tool Go to step 4. luminates, per-
switch to ON. form diagnostics of
4)Read the DTC on the Subaru Select Monitor MIL (CHECK EN-
or OBD-II general scan tool. GINE malfunction
indicator lamp) cir-
cuit or combination
meter. <Ref. to
EN-52, Engine
Malfunction Indica-
tor Lamp (MIL).>
4 PERFORM THE DIAGNOSIS. Does the Subaru Select Moni- Inspect using Complete the
1)Perform the clear memory mode. <Ref. to tor or OBD-II general scan tool “Diagnostics Pro- diagnosis.
EN-49, Clear Memory Mode.> indicate DTC? cedure with Diag-
2)Perform the inspection mode. <Ref. to EN- nostic Trouble
42, Inspection Mode.> Code (DTC)”.
<Ref. to EN-90,
Diagnostic Proce-
dure with Diagnos-
tic Trouble Code
(DTC).>
EN-2
2. AUTOMATIC TRANSMISSION
When the diagnostic trouble code (DTC) about au-
tomatic transmission is shown on display, carry out
the following basic check. After that, carry out the
replacement or repair work.
1) ATF level check <Ref. to AT-9, Automatic Trans-
mission Fluid.>
2) Differential gear oil level check <Ref. to AT-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-11,
Differential Gear Oil.>
5) Stall test <Ref. to AT-13, Stall Test.>
6) Line pressure test <Ref. to AT-16, Line Pressure
Test.>
7) Transfer clutch pressure test <Ref. to AT-18,
Transfer Clutch Pressure Test.>
8) Time lag test <Ref. to AT-15, Time Lag Test.>
9) Road test <Ref. to AT-12, Road Test.>
10) Shift characteristics <Ref. to AT-18, Transfer
Clutch Pressure Test.>
EN-3
CHECK LIST FOR INTERVIEW
2. Check List for Interview

A: CHECK
1. CHECK LIST NO. 1
Check the following items when problem has occurred.
NOTE:
Use copies of this page for interviewing customers.
Customer's name Engine No.
Date of sale Fuel brand
Date of repair Odometer reading km
Vin No. miles
Weather ❏ Fine
❏ Cloudy
❏ Rainy
❏ Snowy
❏ Various/Others:
Outdoor temperature °C (°F)
❏ Hot
❏ Warm
❏ Cool
❏ Cold
Place ❏ Highway
❏ Suburbs
❏ Inner city
❏ Uphill
❏ Downhill
❏ Rough road
❏ Others:
Engine temperature ❏ Cold
❏ Warming-up
❏ After warming-up
❏ Any temperature
❏ Others:
Engine speed rpm
Vehicle speed MPH
Driving conditions ❏ Not affected
❏ At starting
❏ While idling
❏ At racing
❏ While accelerating
❏ While cruising
❏ While decelerating
❏ While turning (RH/LH)
Headlight ❏ ON/❏ OFF Rear defogger ❏ ON/❏ OFF
Blower ❏ ON/❏ OFF Radio ❏ ON/❏ OFF
A/C compressor ❏ ON/❏ OFF CD/Cassette ❏ ON/❏ OFF
Cooling fan ❏ ON/❏ OFF Car phone ❏ ON/❏ OFF
Front wiper ❏ ON/❏ OFF CB ❏ ON/❏ OFF
Rear wiper ❏ ON/❏ OFF
EN-4
2. CHECK LIST NO. 2

Check the following items about the vehicle's state when MIL turns on.
NOTE:
a) Other warning lights or indicators turn on. ❏ Yes/❏ No
❏ Low fuel warning light
❏ Charge indicator light
❏ AT diagnostics indicator light
❏ ABS warning light
❏ Engine oil pressure warning light
b) Fuel level
• Lack of gasoline: ❏ Yes/❏ No
• Indicator position of fuel gauge:
c) Intentional connecting or disconnecting of harness connectors or spark plug cords: ❏ Yes/❏ No
• What:
d) Intentional connecting or disconnecting of hoses: ❏ Yes/❏ No
• What:
e) Installing of parts other than genuine parts: ❏ Yes/❏ No
• What:
• Where:
f) Occurrence of noise: ❏ Yes/❏ No
• From where:
• What kind:
g) Occurrence of smell: ❏ Yes/❏ No
• From where:
• What kind:
h) Intrusion of water into engine compartment or passenger compartment: ❏ Yes/❏ No
i) Troubles occurred
❏ Engine does not start.
❏ Engine stalls during idling.
❏ Engine stalls while driving.
❏ Engine speed decreases.
❏ Engine speed does not decrease.
❏ Rough idling
❏ Poor acceleration
❏ Back fire
❏ After fire
❏ No shift
❏ Excessive shift shock
EN-5
GENERAL DESCRIPTION
3. General Description 8) Use the ECM mounting stud bolt at the body
head grounding points when measuring voltage
A: CAUTION and resistance inside the passenger compartment.
1) Airbag system wiring harness is routed near the
engine control module (ECM), main relay and fuel
pump relay.
CAUTION:
• All airbag system wiring harness and 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-
EN1393
ule (TCM), main relay and fuel pump relay.
2) Never connect the battery in reverse polarity. (A) Stud bolt
• The ECM will be destroyed instantly.
• The fuel injector and other part will be damaged 9) Use the engine grounding terminal or engine
in just a few minutes more. proper as the grounding point to the body, when
3) Do not disconnect the battery cables while the measuring voltage and resistance in the engine
engine is running. compartment.
• A large counter electromotive force will be gener-
ated in the alternator, and this voltage may damage
electronic parts such as ECM, etc.
4) Before disconnecting the connectors of each
sensor and the ECM, be sure to turn the ignition
switch to OFF.
5) Poor contact has been identified as a primary
cause of this problem. To measure the voltage and/
or resistance of individual sensors or all electrical
control modules at the harness side connector, use
a tapered pin with a diameter of less than 0.64 mm B2M2779
(0.025 in). Do not insert the pin more than 5 mm 10) Use the TCM mounting stud bolts at the body
(0.20 in) into the part. head grounding point, when measuring voltage and
6) Before removing the ECM from located position, resistance inside the passenger compartment.
disconnect two cables on battery.
• Otherwise, the ECM may be damaged.
CAUTION:
the wrong spec. ECM to avoid any damage on
the fuel injection system.
7) The connectors to each sensor in the engine
compartment and the harness connectors on the
engine side and body side are all designed to be
waterproof. However, it is still necessary to take
care not to allow water to get into the connectors EN1394
when washing the vehicle, or when servicing the
vehicle on a rainy day. (A) Stud bolt
11) Every MFI-related part is a precision part. Do

not drop them.
EN-6
GENERAL DESCRIPTION
12) Observe the following cautions when installing B: INSPECTION

a radio in MFI equipped models. Before performing diagnostics, check the following
CAUTION: items which might affect engine problems:
• The antenna must be kept as far apart as pos-
sible from the control unit.
1. BATTERY
(The ECM is located under the steering column, 1) Measure the battery voltage and specific gravity
inside of the instrument panel lower trim panel.) of electrolyte.
• The antenna feeder must be placed as far Standard voltage: 12 V
apart as possible from the ECM and MFI har-
ness. Specific gravity: Above 1.260
• Carefully adjust the antenna for correct 2) Check the condition of the main and other fuses,
matching. and harnesses and connectors. Also check for
• When mounting a large power type radio, pay proper grounding.
special attention to the three items above men-
tioned. 2. ENGINE GROUNDING
• Incorrect installation of the radio may affect Make sure the engine grounding cable is properly
the operation of the ECM. connected to the engine.
13) Before disconnecting the fuel hose, disconnect
the fuel pump connector and crank the engine for
more than 5 seconds to release pressure in the fuel
system. If the engine starts during this operation,
run it until it stops.
14) Problems in the electronic-controlled automatic
transmission may be caused by failure of the 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. B2M2779
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 5 seconds at a time (from closed throttle,
fully open throttle to stall engine speed).
17) On ABS vehicle, when performing driving test
in jacked-up or lifted-up position, sometimes the
warning light may be lit, but this is not a malfunction
of the system. The reason for this is the speed 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.
EN-7
GENERAL DESCRIPTION
C: NOTE 2. ENGINE AND EMISSION CONTROL SYS-

TEM
1. DESCRIPTION
• The Multipoint Fuel Injection (MFI) system is a
• The on-board diagnostics (OBD) system detects system that supplies the optimum air-fuel mixture
and indicates a fault in various inputs and outputs to the engine for all the various operating condi-
of the complex electronic control. CHECK ENGINE tions through the use of the latest electronic tech-
malfunction indicator lamp (MIL) in the combination nology.
meter indicates occurrence of a fault or trouble. With this system fuel, which is pressurized at a con-
• Further, against such a failure or sensors as may stant pressure, is injected into the intake air pas-
disable the drive, the fail-safe function is provided sage of the cylinder head. The injection quantity of
to ensure the minimal driveability. fuel is controlled by an intermittent injection system
• The OBD system incorporated with the vehicles where the electro-magnetic injection valve (fuel in-
within this engine family complies with Section jector) opens only for a short period of time, de-
1968.1, California Code of Regulations (OBD-II pending on the quantity of air required for one cycle
regulation). The OBD system monitors the compo- of operation. In actual operation, the injection quan-
nents and the system malfunction listed in Engine tity is determined by the duration of an electric
Section which affects on emissions. pulse applied to the fuel injector and this permits
• When the system decides that a malfunction oc- simple, yet highly precise metering of the fuel.
curs, MIL illuminates. At the same time of the MIL il- • Further, all the operating conditions of the engine
lumination or blinking, a diagnostic trouble code are converted into electric signals, and this results
(DTC) and a freeze frame engine conditions are in additional features of the system, such as large
stored into on-board computer. improved adaptability, easier addition of compen-
• The OBD system stores freeze frame engine sating element, etc.
condition data (engine load, engine coolant tem- The MFI system also has the following features:
perature, fuel trim, engine speed and vehicle • Reduced emission of harmful exhaust gases.
speed, etc.) into on-board computer when it detects • Reduced in fuel consumption.
a malfunction first. • Increased engine output.
• If the OBD system detects the various malfunc- • Superior acceleration and deceleration.
tions including the fault of fuel trim or misfire, the
• Superior startability and warm-up perfor-
OBD system first stores freeze frame engine condi-
mance in cold weather since compensation is
tions about the fuel trim or misfire.
made for coolant and intake air temperature.
• When the malfunction does not occur again for
three consecutive driving cycles, MIL is turned off, 3. AUTOMATIC TRANSMISSION AND
but DTC remains at on-board computer. ELECTRONIC-HYDRAULIC CONTROL SYS-
• The OBD-II system is capable of communication TEM
with a general scan tool (OBD-II general scan tool)
formed by ISO 9141 CARB. The electronic-hydraulic control system consists of
• The OBD-II diagnostics procedure is different various sensors and switches, a transmission con-
from the usual diagnostics procedure. When trou- trol module (TCM) and the hydraulic controller in-
bleshooting OBD-II vehicles, connect Subaru Se- cluding solenoid valves. The system controls the
lect Monitor or the OBD-II general scan tool to the transmission proper including shift control, lock-up
vehicle. 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).
EN-8
GENERAL DESCRIPTION
D: PREPARATION TOOL
24082AA190 CARTRIDGE Troubleshooting for electrical
(New adopted tool) systems.
B2M3876
22771AA030 SELECT MONITOR KIT Troubleshooting for electrical
systems.
• English: 22771AA030 (With-
out printer)
• German: 22771AA070
(Without printer)
• French: 22771AA080
(Without printer)
• Spanish: 22771AA090
(Without printer)
B2M3877
EN-9
ELECTRICAL COMPONENTS LOCATION
4. Electrical Components Location

A: LOCATION
1. ENGINE
• Module
LHD model (1)
(3) (2) (4)

EN1423
RHD model (3) (2) (4)
(1)
EN1424
(1) Engine control module (ECM) (3) Test mode connector

(2) CHECK ENGINE malfunction indi- (4) Data link connector
cator lamp (MIL)
EN-10
(2)
B3M1575A EN0718
(3)
EN0716 (4) EN1425
EN-11
• Sensor
(1) (3) (4) (2) (5)
(7) (6)
EN0719
(1) Atmospheric pressure sensor (3) Engine coolant temperature sen- (5) Knock sensor
(2) Intake air temperature and pressor (6) Camshaft position sensor
sure sensor (4) Throttle position sensor (7) Crankshaft position sensor
EN-12
B2M3713A B2M3714A
S2M1248B B2M2240A
B2M2241A B2M2242A
B2M0213J
EN-13
B2M4231A
(1) Front oxygen (A/F) sensor (3) Front catalytic converter

(2) Rear oxygen sensor (4) Rear catalytic converter
S2M0264A S2M0265A
OBD0524G OBD0525G
EN-14
LHD model (1)
(2)
EN1019
RHD model (1)
(2)
EN1020
(1) Fuel level sensor (2) Fuel sub level sensor (2500 cc
model only)
EN1036 EN1037
EN-15
• Solenoid Valve, Emission Control System Parts and Ignition System Parts
(3) (1) (4) (2)
EN0736
(1) Air assist injector solenoid valve (3) Purge control solenoid valve
(2) Idle air control solenoid valve (4) Ignition coil & ignitor ASSY
EN-16
B2M3715A H2M3259A
H2M3258B B2M3720A
EN-17
(1) (3) (4) (2)
(6) (5) (7)

EN0741
(1) (2)
(6) (5) (7) (3) (4)

EN0742
(1) Inhibitor switch (4) Fuel pump relay (7) Starter

(2) Fuel pump (5) Radiator main fan relay
(3) Main relay (6) Radiator sub fan relay
EN-18
B2M2246A EN1505
LHD model RHD model (3)

(3) (4) (4)
EN1504 EN1506
(6)
(5)
EN0746
B2M2247E
EN-19
2. TRANSMISSION
• Module
(1) (2)
EN0751
(1) (2)
EN0752
(1) Transmission control module (2) AT diagnostic indicator light (for

(TCM) (for AT vehicles) AT vehicles)
EN-20
B3M1592D B3M1652B
(2)
EN0754
EN-21
• Sensor
B2M2258A B2M2259A
B2M2260A B2M2261A
OBD0653B
(1) Rear vehicle speed sensor (for AT vehicles)

(2) Front vehicle speed sensor (for MT vehicles)
(3) Front vehicle speed sensor (for AT vehicles)
(4) Torque converter turbine speed sensor
(5) ATF temperature sensor (for AT vehicles)
(6) Brake light switch
EN-22
• Solenoid Valve and Switch (AT vehicles)
B2M2246F B2M2263K
B2M2264F
(1) Inhibitor switch

(2) Shift solenoid valve 1
(4) Line pressure duty solenoid
(5) Lock-up duty solenoid
(6) Transfer duty solenoid
(7) 2-4 brake duty solenoid
(8) Low clutch timing solenoid valve
(9) 2-4 brake timing solenoid valve
• Solenoid Valve and Switch (MT vehicles)
B2M2265A
(1) Neutral position switch
EN-23
ENGINE CONTROL MODULE (ECM) I/O SIGNAL
5. Engine Control Module (ECM) I/O Signal

A: ELECTRICAL SPECIFICATION
B2M2267A
Con- Signal (V)

Terminal
Content nector Ignition SW ON Note
No. Engine ON (Idling)
No. (Engine OFF)
Crank- Signal (+) B135 2* 1 0 −7 — +7 Sensor output waveform
shaft posi- Signal (−) B135 9* 8 0 0 —
tion sensor Shield B135 10 0 0 —
Camshaft Signal (+) B135 1* 2 0 −7 — +7 Sensor output waveform
position Signal (−) B135 8* 9 0 0 —
sensor Shield B135 10 0 0 —
Fully closed: 0.2 — 1.0
Signal B136 17 —
Fully opened: 4.2 — 4.7
Throttle
Power
position B136 15 5 5 —
supply
sensor
GND (sen-
B136 16 0 0 —
sor)
Signal B136 18 0 0 — 0.9 —
Rear oxy-
Shield B136 24 0 0 —
gen sen-
sor GND (sen-
B136 16 0 0 —
sor)
Front oxy- Signal 1 B134 23 0 — 1.0 0 — 1.0 —
gen (A/F)
sensor Signal 2 B134 22 0 — 1.0 0 — 1.0 —
heater
Rear oxygen sensor
B134 21 0 — 1.0 0 — 1.0 —
heater signal
Engine Signal B136 14 1.0 — 1.4 1.0 — 1.4 After warm-up the engine.
coolant
tempera- GND (sen-
ture sen- B136 16 0 0 After warm-up the engine.
sor)
sor
“5” and “0” are repeatedly dis-
Vehicle speed signal B135 24 0 or 5 0 or 5
played when vehicle is driven.
*: With immobilizer
EN-24
Con- Signal (V)

Terminal
No. (Engine OFF)
Starter switch B135 28 0 0 Cranking: 8 — 14
ON: 10 — 13 ON: 13 — 14
A/C switch B135 27 —
OFF: 0 OFF: 0
Ignition switch B135 7 10 — 13 13 — 14 —
ON: 12±0.5 On MT vehicle; Switch is ON
MT B135 26
Neutral OFF: 0 when gear is in neutral position.
position ON AT vehicle; Switch is ON
switch ON: 0
AT B135 26 when shift is in “N” or “P” posi-
OFF: 12±0.5
tion.
Test mode connector B135 14 5 5 When connected: 0
Knock Signal B136 4 2.8 2.8 —
Back-up power supply B136 9 10 — 13 13 — 14 Ignition switch “OFF”: 10 — 13
Control unit power sup- B136 1 10 — 13 13 — 14 —
ply B136 2 10 — 13 13 — 14 —
Sensor power supply B136 15 5 5 —
Line end check 1 B135 20 0 0 —
Ignition #1, #2 B134 25 0 1 — 3.4 Waveform
control #3, #4 B134 26 0 1 — 3.4 Waveform
#1 B134 4 10 — 13 1 — 14 Waveform
Fuel injec- #2 B134 13 10 — 13 1 — 14 Waveform
tor #3 B134 14 10 — 13 1 — 14 Waveform
#4 B134 15 10 — 13 1 — 14 Waveform
Signal 1 B134 5 — 1 — 13 Waveform
Idle air Signal 2 B134 6 — 1 — 13 Waveform
control Signal 3 B134 19 — 1 — 13 Waveform
solenoid Signal 4 B134 20 — 1 — 13 Waveform
valve Power
B136 2 10 — 13 13 — 14 —
supply
ON: 0.5, or less
Fuel pump relay control B134 29* 16 0.5, or less —
OFF: 10 — 13
ON: 0.5, or less ON: 0.5, or less
A/C relay control B134 17 —
OFF: 10 — 13 OFF: 13 — 14
Radiator fan relay 1 ON: 0.5, or less ON: 0.5, or less
B134 3 —
control OFF: 10 — 13 OFF: 13 — 14
B134 12 With A/C vehicles only
control OFF: 10 — 13 OFF: 13 — 14
Malfunction indicator Light “ON”: 1, or less
B134 11 — —
lamp Light “OFF”: 10 — 14
Engine speed output B134 30 — 0 — 13, or more Waveform
Torque control 1 signal B135 16 5 More than 4 V —
Torque control 2 signal B135 17 5 More than 4 V —
Torque control cut sig-
B134 31 8 8 —
nal
Purge control solenoid ON: 1, or less ON: 1, or less
B134 2 —
valve OFF: 10 — 13 OFF: 13 — 14
Signal B136 29 3.9 — 4.1 2.0 — 2.3
Atmo-
Power
spheric B136 15 5 5
supply —
pressure
sensor GND (sen-
B136 16 0 0
sor)
*: With immobilizer
EN-25
Con- Signal (V)

Terminal
No. (Engine OFF)
Fuel level sensor B136 27 0.12 — 4.75 0.12 — 4.75 For europe model
AT diagnosis input sig- Less than 1 ←→ Less than 1 ←→
B135 4 Waveform
nal More than 4 More than 4
ON: 0 ON: 0
Small light switch B136 3 —
OFF: 10 — 13 OFF: 13 — 14
ON: 0 ON: 0
Blower fan switch B136 30 —
OFF: 10 — 13 OFF: 13 — 14
ON: 0 ON: 0
Rear defogger switch B135 21 —
OFF: 10 — 13 OFF: 13 — 14
Front oxygen (A/F) sen-
B136 19 2.8 — 3.2 2.8 — 3.2 —
sor signal 1
B136 6 2.4 — 2.7 2.4 — 2.7 —
sor signal 2
B136 7 0.2 — 4.9 0.2 — 4.9 —
sor signal 3
B136 20 0.2 — 4.9 0.2 — 4.9 —
sor signal 4
Pressure sensor B136 5 2.4 — 4.8 0.4 — 1.8 —
Intake air temperature
B136 13 2.3 — 2.5 1.4 — 1.6 —
sensor
SSM/GST communica- Less than 1 ←→ Less than 1 ←→
B135 3 —
tion line More than 4 More than 4
GND (sensors) B136 16 0 0 —
GND (injectors) B134 7 0 0 —
GND (ignition system) B134 27 0 0 —
GND (power supply) B134 8 0 0 —
B136 21 0 0 —
GND (control systems)
B136 22 0 0 —
GND (oxygen sensor
B134 35 0 0 —
heater 1)
GND (oxygen sensor
B134 34 0 0 —
heater 2)
EN-26
ENGINE CONDITION DATA
6. Engine Condition Data

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

to B54 to B55
9 8 7 6 5 4 3 2 1 9 8 7 6 5 4 3 2 1
18 17 16 15 14 13 12 11 10 18 17 16 15 14 13 12 11 10
24 23 22 21 20 19 24 23 22 21 20 19
to B56
9 8 7 6 5 4 3 2 1
18 17 16 15 14 13 12 11 10
24 23 22 21 20 19
TR0532
Check with ignition switch ON.

Con-
Termi- Resistance to
Content nector Measuring conditions Voltage (V)
nal No. body (ohms)
No.
Back-up power supply B56 1 Ignition switch OFF 10 — 13 —
B54 23 Ignition switch ON (with
Ignition power supply 10 — 13 —
B54 24 engine OFF)
Select lever in “P” range Less than 1
“P” range
B55 1 Select lever in any other than —
switch More than 8
“P” range (except “N” range)
Select lever in “N” range Less than 1
“N” range
switch More than 8
“N” range (except “P” range)
Select lever in “R” range Less than 1
“R” range
switch More than 8
“R” range
Select lever in “D” range Less than 1
Inhibitor “D” range
switch switch More than 8
“D” range
Select lever in “3” range Less than 1
“3” range
switch More than 8
“3” range
“2” range
switch More than 8
“2” range
“1” range
switch More than 8
“1” range
Brake pedal depressed. More than 10.5
Brake switch B55 12 —
Brake pedal released. Less than 1
ABS switch ON Less than 1
ABS signal B55 21 —
ABS switch OFF 6.5 — 15
EN-28

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

Con-
nal No. body (ohms)
No.
engine OFF)
1.5 — 4.0
Throttle fully closed after
warm-up.
Line pressure duty solenoid B54 9 2.0 — 4.5
engine OFF)
Less than 0.5
Throttle fully open after
warm-up.
When lock up occurs. More than 8.5
Lock-up duty solenoid B54 7 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 B54 6 switch (with throttle fully 10 — 17
Less than 0.5
open and with select lever in
1st gear).
engine OFF)
1.5 — 4.0
warm-up.
2-4 brake duty solenoid B54 18 2.0 — 4.5
engine OFF)
Less than 0.5
warm-up.
1st gear Less than 1
2-4 brake timing solenoid B54 16 10 — 16
3rd gear More than 9
2nd gear Less than 1
Low clutch timing solenoid B54 15 10 — 16
4th gear More than 9
Sensor ground line 1 B54 20 — 0 Less than 1
B56 19
System ground line — 0 Less than 1
B54 21
Fuse removed. 6 — 9.1
FWD switch B55 20 —
Fuse installed. Less than 1
Fuse on FWD switch Less than 1
FWD indicator light B56 2 Fuse removed from FWD —
More than 9
switch
Data link signal (Subaru
B56 15 — — —
Select Monitor)
EN-30
DATA LINK CONNECTOR
8. Data Link Connector

A: NOTE
1) This connector is used both for the OBD-II general scan tools and Subaru Select Monitor.
2) Terminal No. 4 to No. 6 of the data link connector is used for the Subaru Select Monitor signal.
CAUTION:
Do not connect any scan tools other than the OBD-II general scan tools and Subaru Select Monitor,
because the circuit for Subaru Select Monitor may be damaged.
H2M1280
Terminal No. Contents Terminal No. Contents

1 Power supply 9 Blank
2 Blank 10 K line of ISO 9141 CARB
3 Blank 11 Blank
Subaru Select Monitor signal (ECM to Subaru
4 12 Ground
Select Monitor)*
Subaru Select Monitor signal (Subaru Select
5 13 Ground
Monitor to ECM)*
6 Line end check signal 1 14 Blank
7 Blank 15 Blank
8 Blank 16 Blank
*: Circuit only for Subaru Select Monitor
EN-31
OBD-II GENERAL SCAN TOOL
9. OBD-II General Scan Tool 3) Using the OBD-II general scan tool, call up diag-
nostic trouble code(s) (DTC(s)) and freeze frame
A: OPERATION data.
OBD-II general scan tool functions consist of:
1. HOW TO USE OBD-II GENERAL SCAN (1) MODE $01: Current powertrain diagnostic
TOOL data
1) Prepare a general scan tool (OBD-II general (2) MODE $02: Powertrain freeze frame data
scan tool) required by SAE J1978. (3) MODE $03: Emission-related powertrain di-
2) Connect the OBD-II general scan tool to data agnostic trouble codes (DTCs)
link connector located in the lower portion of instru- (4) MODE $04: Clear/Reset emission-related
ment panel (on the driver's side). diagnostic information
Read out the data according to repair procedures.
(For detailed operation procedures, refer to the
OBD-II General Scan Tool Operation Manual.)
NOTE:
For details concerning diagnostic trouble codes
(DTCs), refer to the List of Diagnostic Trouble Code
(DTC). <Ref. to EN-83, List of Diagnostic Trouble
Code (DTC).>
EN0768
2. MODE $01 (CURRENT POWERTRAIN DIAGNOSTIC DATA)

Refers to data denoting the current operating condition of analog input/output, digital input/output and/or the
powertrain system.
A list of the support data and PID (Parameter Identification) codes are shown in the following table.
PID Data Unit of measure
01 Number of emission-related powertrain trouble codes and MIL status ON/OFF
03 Fuel system control status —
04 Calculated engine load value %
05 Engine coolant temperature °C
06 Short term fuel trim %
07 Long term fuel trim %
0B Intake manifold absolute pressure kPa
0C Engine revolution rpm
0D Vehicle speed km/h
0E Ignition timing advance °
0F Intake air temperature °C
10 Air flow rate from pressure sensor g/sec
11 Throttle valve opening angle %
13 Check whether oxygen sensor is installed. —
Oxygen sensor output voltage and short term fuel trim associated with oxygen sensor—bank
15 V and %
1 sensor 2
24 A/F sensor 1 output voltage and short term fuel trim associated with A/F sensor 1 V and %
1C On-board diagnosis system —
NOTE:
Refer to OBD-II general scan tool manufacturer's instruction manual to access generic OBD-II PIDs (MODE
$01).
EN-32
3. MODE $02 (POWERTRAIN FREEZE FRAME DATA)

Refers to data denoting the operating condition when trouble is sensed by the on-board diagnosis system.
02 Trouble code that caused CARB required freeze frame data storage —
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-41, Read Diagnostic Trouble Code (DTC).>
5. MODE $04 (CLEAR/RESET EMISSION-RELATED DIAGNOSTIC INFORMATION)
Refers to the mode used to clear or reset emission-related diagnostic information (OBD-II trouble diagnostic
information).
NOTE:
Refer to OBD-II general scan tool manufacturer's instruction manual to clear or reset emission-related diag-
nostic information (MODE $04).
EN-33
SUBARU SELECT MONITOR
10.Subaru Select Monitor (2) Connect the diagnosis cable to data link
connector.
A: OPERATION CAUTION:
1. HOW TO USE SUBARU SELECT MONI- Do not connect the scan tools except for Suba-
TOR ru Select Monitor and OBD-II general scan tool.
5) Turn the ignition switch to ON (engine OFF) and
1) Prepare the Subaru Select Monitor kit. <Ref. to
Subaru Select Monitor switch to ON.
EN-9, PREPARATION TOOL, General Descrip-
tion.>
S2M0288E
S2M0285
(A) Power switch
2) Connect the diagnosis cable to Subaru Select
Monitor. 6) Using the Subaru Select Monitor, call up diag-
3) Insert the cartridge into Subaru Select Monitor. nostic trouble code(s) (DTC(s)) and various data,
<Ref. to EN-9, PREPARATION TOOL, General then record them.
Description.> 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-41,
Read Diagnostic Trouble Code (DTC).>
3. READ DIAGNOSTIC TROUBLE CODE
(DTC) FOR ENGINE. (OBD MODE)
mation about how to indicate DTC. <Ref. to EN-41,
S2M0286A Read Diagnostic Trouble Code (DTC).>
4) Connect the Subaru Select Monitor to data link
connector.
(1) Data link connector located in the lower por-
tion of instrument panel (on the driver's side).
EN0768
EN-34
4. READ CURRENT DATA FOR ENGINE. (NORMAL MODE)

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

Starter switch signal Starter Switch Signal ON or OFF
Idle switch signal Idle Switch Signal ON or OFF
Crankshaft position sensor signal Crankshaft Position Sig. ON or OFF
Camshaft position sensor signal Camshaft Position Sig. ON or OFF
Rear defogger switch signal Rear Defogger Switch ON or OFF
Blower fan switch signal Blower Fan Switch ON or OFF
Small light switch signal Light Switch ON or OFF
Air assist injector solenoid valve signal Assist Air Sol. Valve ON or OFF
AT vehicle ID signal AT Vehicle ID Signal ON or OFF
NOTE:
For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL.
EN-36
5. READ CURRENT DATA FOR ENGINE. (OBD MODE)

key.
4) On the «Engine Diagnosis» display screen, select the {OBD System} and press [YES] key.
5) On the «OBD Menu» display screen, select the {Current Data Display & Save} and press [YES] key.
Number of diagnosis code Number of Diagnosis Code —
Malfunction indicator lamp status MI (MIL) ON or OFF
Monitoring 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 No support
Test of secondary air system Secondary air system No support
Test of air conditioning system refrigerant A/C system refrigerant No support
Test of oxygen sensor Oxygen sensor Complete or incomplete
Test of oxygen sensor heater O2 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 %
Short term fuel trim by front oxygen (A/F) sensor Short term fuel trim B1 %
Long term fuel trim by front oxygen (A/F) sensor Long term fuel trim B1 %
psi
Ignition timing advance for #1 cylinder Ignition timing adv. #1 °
Intake air amount Mass Air Flow g/s
A/F sensor equipment A/F sensor ON or OFF
Rear oxygen sensor output signal Oxygen Sensor #12 V
Air fuel ratio correction by rear oxygen sensor Short term fuel trim #12 %
On-board diagnostic system OBD System —
NOTE:
EN-37
6. READ FREEZE FRAME DATA FOR ENGINE. (OBD MODE)

key.
5) On the «OBD Menu» display screen, select the {Freeze Frame Data} and press [YES] key.
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
psi
NOTE:
7. READ OXYGEN SENSOR MONITORING TEST RESULTS DATA FOR ENGINE. (OBD
MODE)
key.
5) On the «OBD Menu» display screen, select the {O2 Sensor Monitor} and press [YES] key.
6) On the «O2 Sensor Select» display screen, select the {Bank 1-Sensor1} or {Bank 1-Sensor2} and press
[YES] key.
• Bank 1-Sensor1 indicates the front oxygen or A/F sensor, and Bank 1-Sensor2 indicates the rear oxygen
sensor.
Oxygen sensor for monitoring test <O2 Sensor Monitor (-------)> —
Rich to lean oxygen sensor threshold voltage Rich to lean sensor volt V
Lean to rich oxygen sensor threshold voltage Lean to rich sensor volt V
Low oxygen sensor voltage for switch time calculation Low sensor voltage V
High oxygen sensor voltage for switch time calculation High sensor voltage V
Rich to lean oxygen sensor switch time Rich to lean switch time sec
Lean to rich oxygen sensor switch time Lean to rich switch time sec
Maximum oxygen sensor voltage for test cycle Maximum sensor Voltage V
Minimum oxygen sensor voltage for test cycle Minimum sensor Voltage V
NOTE:
EN-38
8. LED OPERATION MODE FOR ENGINE

key.
5) On the «Data Display Menu» display screen, select the {Data & LED Display} and press [YES] key.
6) Using the scroll key, move the display screen up or down until the desired data is shown.
Contents Display Message LED “ON” requirements
Ignition switch signal Ignition Switch ON or OFF When ignition switch is turned to ON.
Test mode connector signal Test Mode Signal ON or OFF When test mode connector is connected.
Neutral position switch signal Neutral Position Switch ON or OFF When neutral position signal is entered.
Air conditioning switch signal A/C Switch ON or OFF When air conditioning switch is turned ON.
Air conditioning relay signal A/C Relay ON or OFF When air conditioning relay is in function.
Radiator main fan relay signal Radiator Fan Relay #1 ON or OFF When radiator main fan relay is in function.
Fuel pump relay signal Fuel Pump Relay ON or OFF When fuel pump relay is in function.
Knocking signal Knocking Signal ON or OFF When knocking signal is entered.
Radiator sub fan relay signal Radiator Fan Relay #2 ON or OFF When radiator sub fan relay is in function.
When engine torque control signal 1 is
entered.
entered.
Engine torque control permission When engine torque control permission sig-
Torque Control Permit ON or OFF
signal nal is entered.
Front oxygen (A/F) sensor rich sig- When front oxygen (A/F) sensor mixture ratio
Front O2 Rich Signal #1 ON or OFF
nal is rich.
When rear oxygen sensor mixture ratio is
rich.
Starter switch signal Starter Switch Signal ON or OFF When starter switch signal is entered.
Idle switch signal Idle Switch Signal ON or OFF When idle switch signal is entered.
When crankshaft position sensor signal is
entered.
When camshaft position sensor signal is
entered.
NOTE:
EN-39
9. READ CURRENT DATA FOR AT.

2) On the «System Selection Menu» display screen, select the {Transmission Control System} and press
[YES] key.
3) Press the [YES] key after displayed the information of transmission type.
4) On the «Transmission Diagnosis» display screen, select the {Current Data Display & Save} and press
[YES] key.
Rear vehicle speed sensor signal Vehicle Speed #1 km/h or MPH
Front vehicle speed sensor signal Vehicle Speed #2 km/h or MPH
Automatic transmission fluid temperature signal ATF Temp. °C or °F
Gear position Gear Position —
Line pressure control duty ratio Line Pressure Duty Ratio %
Lock up clutch control duty ratio Lock Up Duty Ratio %
Transfer clutch control duty ratio Transfer Duty Ratio %
Power supply for throttle position sensor Throttle Sensor Power V
Torque converter turbine speed signal AT Turbine Speed rpm
2-4 brake timing pressure control duty ratio 2-4B Duty Ratio %
Intake manifold pressure sensor voltage Mani. Pressure Voltage V
2 wheel drive switch signal 2WD Switch ON or OFF
Kick down switch signal Kick Down Switch ON or OFF
Stop lamp switch signal Stop Lamp Switch ON or OFF
Anti lock brake system signal ABS Signal ON or OFF
Cruise control system signal Cruise Control Signal ON or OFF
Neutral/Parking range signal N/P Range Signal ON or OFF
Reverse range signal R Range Signal ON or OFF
Drive range signal D Range Signal ON or OFF
3rd range signal 3rd Range Signal ON or OFF
2nd range signal 2nd Range Signal ON or OFF
1st range signal 1st Range Signal ON or OFF
Shift control solenoid A Shift Solenoid #1 ON or OFF
Shift control solenoid B Shift Solenoid #2 ON or OFF
Torque control output signal #1 Torque Control Signal #1 ON or OFF
Torque control cut signal Torque Control Cut Sig. ON or OFF
2-4 brake timing control solenoid valve 2-4 Brake Timing Sol. ON or OFF
Low clutch timing control solenoid valve Low Clutch Timing Sol. ON or OFF
Automatic transmission diagnosis indicator lamp AT Diagnosis Lamp ON or OFF
NOTE:
EN-40
READ DIAGNOSTIC TROUBLE CODE (DTC)
11.Read Diagnostic Trouble 3. OBD-II GENERAL SCAN TOOL

Code (DTC) Refers to data denoting emission-related power-
train diagnostic trouble codes (DTCs).
A: OPERATION For details concerning diagnostic trouble codes
1. SUBARU SELECT MONITOR (NORMAL
MODE) Code (DTC).>
1) On the «Main Menu» display screen, select the NOTE:
{Each System Check} and press [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 (DTCs)
press [YES] key. (MODE $03).
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(s) Display} and press
[YES] key.
5) On the «Diagnostic Code(s) Display» display
screen, select the {Current Diagnostic Code(s)} or
{History Diagnostic Code(s)} and press [YES] key.
NOTE:
• For detailed 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
Code (DTC).>
2. SUBARU SELECT MONITOR (OBD
MODE)
1) On the «Main Menu» display screen, select the
{2. Each System Check} and press [YES] key.
2) On the «System Selection Menu» display
screen, select the {Engine Control System} and
press [YES] key.
lect the {OBD System} and press [YES] key.
5) On the «OBD Menu» display screen, select the
{Diagnosis Code(s) Display} and press [YES] key.
6) Make sure that a diagnostic trouble code (DTC)
is shown on the display screen.
NOTE:
UAL.
• For detailed concerning diagnostic trouble codes
Code (DTC).>
EN-41
INSPECTION MODE
12.Inspection Mode
A: OPERATION
Carry out trouble diagnosis shown in the following DTC table.
When performing trouble diagnosis which is not shown in the DTC table, refer to the next item Drive cycle.
<Ref. to EN-47, Drive Cycle.>
DTC
Item
No.
P0031 Front oxygen (A/F) sensor heater circuit low input
P0032 Front oxygen (A/F) sensor heater circuit high input
P0037 Rear oxygen sensor heater circuit malfunction
P0038 Rear oxygen sensor heater circuit high input
P0066 Air assist injector solenoid valve circuit low input
P0067 Air assist injector solenoid valve circuit high input
P0106 Pressure sensor circuit range/performance problem (low input)
P0107 Pressure sensor circuit low input
P0108 Pressure sensor circuit high input
P0112 Intake air temperature sensor circuit low input
P0113 Intake air temperature sensor circuit high input
P0117 Engine coolant temperature sensor circuit low input
P0118 Engine coolant temperature sensor circuit high input
P0122 Throttle position sensor circuit low input
P0123 Throttle position sensor circuit high input
P0131 Front oxygen (A/F) sensor circuit malfunction (open circuit)
P0132 Front oxygen (A/F) sensor circuit malfunction (short circuit)
P0136 Rear oxygen sensor circuit malfunction
P0327 Knock sensor circuit low input
P0328 Knock sensor circuit high input
P0335 Crankshaft position sensor circuit malfunction
P0336 Crankshaft position sensor circuit range/performance problem
P0340 Camshaft position sensor circuit malfunction
P0341 Camshaft position sensor circuit range/performance problem
P0444 Evaporative emission control system purge control valve circuit low input
P0462 Fuel level sensor circuit low input
P0463 Fuel level sensor circuit high input
P0480 Cooling fan relay 1 circuit low input
P0500 Vehicle speed sensor malfunction
P0512 Starter switch circuit high input
P0513 Incorrect immobilizer key
P0562 Charge system circuit low input
P0563 Charge system circuit high input
P0604 Internal control module memory check sum error
P0703 Brake switch input malfunction
P0705 Transmission range sensor circuit malfunction
P0710 Transmission fluid temperature sensor circuit malfunction
P0715 Torque converter turbine speed sensor circuit malfunction
P0720 Output speed sensor (vehicle speed sensor 2) circuit malfunction
P0725 Engine speed input circuit malfunction
P0731 Gear 1 incorrect ratio
P0741 Torque converter clutch system malfunction
EN-42
INSPECTION MODE
DTC
Item
No.
P0743 Torque converter clutch system (Lock-up duty solenoid) electrical
P0748 Pressure control solenoid (Line pressure duty solenoid) electrical
P0753 Shift solenoid A (Shift solenoid 1) electrical
P0758 Shift solenoid B (Shift solenoid 2) electrical
P0778 2-4 brake pressure control solenoid valve circuit malfunction
P0785 2-4 brake timing control solenoid valve circuit malfunction
P1110 Atmospheric pressure sensor low input
P1111 Atmospheric pressure sensor high input
P1112 Atmospheric pressure sensor range/performance problem
P1146 Pressure sensor circuit range/performance problem (high input)
P1480 Cooling fan relay 1 circuit high input
P1507 Idle control system malfunction (fail-safe)
P1510 Idle air control solenoid valve signal 1 circuit low input
P1511 Idle air control solenoid valve signal 1 circuit high input
P1518 Starter switch circuit low input
P1540 Vehicle speed sensor malfunction 2
P1560 Back-up voltage circuit malfunction
P1570 Antenna
P1571 Reference code incompatibility
P1572 IMM circuit failure except antenna circuit
P1574 Key communication failure
P1576 EGI control module EEPROM
P1577 IMM control module EEPROM
P1590 Neutral position switch circuit high input (AT model)
P1591 Neutral position switch circuit low input (AT model)
P1592 Neutral position switch circuit (MT model)
P1594 Automatic transmission diagnosis input signal circuit malfunction
P1595 Automatic transmission diagnosis input signal circuit low input
P1596 Automatic transmission diagnosis input signal circuit high input
P1698 Engine torque control cut signal circuit low input
P1699 Engine torque control cut signal circuit high input
P1700 Throttle position sensor circuit malfunction for automatic transmission
P1701 Cruise control set signal circuit malfunction for automatic transmission
P1703 Low clutch timing control solenoid valve circuit malfunction
P1711 Engine torque control signal 1 circuit malfunction
P1712 Engine torque control signal 2 circuit malfunction
EN-43
INSPECTION MODE
1. PREPARATION FOR THE INSPECTION 2. SUBARU SELECT MONITOR

MODE 1) After performing the diagnostics and clearing the
1) Make sure that the fuel remains approx. half memory, check for any remaining unresolved trou-
amount [20 — 40 2 (5.3 — 10.6 US gal, 4.4 — 8.8 ble data. <Ref. to EN-49, Clear Memory Mode.>
Imp gal)] and the battery voltage is 12 V or more. 2) Warm up the engine.
2) Raise the vehicle using a garage jack and place 3) Prepare the Subaru Select Monitor kit. <Ref. to
on safety stands or drive the vehicle onto free roll- EN-9, PREPARATION TOOL, General Descrip-
ers. tion.>
WARNING:
• Before raising the vehicle, ensure the parking
brake is applied.
• Do not use a pantograph jack in place of a
safety stand.
• Secure a rope or wire to the front and rear
towing or tie-down hooks to prevent the lateral
runout of front wheels.
• Do not abruptly depress/release the clutch
pedal or accelerator pedal during works even S2M0285
when engine is operating at low speeds since
this may cause vehicle to jump off free rollers. 4) Connect the diagnosis cable to Subaru Select
• In order to prevent the vehicle from slipping Monitor.
due to vibration, do not place any wooden 5) Insert the cartridge into Subaru Select Monitor.
blocks or similar items between the safety <Ref. to EN-9, PREPARATION TOOL, General
stands and the vehicle. Description.>
• Since the rear wheels will also rotate, do not
place anything near them. Also, make sure that
nobody goes in front of the vehicle.
S2M0286A
6) Connect the test mode connector (A) at the low-

er portion of instrument panel (on the driver's side).
(A)
EN0773
B2M2969C
(A) Safety stand

(B) Free rollers
EN-44
INSPECTION MODE
7) Connect the Subaru Select Monitor to data link 14) Perform subsequent procedures as instructed
connector. on the display screen.
(1) Connect the Subaru Select Monitor to data • If trouble still remains in the memory, the corre-
link connector located in the lower portion of the sponding diagnostic trouble code (DTC) appears
instrument panel (on the driver's side). on the display screen.
NOTE:
UAL.
• For detailed concerning the diagnostic trouble
codes (DTCs), refer to the List of Diagnostic Trou-
ble Code (DTC).
<Ref. to EN-83, List of Diagnostic Trouble Code
(DTC).>
EN0768
• Release the parking brake.
• The speed difference between front and rear
(2) Connect the diagnosis cable to data link wheels may light either the ABS warning light, but
connector. this indicates no malfunctions. When the engine
CAUTION: control diagnosis is finished, perform the ABS
Do not connect the scan tools except for Suba- memory clearance procedure of self-diagnosis sys-
ru Select Monitor and OBD-II general scan tool. tem.
8) Turn the ignition switch to ON (engine OFF) and 3. OBD-II GENERAL SCAN TOOL
Subaru Select Monitor switch to ON. 1) After performing the diagnostics and clearing
memory, check for any remaining unresolved trou-
ble data: <Ref. to EN-49, Clear Memory Mode.>
2) Warm up the engine.
er side of instrument panel (on the driver's side).
S2M0288C
(A) Power switch
9) On the «Main Menu» display screen, select the (A)

{2. Each System Check} and press the [YES] key.
10) On the «System Selection Menu» display EN0773

press the [YES] key.
11) Press the [YES] key after displayed the infor-
mation of engine type.
lect the {Dealer Check Mode Procedure} and press
the [YES] key.
13) When the “Perform Inspection (Dealer Check)
Mode?” is shown on the display screen, press the
[YES] key.
EN-45
INSPECTION MODE
4) Connect the OBD-II general scan tool to its data

link connector in the lower portion of instrument
panel (on the driver's side).
CAUTION:
Do not connect the scan tools except for Suba-
ru Select Monitor and OBD-II general scan tool.
EN0768

NOTE:
• Ensure the selector lever is placed in “P” position
before starting. (AT vehicles)
• Depress the clutch pedal when starting engine.
(MT vehicles)
6) Using the selector lever or shift lever, turn the “P”
position switch and “N” position switch to ON.
7) Depress the brake pedal to turn brake switch
ON. (AT vehicles)
8) Keep the engine speed in 2,500 — 3,000 rpm
range for 40 seconds.
9) Place the selector lever or shift lever in “D” posi-
tion (AT vehicles) or “1st” gear (MT vehicles) and
drive the vehicle at 5 to 10 km/h (3 to 6 MPH).
NOTE:
• On AWD vehicles, release the parking brake.
wheels may light ABS warning light, but this indi-
cates no malfunctions. When the engine control di-
agnosis is finished, perform the ABS memory
clearance procedure of self-diagnosis system.
10) Using the OBD-II general scan tool, check for
diagnostic trouble code(s) (DTC(s)) and record the
result(s).
NOTE:
• For detailed operation procedures, refer to the
OBD-II General Scan Tool Instruction Manual.
(DTC).
<Ref. to EN-83, List of Diagnostic Trouble Code
(DTC).>
EN-46
DRIVE CYCLE
13.Drive Cycle
A: OPERATION
There are three drive patterns for the trouble diagnosis. Driving in the specified pattern allows to diagnose
malfunctioning items listed below. After the malfunctioning items listed below are repaired, always check
whether they correctly resume their functions by driving in the required drive pattern.
1. PREPARATION FOR THE DRIVE CYCLE
1) Make sure that the fuel remains approx. half amount [20 — 40 2 (5.3 — 10.6 US gal, 4.4 — 8.8 Imp gal)],
and battery voltage is 12V or more.
2) After performing the diagnostics and cleaning memory, check for any remaining unresolved trouble data.
<Ref. to EN-49, Clear Memory Mode.>
3) Separate the test mode connector.
NOTE:
• Except for the water temperature specified items at starting, the diagnosis is carried out after engine warm
up.
• Carry out the diagnosis which is marked * on DTC twice, then, after finishing first diagnosis, stop the engine
and do second time at the same condition.
2. AFTER RUNNING 20 MINUTES AT 80 KM/H (50 MPH), IDLE ENGINE FOR 1 MINUTE.
DTC
Item Condition
No.
Intake air temperature sensor circuit range/perfor-
*P0111 Coolant temperature at start is less than 30°C (86°F).
mance problem
Insufficient coolant temperature for closed loop
*P0125 Coolant temperature at start is less than 20°C (68°F).
fuel control
Front oxygen (A/F) sensor circuit range/perfor-
*P0130 —
mance problem (Lean)
*P0133 Front oxygen (A/F) sensor circuit slow response —
*P0170 Fuel trim malfunction —
*P0420 Catalyst system efficiency below threshold —
Evaporative emission control system purge con-
P0445 —
trol valve circuit high input
Fuel level sensor circuit range/performance prob-
P0461 —
lem
*P0464 Fuel level sensor intermittent input —
Front oxygen (A/F) sensor circuit range/perfor-
*P1137 —
mance problem
Fuel level sensor circuit range/performance prob-
*P1442 —
lem 2
EN-47
DRIVE CYCLE
3. IDLE FOR 10 MINUTES

NOTE:
Before the diagnosis, drive the vehicle at 4 km/h (6 MPH) or more.
DTC No. Item Condition
*P0483 Cooling fan function problem —
*P0506 Idle control system RPM lower than expected —
*P0507 Idle control system RPM higher than expected —
4. DRIVE ACCORDING TO THE FOLLOWING DRIVE PATTERN
Vehicle speed km/h (MPH)
96 (60)
65 (40)
0
50 100 150 (Seconds)
B2M4775
(A) Idle engine for 1 minute. (D) Decelerate with fully closed throt- (G) Stop vehicle with throttle fully
(B) Accelerate to 97 km/h (60 MPH) tle to 64 km/h (40 MPH). closed.Stop vehicle with throttle
within 20 seconds. (E) Drive vehicle at 64 km/h (40 MPH) fully closed.Stop vehicle with
(C) Drive vehicle at 97 km/h (60 MPH) for 10 seconds. throttle fully closed.
for 20 seconds. (F) Accelerate to 97 km/h (60 MPH)
within 10 seconds.
DTC No. Item Condition

*P0121 Throttle position sensor circuit range/performance problem (high input) —
*P0139 Rear oxygen sensor circuit slow response —
*P0301 Cylinder 1 misfire detected —
*P1142 Throttle position sensor circuit range/performance problem (low input) —
EN-48
CLEAR MEMORY MODE
14.Clear Memory Mode 3. OBD-II GENERAL SCAN TOOL

A: OPERATION For clear memory procedures using the OBD-II
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 ON. Wait 3 seconds
{2. Each System Check} and press [YES] key. before starting the engine.
press [YES] key.
lect the {Clear Memory} and press [YES] key.
5) When the ‘Done’ and ‘Turn Ignition Switch OFF’
are shown on the display screen, turn the Subaru
Select Monitor and ignition switch to OFF.
NOTE:
• After the memory has been cleared, the idle air
this, turn the ignition switch to ON. Wait 3 seconds
before starting the engine.
UAL.
MODE)
press [YES] key.
{4. Diagnosis Code(s) Cleared} and press [YES]
key.
6) When the `Clear Diagnostic Code?' is shown on
the display screen, press [YES] key.
7) Turn the Subaru Select Monitor and ignition
switch to OFF.
NOTE:
• After the memory has been cleared, the idle air
this, turn the ignition switch to ON. Wait 3 seconds
before starting the engine.
UAL.
EN-49
COMPULSORY VALVE OPERATION CHECK MODE
15.Compulsory Valve Operation 5) Connect the Subaru Select Monitor to data link
connector.
Check Mode (1) Connect the Subaru Select Monitor to data
A: OPERATION link connector located in the lower portion of in-
1) Prepare the Subaru Select Monitor kit. <Ref. to strument panel (on the driver's side).
EN-9, PREPARATION TOOL, General Descrip-
tion.>
EN0768
(2) Connect the diagnosis cable to data link

S2M0285 connector.
2) Connect the diagnosis cable to Subaru Select CAUTION:
Monitor. Do not connect the scan tools except for Suba-
3) Insert the cartridge into Subaru Select Monitor. ru Select Monitor and OBD-II general scan tool.
<Ref. to EN-9, PREPARATION TOOL, General 6) Turn the ignition switch to ON (engine OFF) and
Description.> Subaru Select Monitor switch to ON.
S2M0286A S2M0288E

er portion of instrument panel (on the driver's side). (A) Power switch

press [YES] key.
(A) lect the {System Operation Check Mode} and press
[YES] key.
EN0773
11) On the «System Operation Check Mode» dis-
play screen, select the {Actuator ON/OFF Opera-
tion} and press [YES] key.
12) Select the desired compulsory actuator on the
«Actuator ON/OFF Operation» display screen and
press [YES] key.
EN-50
13) Pressing the [NO] key completes the compulsory operation check mode. The display will then return to
the «Actuator ON/OFF Operation» screen.
Contents Display
Compulsory fuel pump relay operation check Fuel Pump Relay
Compulsory radiator fan relay operation check Radiator Fan Relay
Compulsory air conditioning relay operation check A/C Compressor Relay
Compulsory purge control solenoid valve operation check CPC Solenoid Valve
Compulsory air assist injector solenoid valve operation 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
PCV Solenoid Valve
Vent Control Solenoid Valve
FICD Solenoid
Pressure Switching Sol. 1
Fuel Tank Sensor Control Valve
• For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL.
EN-51
ENGINE MALFUNCTION INDICATOR LAMP (MIL)
16.Engine Malfunction Indicator Lamp (MIL)

A: PROCEDURE
1. Activation of check engine malfunction indicator lamp (MIL). <Ref. to EN-53, ACTIVATION OF CHECK ENGINE MALFUNC-
TION INDICATOR LAMP (MIL), Engine Malfunction Indicator Lamp (MIL).>
↓
2. Check that engine malfunction indicator lamp (MIL) does not come on. <Ref. to EN-54, CHECK ENGINE MALFUNCTION
INDICATOR LAMP (MIL) DOES NOT COME ON., Engine Malfunction Indicator Lamp (MIL).>
↓
3. Check that engine malfunction indicator lamp (MIL) does not go off. <Ref. to EN-56, CHECK ENGINE MALFUNCTION INDI-
CATOR LAMP (MIL) DOES NOT GO OFF., Engine Malfunction Indicator Lamp (MIL).>
↓
4. Check that engine malfunction indicator lamp (MIL) does not blink at a cycle of 3 Hz. <Ref. to EN-58, CHECK ENGINE MAL-
FUNCTION INDICATOR LAMP (MIL) DOES NOT BLINK AT A CYCLE OF 3 HZ., Engine Malfunction Indicator Lamp (MIL).>
↓
5. Check that engine malfunction indicator lamp (MIL) remains blinking at a cycle of 3 Hz. <Ref. to EN-60, CHECK ENGINE
MALFUNCTION INDICATOR LAMP (MIL) REMAINS BLINKING AT A CYCLE OF 3 HZ., Engine Malfunction Indicator Lamp
(MIL).>
EN-52
B: ACTIVATION OF CHECK ENGINE 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-54, CHECK ENGINE
MALFUNCTION INDICATOR LAMP (MIL) DOES
NOT COME ON., Engine Malfunction Indicator
Lamp (MIL).> OBD0055A
EN0774
2) After starting the engine, the MIL goes out. If it

does not, either the engine or the emission control
system is malfunctioning.
OBD0053A
3) If the diagnosis system senses a misfire which

could damage the catalyzer, the MIL will blink at a
cycle of 1 Hz.
OBD0054A
EN-53
C: CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) DOES NOT COME

ON.
• DIAGNOSIS:
• The CHECK ENGINE malfunction indicator lamp (MIL) circuit is open or shorted.
• TROUBLE SYMPTOM:
• When the ignition switch is turned to ON (engine OFF), MIL does not come on.
• WIRING DIAGRAM:
IGNITION
B72 BATTERY
SWITCH
No.13 SBF-4 SBF-1
4 1
LHD RHD
AT MT
B36 B38 B36

23
22
i1 i3 i1
AT MT
LHD RHD
A7
C6
i2
1 LHD :16
1
COMBINATION
RHD :13
METER B37
A: i10
11
C: i12
B134 ECM
B72 B36 B134 i1 A: i10
1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10
1 2 1 2 3 4 5 6
12 13 14 15 16 17 18 19 20 21 22 23 24 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
3 4 7 8 9 10 11 12 13 14
24 25 26 27 28 29 30 31 32 33 34 35
LHD: i2 RHD: i2 C: i12 i3
1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10
12 13 14 15 16 17 18 19 20 21 22 23 24 10 11 12 13 14 15 16 17 18 19 20 21
7 8 9 10 11 12 13 14 11 12 13 14 15 16 17 18 19 20 21 22
22 23 24 25 26 27 28 29 30 31 32
EN1395
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.
2)Measure the voltage between ECM connec-
tor and chassis ground.
(B134) No. 11 (+) — Chassis ground (−):
2 CHECK POOR CONTACT. Does the MIL come on when Repair the poor Go to step 3.
shaking or pulling ECM con- contact in ECM
nector and harness? connector.
EN-54
Step Check Yes No

3 CHECK ECM CONNECTOR. Is the ECM connector correctly Replace the ECM. Repair the con-
connected? <Ref. to FU-51, nection of ECM
Engine Control connector.
Module.>
4 CHECK HARNESS BETWEEN COMBINA- Is the resistance less than 1 Go to step 5. Repair the har-
TION METER AND ECM CONNECTOR. Ω? ness and connec-
1)Turn the ignition switch to OFF. tor.
2)Remove the combination meter. <Ref. to IDI- NOTE:
15, Combination Meter Assembly.> In this case, repair
3)Disconnect the connector from ECM and the following:
combination meter. • Open circuit in
4)Measure the resistance of harness between harness between
ECM and combination meter connector. ECM and combi-
Connector & terminal nation meter con-
(B134) No. 11 — (i12) No. 6: nector
• Poor contact in
coupling connector
(i2)
5 CHECK POOR CONTACT. Is there poor contact in combi- Repair the poor Go to step 6.
Check poor contact in combination meter con- nation meter connector? contact in combi-
nector. nation meter con-
nector.
6 CHECK HARNESS BETWEEN COMBINA- Is the voltage more than 10 V? Go to step 7. Check the follow-
TION METER AND IGNITION SWITCH CON- ing and repair if
NECTOR. necessary.
1)Turn the ignition switch to ON. NOTE:
2)Measure the voltage between combination • Broken down
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
connector
7 CHECK LAMP BULB. Is the lamp bulb condition OK? Repair the combi- Replace the lamp
Remove the engine malfunction indicator lamp nation meter con- bulb.
bulb. nector.
EN-55
D: CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) DOES NOT GO

OFF.
• DIAGNOSIS:
• The CHECK ENGINE malfunction indicator lamp (MIL) circuit is shorted.
• Although MIL comes on when engine runs, but trouble code is not shown on Subaru Select Monitor or
OBD-II general scan tool display.
• WIRING DIAGRAM:
IGNITION
B72 BATTERY
SWITCH
No.13 SBF-4 SBF-1
4 1
LHD RHD
AT MT
B36 B38 B36

23
22
i1 i3 i1
AT MT
LHD RHD
A7
C6
i2
1 LHD :16
1
COMBINATION
RHD :13
METER B37
A: i10
11
C: i12
B134 ECM
B72 B36 B134 i1 A: i10
1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10
1 2 1 2 3 4 5 6
12 13 14 15 16 17 18 19 20 21 22 23 24 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
3 4 7 8 9 10 11 12 13 14
24 25 26 27 28 29 30 31 32 33 34 35
1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10
12 13 14 15 16 17 18 19 20 21 22 23 24 10 11 12 13 14 15 16 17 18 19 20 21
7 8 9 10 11 12 13 14 11 12 13 14 15 16 17 18 19 20 21 22
22 23 24 25 26 27 28 29 30 31 32
EN1395
Step Check Yes No

1 CHECK HARNESS BETWEEN COMBINA- Does the MIL come on? Repair the short Replace the ECM.
TION METER AND ECM CONNECTOR. circuit in harness <Ref. to FU-51,
1)Turn the ignition switch to OFF. between combina- Engine Control
2)Disconnect the connector from ECM. tion meter and Module.>
3)Turn the ignition switch to ON. ECM connector.
EN-56
EN-57
E: CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) DOES NOT BLINK

AT A CYCLE OF 3 HZ.
• DIAGNOSIS:
• Test mode connector circuit is open.
• During inspection mode, MIL does not blink at a cycle of 3 Hz.
• WIRING DIAGRAM:
IGNITION
B72 BATTERY
SWITCH
No.13 SBF-4 SBF-1
4 1
LHD RHD
AT MT
B36 B38 B36
23
22
i1 i3 i1
AT MT
LHD RHD
A7
C6 0 1 1 16
i2 B125 B126 B75 B76 B22 E3

1
1 LHD :16
COMBINATION RHD :13 B37
METER
A: i10
A11
B14
C: i12
A: B134
ECM
B: B135
B75 B125 B72 A: i10 C: i12 B22 B36
1 1 1 2 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11
2 3 4 7 8 9 10 11 12 13 14 5 6 7 8 12 13 14 15 16 17 18 19 20 21 22 23 24
9 10 11 12
13 14 15 16
B135 i1 RHD: i2 B134
1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8
1 2 3 4 5 6
8 9 10 11 12 13 14 15 16 17 18 19 10 11 12 13 14 15 16 17 18 19 20 21 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
7 8 9 10 11 12 13 14
20 21 22 23 24 25 26 27 28 22 23 24 25 26 27 28 29 30 31 32 24 25 26 27 28 29 30 31 32 33 34 35
LHD: i2 i3
1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9 10
12 13 14 15 16 17 18 19 20 21 22 23 24 11 12 13 14 15 16 17 18 19 20 21 22
EN1396
EN-58
Step Check Yes No

1 CHECK STATUS OF CHECK ENGINE MAL- Does the MIL come on? Go to step 2. Repair the MIL cir-
FUNCTION INDICATOR LAMP (MIL). cuit. <Ref. to EN-
1)Turn the ignition switch to OFF. 54, CHECK
2)Disconnect the test mode connector. ENGINE MAL-
3)Turn the ignition switch to ON. (engine OFF) FUNCTION INDI-
CATOR LAMP
(MIL) DOES NOT
COME ON.,
Engine Malfunc-
tion Indicator
Lamp (MIL).>
2 CHECK HARNESS BETWEEN COMBINA- Does the MIL come on? Repair the ground Go to step 3.
TION METER AND ECM CONNECTOR. short circuit in har-
1)Turn the ignition switch to OFF. ness between
2)Disconnect the connector from ECM. combination meter
3)Turn the ignition switch to ON. and ECM connec-
tor.
3 CHECK HARNESS BETWEEN TEST MODE Is the resistance less than 1 Go to step 4. Repair the har-
CONNECTOR AND CHASSIS GROUND. Ω? ness and connec-
2)Disconnect the connector from ECM. NOTE:
3)Measure the resistance of harness between In this case, repair
test mode connector and chassis ground. the following:
Connector & terminal • Open circuit in
(B76) No. 1 — Chassis ground: harness between
test mode connec-
tor and chassis
ground
4 CHECK POOR CONTACT. Is there poor contact in ECM Repair the poor Go to step 5.
Check poor contact in ECM connector. connector? contact in ECM
connector.
5 CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Go to step 6. Repair the open
TEST MODE CONNECTOR. Ω? circuit 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.
(B135) No. 14 — Chassis ground:
6 CHECK POOR CONTACT. Is there poor contact in ECM Repair the poor Replace the ECM.
Check poor contact in ECM connector. connector? contact in ECM <Ref. to FU-51,
connector. Engine Control
Module.>
EN-59
F: CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) REMAINS BLINK-

ING AT A CYCLE OF 3 HZ.
• DIAGNOSIS:
• Test mode connector circuit is shorted.
• MIL blinks at a cycle of 3 Hz when ignition switch is turned to ON.
• WIRING DIAGRAM:
IGNITION
B72 BATTERY
SWITCH
No.13 SBF-4 SBF-1
4 1
LHD RHD
AT MT
B36 B38 B36
23
22
i1 i3 i1
AT MT
LHD RHD
A7
C6 0 1 1 16
i2 B125 B126 B75 B76 B22 E3

1
1 LHD :16
COMBINATION RHD :13 B37
METER
A: i10
A11
B14
C: i12
A: B134
ECM
B: B135
B75 B125 B72 A: i10 C: i12 B22 B36
1 1 1 2 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11
2 3 4 7 8 9 10 11 12 13 14 5 6 7 8 12 13 14 15 16 17 18 19 20 21 22 23 24
9 10 11 12
13 14 15 16
B135 i1 RHD: i2 B134
1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8
1 2 3 4 5 6
8 9 10 11 12 13 14 15 16 17 18 19 10 11 12 13 14 15 16 17 18 19 20 21 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
7 8 9 10 11 12 13 14
20 21 22 23 24 25 26 27 28 22 23 24 25 26 27 28 29 30 31 32 24 25 26 27 28 29 30 31 32 33 34 35
LHD: i2 i3
1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9 10
12 13 14 15 16 17 18 19 20 21 22 23 24 11 12 13 14 15 16 17 18 19 20 21 22
EN1396
EN-60
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.
MIL blinks at a cy-
cle of 3 Hz when
test mode connec-
tor is connected.
2 CHECK HARNESS BETWEEN ECM CON- Is the resistance less than 5 Repair the short Replace the ECM.
NECTOR AND ENGINE GROUNDING TER- Ω? circuit in harness <Ref. to FU-51,
MINAL. between ECM and Engine Control
1)Turn the ignition switch to OFF. test mode connec- Module.>
2)Disconnect the connector from ECM. tor.
ECM connector and chassis ground.
EN-61
DIAGNOSTICS FOR ENGINE STARTING FAILURE
17.Diagnostics for Engine Starting Failure

A: PROCEDURE
1. Inspection of starter motor circuit. <Ref. to EN-64, STARTER MOTOR CIRCUIT, Diagnostics for Engine Starting Failure.>
↓
2. Inspection of ECM power supply and ground line. <Ref. to EN-68, CONTROL MODULE POWER SUPPLY AND GROUND
LINE, Diagnostics for Engine Starting Failure.>
↓
3. Inspection of ignition control system. <Ref. to EN-72, IGNITION CONTROL SYSTEM, Diagnostics for Engine Starting Fail-
ure.>
↓
4. Inspection of fuel pump circuit. <Ref. to EN-76, FUEL PUMP CIRCUIT, Diagnostics for Engine Starting Failure.>
↓
5. Inspection of fuel injector circuit. <Ref. to EN-80, FUEL INJECTOR CIRCUIT, Diagnostics for Engine Starting Failure.>
EN-62
EN-63
B: STARTER MOTOR CIRCUIT

CAUTION:
After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to EN-49, Clear
Memory Mode.> and INSPECTION MODE <Ref. to EN-42, Inspection Mode.> .
• WIRING DIAGRAM:
BATTERY
SBF-4 SBF-1
1
IGNITION
SWITCH
B72
3
INHIBITOR SWITCH
P R N D 3 2 1
AT 12 12
11 7
MT
B12 T3 T7
MT
B135 ECM 28 AT
B14
STARTER
MOTOR
B72 B12 T7 B135
1 2 3 4 1 2 3 4 5 6 1 2 3 4 5 6 7
1 2
5 6 7 8 7 8 9 10 11 12 8 9 10 11 12 13 14 15 16 17 18 19
3 4
9 10 11 12 20 21 22 23 24 25 26 27 28
EN0862
Step Check Yes No

1 CHECK OPERATION OF STARTER MOTOR. Does the starter motor oper- Go to step 2. Go to step 3.
ate when the switch starts?
2 CHECK DIAGNOSTIC TROUBLE CODE Is the DTC stored in memory? Record the DTC. Go to step 3.
(DTC). <Ref. to EN-83, LIST, List of Repair the trouble
<Ref. to EN-41, OPERATION, Read Diagnos- Diagnostic Trouble Code case. <Ref. to EN-
tic Trouble Code (DTC).> (DTC).> 90, Diagnostic
Procedure with
Diagnostic Trou-
ble Code (DTC).>
EN-64
Step Check Yes No

3 CHECK INPUT SIGNAL FOR STARTER MO- Is the voltage more than 10 V? Go to step 4. Go to step 5.
TOR.
2)Disconnect the connector from starter motor.
3)Turn the ignition switch to START.
4)Measure the power supply voltage between
starter motor connector terminal and engine
ground.
(B14) No. 1 (+) — Engine ground (−):
NOTE:
On AT vehicles, place the selector lever in the
“P” or “N” position.
4 CHECK GROUND CIRCUIT OF STARTER Is the resistance less than 5 Check the starter Repair the open
MOTOR. Ω? motor. <Ref. to circuit of ground
1)Turn the ignition switch to OFF. SC-5, Starter.> cable.
2)Disconnect the terminal from starter motor.
3)Measure the resistance of ground cable
between ground cable terminal and engine
ground.
5 CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Repair the ground Go to step 6.
STARTER MOTOR CIRCUIT. Ω? short circuit.
2)Measure the resistance between starter
motor and ECM.
(B14) No. 1 — Engine ground:
6 CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Go to step 7. Repair the ground
2)Measure the resistance of fuse.
7 CHECK HARNESS BETWEEN BATTERY Is the voltage more than 10 V? Go to step 8. Repair the open
AND IGNITION SWITCH CONNECTOR. circuit in harness
1)Turn the ignition switch to OFF. between ignition
2)Disconnect the connector from ignition switch and battery.
switch.
ignition switch connector and chassis ground.
8 CHECK HARNESS BETWEEN BATTERY Is the voltage more than 10 V? Go to step 9. Replace the igni-
AND IGNITION SWITCH CONNECTOR. tion switch.
1)Connect the connector to ignition switch.
3)Measure the voltage between ignition switch
and chassis ground.
9 CHECK TRANSMISSION TYPE. Is the vehicle AT? Go to step 10. Repair the open
circuit between
ignition switch and
starter motor cir-
cuit.
EN-65
Step Check Yes No

10 CHECK INHIBITOR SWITCH CIRCUIT. Is the resistance less than 1 Repair the open Go to step 11.
1)Turn the ignition switch to OFF. Ω? circuit in harness
2)Place the selector lever in the “P” or “N” posi- between starter
tion. motor and ignition
3)Separate the transmission harness connec- switch connector.
tor.
4)Measure the resistance between transmis-
sion harness connector receptacle's terminals.
(T3) No. 11 — No. 12:
11 CHECK TRANSMISSION HARNESS. Is the resistance less than 1 Go to step 12. Repair the open
1)Disconnect the connector from inhibitor Ω? circuit in harness
switch. between transmis-
2)Measure the resistance of harness between sion harness and
transmission harness and inhibitor switch con- inhibitor switch
nector. connector.
(T3) No. 11 — (T7) No. 7:
12 CHECK POOR CONTACT. Is there poor contact in inhibi- Repair the poor Replace the inhibi-
Check poor contact in inhibitor switch connector switch connector? contact in inhibitor tor switch.
tor. switch connector.
EN-66
EN-67
C: CONTROL MODULE POWER SUPPLY AND GROUND LINE

CAUTION:
Memory Mode.> and INSPECTION MODE. <Ref. to EN-42, Inspection Mode.>
• WIRING DIAGRAM:
MAIN RELAY
4 TO FRONT OXYGEN (A/F) SENSOR
RHD
RHD
6
SBF-5
5 LHD 2 LHD
3
B61 F44
2
1 IGNITION
B72 BATTERY
SWITCH
B47 No.11 SBF-4 SBF-1
4 1
B19
C1
C2
C9
B7
A: B134
B: B135 ECM
1 AT MODEL: B6
C: B136
MT MODEL: B25
A34
A35
A27
C22
C21
1
A7
A8
B22
13
15
14
16
8
E3
B72 F44 B47 B22 B: B135 C: B136
1 2 3 4 1 2 1 2 3 4 1 2 3 4 5 6 7 1 2 3 4 5 6 7
1 2
5 6 7 8 3 4 5 6 7 8 8 9 10 11 12 13 14 15 16 17 18 19 8 9 10 11 12 13 14 15 16 17 18 19 20
3 4
5 6 9 10 11 12 20 21 22 23 24 25 26 27 28 21 22 23 24 25 26 27 28 29 30
13 14 15 16
A: B134
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25 26 27 28 29 30 31 32 33 34 35
EN1397
Step Check Yes No

1 CHECK MAIN RELAY. Is the resistance less than 10 Go to step 2. Replace the main
1)Turn the ignition switch to OFF. Ω? relay.
2)Remove the main relay.
3)Connect the battery to main relay terminals
No. 1 and No. 2.
4)Measure the resistance between main relay
terminals.
Terminals
No. 3 — No. 5:
No. 4 — No. 6:
EN-68
Step Check Yes No

2 CHECK GROUND CIRCUIT OF ECM. Is the resistance less than 5 Go to step 3. Repair the open
1)Disconnect the connector from ECM. Ω? circuit in harness
2)Measure the resistance of harness between between ECM
ECM and chassis ground. connector and
Connector & terminal engine grounding
(B136) No. 21 — Chassis ground: terminal.
(B135) No. 25 — Chassis ground: (MT
vehicle)
(B135) No. 6 — Chassis ground: (AT
vehicle)
3 CHECK INPUT VOLTAGE OF ECM. Is the voltage more than 10 V? Go to step 4. Repair the open or
Measure the voltage between ECM connector ground short cir-
and chassis ground. cuit of power sup-
Connector & terminal ply circuit.
(B136) No. 9 (+) — Chassis ground (–):
1)Turn the ignition switch to ON. ground short cir-
2)Measure the voltage between ECM connec- cuit of power sup-
tor and chassis ground. ply circuit.
5 CHECK HARNESS BETWEEN ECM AND Is the resistance more than 1 Go to step 6. Repair the ground
MAIN RELAY CONNECTOR. MΩ? short circuit in har-
2)Measure the resistance between ECM and ECM connector
chassis ground. and main relay
Connector & terminal connector, then
(B135) No. 19 — Chassis ground: replace the ECM.
6 CHECK OUTPUT VOLTAGE FROM ECM. Is the voltage more than 10 V? Go to step 7. Replace the ECM.
1)Connect the connector to ECM.
7 CHECK INPUT VOLTAGE OF MAIN RELAY. Is the voltage more than 10 V? Go to step 8. Repair the open
Check the voltage between main relay connec- circuit in harness
tor and chassis ground. between ECM
Connector & terminal connector and
(B47) No. 2 (+) — Chassis ground (–): main relay con-
nector.
8 CHECK GROUND CIRCUIT OF MAIN RE- Is the resistance less than 5 Go to step 9. Repair the open
LAY. Ω? circuit between
1)Turn the ignition switch to OFF. main relay and
2)Measure the resistance between main relay chassis ground.
9 CHECK INPUT VOLTAGE OF MAIN RELAY. Is the voltage more than 10 V? Go to step 10. Repair the 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-
(B47) No. 5 (+) — Chassis ground (−): cuit.
EN-69
Step Check Yes No

10 CHECK INPUT VOLTAGE OF ECM. Is the voltage more than 10 V? Check the ignition Repair the open or
1)Connect the main relay connector. control system. ground short cir-
2)Turn the ignition switch to ON. <Ref. to EN-72, cuit in harness
3)Measure the voltage between ECM connec- IGNITION CON- between ECM
tor and chassis ground. TROL SYSTEM, connector and
Connector & terminal Diagnostics for main relay con-
(B136) No. 1 (+) — Chassis ground (–): Engine Starting nector.
(B136) No. 2 (+) — Chassis ground (–): Failure.>
EN-70
EN-71
D: IGNITION CONTROL SYSTEM

CAUTION:
• WIRING DIAGRAM:
B134 ECM
27
26
25
IGNITION
B72
SWITCH BATTERY
NO.11 SBF-4 SBF-1
4 1
B22
14
6
4
5
E3
1 2.0L AND 2.5L: 4
1.6L: 2
2 2.0L AND 2.5L: 1
1.6L: 4
3 2.0L AND 2.5L: 2

1.6L: 1
E12
1
2
3
3
3 4
1 2
IGNITOR
&
IGNITION COIL ASSY
E12 B72 B22 B134
1 2 3 4 1 2 3 4 1 2 3 4 5 6 7 8
1 2 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
3 4 5 6 7 8
9 10 11 12 24 25 26 27 28 29 30 31 32 33 34 35
13 14 15 16
EN1398
Step Check Yes No

1 CHECK IGNITION SYSTEM FOR SPARKS. Does spark occur at each cyl- Check the fuel Go to step 2.
1)Remove the plug cord cap from each spark inder? pump system.
plug. <Ref. to EN-76,
2)Install new spark plug on plug cord cap. FUEL PUMP CIR-
CAUTION: CUIT, Diagnostics
Do not remove 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
engine to check that spark occurs at each cyl-
inder.
EN-72
Step Check Yes No

2 CHECK POWER SUPPLY CIRCUIT FOR IG- Is the voltage more than 10 V? Go to step 3. Repair the har-
NITION COIL & IGNITOR ASSEMBLY. ness and connec-
2)Disconnect the connector from ignition coil & NOTE:
ignitor assembly. In this case, repair
3)Turn the ignition switch to ON. the following:
4)Measure the power supply voltage between • Open circuit in
ignition coil & ignitor assembly connector and harness between
engine ground. ignition coil & igni-
Connector & terminal tor assembly, and
• 2.0 L and 2.5 L ignition switch
(E12) No. 2 (+) — Engine ground (−): connector
• 1.6 L • Poor contact in
(E12) No. 1 (+) — Engine ground (−): coupling connec-
tors (B22)
3 CHECK HARNESS OF IGNITION COIL & IG- Is the resistance between less Go to step 4. Repair the har-
NITOR ASSEMBLY GROUND CIRCUIT. than 5 Ω? ness and connec-
2)Measure the resistance between ignition coil NOTE:
& ignitor assembly connector and engine In this case, repair
ground. the following:
(E12) No. 3 — Engine ground: harness between
ignition coil & igni-
tor assembly con-
nector and engine
grounding terminal
4 CHECK IGNITION COIL & IGNITOR ASSEM- Is the resistance between 10 Go to step 5. Replace the igni-
BLY. and 15 kΩ? tion coil & ignitor
1)Remove the spark plug cords. assembly. <Ref. to
2)Measure the resistance between spark plug IG-8, Ignition Coil
cord contact portions to check secondary coil. and Ignitor Assem-
Terminals bly.>
• 2.0 L and 2.5 L
No. 1 — No. 2:
• 1.6 L
No. 4 — No. 1:
BLY. and 15 kΩ? tion coil & ignitor
Measure the resistance between spark plug assembly. <Ref. to
cord contact portions to check secondary coil. IG-8, Ignition Coil
Terminals and Ignitor Assem-
• 2.0 L and 2.5 L bly.>
No. 3 — No. 4:
• 1.6 L
No. 3 — No. 2:
6 CHECK INPUT SIGNAL FOR IGNITION COIL Is the voltage more than 10 V? Go to step 7. Replace the igni-
& IGNITOR ASSEMBLY. tion coil & ignitor
1)Connect the connector to ignition coil & igni- assembly. <Ref. to
tor assembly. IG-8, Ignition Coil
2)Check if the voltage varies synchronously and Ignitor Assem-
with engine speed when cranking, while moni- bly.>
toring voltage between ignition coil & ignitor
assembly connector and engine ground.
• 2.0 L and 2.5 L
(E12) No. 1 (+) — Engine ground (–):
• 1.6 L
(E12) No. 4 (+) — Engine ground (−):
EN-73
Step Check Yes No

Check if the voltage varies synchronously with assembly. <Ref. to
engine speed when cranking, while monitoring IG-8, Ignition Coil
voltage between ignition coil & ignitor assem- and Ignitor Assem-
bly connector and engine ground. bly.>
• 2.0 L and 2.5 L
• 1.6 L
8 CHECK HARNESS BETWEEN ECM AND IG- Is the resistance less than 1 Go to step 9. Repair the har-
NITION COIL & IGNITOR ASSEMBLY CON- Ω? ness and connec-
NECTOR. tor.
1)Turn the ignition switch to OFF. NOTE:
2)Disconnect the connector from ECM. In this case, repair
3)Disconnect the connector from ignition coil & the following:
ignitor assembly. • Open circuit in
ECM and ignition coil & ignitor assembly con- ECM and ignition
nector. coil & ignitor
Connector & terminal assembly connec-
• 2.0 L and 2.5 L tor
(B134) No. 25 — (E12) No. 1: • Poor contact in
• 1.6 L coupling connector
(B134) No. 25 — (E12) No. 4: (B22)
NECTOR. tor.
Measure the resistance of harness between NOTE:
ECM and ignition coil & ignitor assembly con- In this case, repair
nector. the following:
• 2.0 L and 2.5 L harness between
(B134) No. 26 — (E12) No. 4: ECM and ignition
• 1.6 L coil & ignitor
(B134) No. 26 — (E12) No. 2: assembly connec-
tor
• Poor contact in
coupling connector
(B22)
10 CHECK HARNESS BETWEEN ECM AND IG- Is the resistance more than 1 Go to step 11. Repair the ground
NITION COIL & IGNITOR ASSEMBLY CON- MΩ? 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-
(B134) No. 25 — Engine ground: tor.
EN-74
Step Check Yes No

12 CHECK POOR CONTACT. Is there poor contact in ECM Repair the poor Check the fuel
Check poor contact in ECM connector. connector? contact in ECM pump circuit. <Ref.
connector. to EN-76, FUEL
PUMP CIRCUIT,
Diagnostics for
Engine Starting
Failure.>
EN-75
E: FUEL PUMP CIRCUIT

CAUTION:
• WIRING DIAGRAM:
RHD
RHD
SBF-5
LHD 2 LHD
IGNITION
B61 F44 B72 BATTERY
SWITCH
No.11 SBF-4 SBF-1
FUEL PUMP 4 1
RELAY
2
1
3 2 B134 ECM
4
B46
B97
1
1 LHD :7
R1 RHD :5
2 WITH
IMMOBILIZER :29
WITHOUT
IMMOBILIZER :16
FUEL PUMP
1 1
4 3
R58 R57 R15
B46 B72 R58 F44 B97 R15 B134
1 2 1 2 3 1 2 1 2 3 4 5 6 7 8
1 2 1 2 3 4 1 2 3 4
3 4 4 5 6 3 4 5 6 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
3 4 5 6 7 8 5 6 7 8
24 25 26 27 28 29 30 31 32 33 34 35
EN1399
Step Check Yes No

1 CHECK OPERATING SOUND OF FUEL Does the fuel pump produce Check the fuel Go to step 2.
PUMP. operating sound? injector circuit.
Make sure that the fuel pump is in operation for <Ref. to EN-80,
2 seconds when turning ignition switch to ON. FUEL INJECTOR
NOTE: CIRCUIT, Diag-
Fuel pump operation can also be executed us- nostics for Engine
ing the Subaru Select Monitor (Function mode: Starting Failure.>
FD01).
For the procedure, refer to “Compulsory Valve
Operation Check Mode”. <Ref. to EN-50, Com-
pulsory Valve Operation Check Mode.>
EN-76
Step Check Yes No

2 CHECK GROUND CIRCUIT OF FUEL PUMP. Is the resistance less than 5 Go to step 3. Repair the har-
1)Turn the ignition switch to OFF. Ω? ness and connec-
2)Remove the fuel pump access hole lid tor.
located on the right rear of trunk compartment NOTE:
floor (Sedan) or luggage compartment floor In this case, repair
(Wagon). the following:
3)Disconnect the connector from fuel pump. • Open circuit in
4)Measure the resistance of harness connec- harness between
tor between fuel pump and chassis ground. fuel pump connec-
Connector & terminal tor and chassis
(R58) No. 4 — Chassis ground: grounding terminal
• Poor contact in
coupling connector
(R15)
3 CHECK POWER SUPPLY TO FUEL PUMP. Is the voltage more than 10 V? Replace the fuel Go to step 4.
1)Turn the ignition switch to ON. pump. <Ref. to
2)Measure the voltage of power supply circuit FU-62, Fuel
between fuel pump connector and chassis Pump.>
ground.
(R58) No. 1 (+) — Chassis ground (−):
4 CHECK HARNESS BETWEEN FUEL PUMP Is the resistance less than 1 Go to step 5. Repair the har-
AND FUEL PUMP RELAY CONNECTOR. Ω? ness and connec-
2)Measure the resistance of harness connec- NOTE:
tor between fuel pump and fuel pump relay. In this case, repair
Connector & terminal the following:
(R58) No. 1 — (B46) No. 4: • Open circuit in
harness between
fuel pump connec-
tor and chassis
grounding terminal
• Poor contact in
coupling connec-
tors
(R15 and B97)
5 CHECK HARNESS BETWEEN FUEL PUMP Is the resistance more than 1 Go to step 6. Repair the short
AND FUEL PUMP RELAY CONNECTOR. MΩ? circuit in harness
Measure the resistance of harness between between fuel
fuel pump and fuel pump relay connector. pump and fuel
Connector & terminal pump relay con-
(R58) No. 1 — Chassis ground: nector.
6 CHECK FUEL PUMP RELAY. Is the resistance less than 10 Go to step 7. Replace the fuel
1)Disconnect the connectors from fuel pump Ω? pump relay. <Ref.
relay and main relay. to FU-53, Fuel
2)Remove the fuel pump relay and main relay 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:
EN-77
Step Check Yes No

FUEL PUMP RELAY CONNECTOR. Ω? circuit 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.
• With immobilizer
(B134) No. 29 — (B46) No. 3:
• Without immobilizer
(B134) No. 16 — (B46) No. 3:
Check poor contact in ECM connector. connector? contact in ECM injector circuit.
connector. <Ref. to EN-80,
FUEL INJECTOR
CIRCUIT, Diag-
nostics for Engine
Starting Failure.>
EN-78
EN-79
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-49, Clear
Memory Mode.> and INSPECTION MODE. <Ref. to EN-42, Inspection Mode.>
• WIRING DIAGRAM:
MAIN RELAY
4 BATTERY
RHD
RHD
6
SBF-5
5 LHD 2 LHD
3
B61 F44
2
1
B47
C2
C1
A: B134 C: B136 ECM

A13
A14
A15
A4
B22
10
11
12
1
E3
E5 E16 E6 E17
2
FUEL INJECTOR FUEL INJECTOR FUEL INJECTOR FUEL INJECTOR

No.1 No.2 No.3 No.4
E5 E16 B47 F44 B22
E6 E17 1 2 1 2 3 4 1 2 3 4
3 4 5 6 7 8 5 6 7 8
1 2 5 6 9 10 11 12
13 14 15 16
C: B136 A: B134
1 2 3 4 5 6 7 1 2 3 4 5 6 7 8
8 9 10 11 12 13 14 15 16 17 18 19 20 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
21 22 23 24 25 26 27 28 29 30 24 25 26 27 28 29 30 31 32 33 34 35
EN0866
Step Check Yes No

1 CHECK OPERATION OF EACH FUEL INJEC- Does the fuel injector emit Check the fuel Go to step 2.
TOR. “operating” sound? pressure. <Ref. to
While cranking the engine, check that each ME-29, INSPEC-
fuel injector emits “operating” sound. Use a TION, Fuel Pres-
sound scope or attach a screwdriver to injector sure.>
for this check.
EN-80
Step Check Yes No

2 CHECK POWER SUPPLY TO EACH FUEL Is the voltage more than 10 V? Go to step 3. Repair the har-
INJECTOR. ness and connec-
2)Disconnect the connector from #1 cylinder NOTE:
fuel injector. In this case, repair
the fuel injector terminal and engine ground. harness between
Connector & terminal main relay and fuel
#1 (E5) No. 2 (+) — Engine ground (–): injector connector
#2 (E16) No. 2 (+) — Engine ground (−): • Poor contact in
#3 (E6) No. 2 (+) — Engine ground (–): main relay con-
#4 (E17) No. 2 (+) — Engine ground (–): nector
• Poor contact in
coupling connector
(B22)
• Poor contact in
fuel injector con-
nector
3 CHECK HARNESS BETWEEN ECM AND Is the resistance between 5 Go to step 4. Repair the har-
FUEL INJECTOR CONNECTOR. and 20 Ω? ness and connec-
2)Measure the resistance of harness between NOTE:
ECM and fuel injector connector. In this case, repair
(B134) No. 4 — (B136) No. 2: • Open circuit in
harness between
ECM and fuel
injector connector
• Poor contact in
coupling connector
(B22)
FUEL INJECTOR CONNECTOR. Ω? short circuit in har-
Measure the resistance of harness between ness between
ECM and fuel injector connector. ECM and fuel
Connector & terminal injector connector.
Measure the resistance of harness between tor.
ECM and fuel injector connector. NOTE:
Connector & terminal In this case, repair
(B134) No. 13 — (B136) No. 2: the following:
• Open circuit in
harness between
ECM and fuel
injector connector
• Poor contact in
coupling connector
(B22)
EN-81
Step Check Yes No

• Open circuit in
harness between
ECM and fuel
injector connector
• Poor contact in
coupling connector
(B22)
• Open circuit in
harness between
ECM and fuel
injector connector
• Poor contact in
coupling connector
(B22)
11 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 Ω? fuel injector.
2)Measure the resistance between each fuel
injector terminals.
Terminals
No. 1 — No. 2:
12 CHECK POOR CONTACT. Is there poor contact in ECM Repair the poor Inspection using
Check poor contact in ECM connector. connector? contact in ECM “General Diagnos-
connector. tic Table”. <Ref. to
EN-292, INSPEC-
TION, General
Diagnostic Table.>
EN-82
LIST OF DIAGNOSTIC TROUBLE CODE (DTC)
18.List of Diagnostic Trouble Code (DTC)

A: LIST
DTC
Item Index
No.
P0031 Front oxygen (A/F) sensor heater cir- <Ref. to EN-90, DTC P0031 — FRONT OXYGEN (A/F) SENSOR HEATER
cuit low input CIRCUIT LOW INPUT —, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P0032 Front oxygen (A/F) sensor heater cir- <Ref. to EN-94, DTC P0032 — FRONT OXYGEN (A/F) SENSOR HEATER
cuit high input CIRCUIT HIGH INPUT —, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P0037 Rear oxygen sensor heater circuit <Ref. to EN-96, DTC P0037 — REAR OXYGEN SENSOR HEATER CIR-
malfunction CUIT MALFUNCTION —, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P0038 Rear oxygen sensor heater circuit <Ref. to EN-100, DTC P0038 — REAR OXYGEN SENSOR HEATER CIR-
high input CUIT HIGH INPUT —, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P0066 Air assist injector solenoid valve cir- <Ref. to EN-102, DTC P0066 — AIR ASSIST INJECTOR SOLENOID
cuit low input VALVE CIRCUIT LOW INPUT —, Diagnostic Procedure with Diagnostic
Trouble Code (DTC).>
P0067 Air assist injector solenoid valve cir- <Ref. to EN-104, DTC P0067 — AIR ASSIST INJECTOR SOLENOID
cuit high input VALVE CIRCUIT HIGH INPUT —, Diagnostic Procedure with Diagnostic
P0106 Pressure sensor circuit range/perfor- <Ref. to EN-106, DTC P0106 — PRESSURE SENSOR CIRCUIT RANGE/
mance problem (low input) PERFORMANCE PROBLEM (LOW INPUT) —, Diagnostic Procedure with
Diagnostic Trouble Code (DTC).>
P0107 Pressure sensor circuit low input <Ref. to EN-110, DTC P0107 — PRESSURE SENSOR CIRCUIT LOW
INPUT —, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0108 Pressure sensor circuit high input <Ref. to EN-114, DTC P0108 — PRESSURE SENSOR CIRCUIT HIGH
P0111 Intake air temperature sensor circuit <Ref. to EN-118, DTC P0111 — INTAKE AIR TEMPERATURE SENSOR
range/performance problem CIRCUIT RANGE/PERFORMANCE PROBLEM —, Diagnostic Procedure
with Diagnostic Trouble Code (DTC).>
low input CIRCUIT LOW INPUT —, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
high input CIRCUIT HIGH INPUT —, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P0117 Engine coolant temperature sensor <Ref. to EN-126, DTC P0117 — ENGINE COOLANT TEMPERATURE SEN-
circuit low input SOR CIRCUIT LOW INPUT —, Diagnostic Procedure with Diagnostic Trou-
ble Code (DTC).>
P0118 Engine coolant temperature sensor <Ref. to EN-128, DTC P0118 — ENGINE COOLANT TEMPERATURE SEN-
circuit high input SOR CIRCUIT HIGH INPUT —, Diagnostic Procedure with Diagnostic Trou-
ble Code (DTC).>
P0121 Throttle position sensor circuit range/ <Ref. to EN-132, DTC P0121 — THROTTLE POSITION SENSOR CIRCUIT
performance problem (high input) RANGE/PERFORMANCE PROBLEM (HIGH INPUT) —, Diagnostic Proce-
dure with Diagnostic Trouble Code (DTC).>
P0122 Throttle position sensor circuit low <Ref. to EN-134, DTC P0122 — THROTTLE POSITION SENSOR CIRCUIT
input LOW INPUT —, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P0123 Throttle position sensor circuit high <Ref. to EN-138, DTC P0123 — THROTTLE POSITION SENSOR CIRCUIT
input HIGH INPUT —, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P0125 Insufficient coolant temperature for <Ref. to EN-140, DTC P0125 — INSUFFICIENT COOLANT TEMPERA-
closed loop fuel control TURE FOR CLOSED LOOP FUEL CONTROL —, Diagnostic Procedure
EN-83
DTC
Item Index
No.
P0130 Front oxygen (A/F) sensor circuit <Ref. to EN-142, DTC P0130 — FRONT OXYGEN (A/F) SENSOR CIRCUIT
range/performance problem (Lean) RANGE/PERFORMANCE PROBLEM (LEAN) —, Diagnostic Procedure with
malfunction (open circuit) MALFUNCTION (OPEN CIRCUIT) —, Diagnostic Procedure with Diagnostic
malfunction (short circuit) MALFUNCTION (SHORT CIRCUIT) —, Diagnostic Procedure with Diagnos-
tic Trouble Code (DTC).>
slow response SLOW RESPONSE —, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P0136 Rear oxygen sensor circuit malfunc- <Ref. to EN-150, DTC P0136 — REAR OXYGEN SENSOR CIRCUIT MAL-
tion FUNCTION —, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0139 Rear oxygen sensor circuit slow <Ref. to EN-154, DTC P0139 — REAR OXYGEN SENSOR CIRCUIT SLOW
response RESPONSE —, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P0170 Fuel trim malfunction <Ref. to EN-156, DTC P0170 — FUEL TRIM MALFUNCTION —, Diagnostic
Procedure with Diagnostic Trouble Code (DTC).>
P0301 Cylinder 1 misfire detected <Ref. to EN-158, DTC P0301 — CYLINDER 1 MISFIRE DETECTED —,
Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0327 Knock sensor circuit low input <Ref. to EN-166, DTC P0327 — KNOCK SENSOR CIRCUIT LOW INPUT —
, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0328 Knock sensor circuit high input <Ref. to EN-168, DTC P0328 — KNOCK SENSOR CIRCUIT HIGH INPUT
—, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0335 Crankshaft position sensor circuit <Ref. to EN-170, DTC P0335 — CRANKSHAFT POSITION SENSOR CIR-
malfunction CUIT MALFUNCTION —, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P0336 Crankshaft position sensor circuit <Ref. to EN-172, DTC P0336 — CRANKSHAFT POSITION SENSOR CIR-
range/performance problem CUIT RANGE/PERFORMANCE PROBLEM —, Diagnostic Procedure with
P0340 Camshaft position sensor circuit mal- <Ref. to EN-174, DTC P0340 — CAMSHAFT POSITION SENSOR CIRCUIT
function MALFUNCTION —, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P0341 Camshaft position sensor circuit <Ref. to EN-176, DTC P0341 — CAMSHAFT POSITION SENSOR CIRCUIT
range/performance problem RANGE/PERFORMANCE PROBLEM —, Diagnostic Procedure with Diag-
nostic Trouble Code (DTC).>
P0420 Catalyst system efficiency below <Ref. to EN-179, DTC P0420 — CATALYST SYSTEM EFFICIENCY
threshold BELOW THRESHOLD —, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P0444 Evaporative emission control system <Ref. to EN-184, DTC P0444 — EVAPORATIVE EMISSION CONTROL
purge control valve circuit low input SYSTEM PURGE CONTROL VALVE CIRCUIT LOW INPUT —, Diagnostic
P0445 Evaporative emission control system <Ref. to EN-188, DTC P0445 — EVAPORATIVE EMISSION CONTROL
purge control valve circuit high input SYSTEM PURGE CONTROL VALVE CIRCUIT HIGH INPUT —, Diagnostic
P0461 Fuel level sensor circuit range/perfor- <Ref. to EN-190, DTC P0461 — FUEL LEVEL SENSOR CIRCUIT RANGE/
mance problem PERFORMANCE PROBLEM —, Diagnostic Procedure with Diagnostic
EN-84
DTC
Item Index
No.
P0462 Fuel level sensor circuit low input <Ref. to EN-192, DTC P0462 — FUEL LEVEL SENSOR CIRCUIT LOW
P0463 Fuel level sensor circuit high input <Ref. to EN-196, DTC P0463 — FUEL LEVEL SENSOR CIRCUIT HIGH
P0464 Fuel level sensor intermittent input <Ref. to EN-200, DTC P0464 — FUEL LEVEL SENSOR INTERMITTENT
INPUT—, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0480 Cooling fan relay 1 circuit low input <Ref. to EN-203, DTC P0480 — COOLING FAN RELAY 1 CIRCUIT LOW
P0483 Cooling fan function problem <Ref. to EN-207, DTC P0483 — COOLING FAN FUNCTION PROBLEM —,
P0500 Vehicle speed sensor malfunction <Ref. to EN-210, DTC P0500 — VEHICLE SPEED SENSOR MALFUNC-
TION —, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0506 Idle control system RPM lower than <Ref. to EN-212, DTC P0506 — IDLE CONTROL SYSTEM RPM LOWER
expected THAN EXPECTED —, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P0507 Idle control system RPM higher than <Ref. to EN-214, DTC P0507 — IDLE CONTROL SYSTEM RPM HIGHER
expected THAN EXPECTED —, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P0512 Starter switch circuit high input <Ref. to EN-216, DTC P0512 — STARTER SWITCH CIRCUIT HIGH INPUT
P0513 Incorrect immobilizer key <Ref. to IM-22, DTC P0153 INCORRECT IMMOBILIZER KEY (USE OF
UNREGISTERED KEY), Diagnostics Chart with Diagnostic Trouble Code
(DTC).>
P0562 Charge system circuit low input <Ref. to EN-218, DTC P0562 — CHARGE SYSTEM CIRCUIT LOW INPUT
P0563 Charge system circuit high input <Ref. to EN-220, DTC P0563 — CHARGE SYSTEM CIRCUIT HIGH INPUT
P0604 Internal control module memory <Ref. to EN-222, DTC P0604 — INTERNAL CONTROL MODULE MEMORY
check sum error CHECK SUM ERROR —, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P0703 Brake switch input malfunction <Ref. to EN-224, DTC P0703 — BRAKE SWITCH INPUT MALFUNCTION
P0705 Transmission range sensor circuit <Ref. to AT-119, CHECK INHIBITOR SWITCH., Diagnostic Procedure for
malfunction No-diagnostic Trouble Code (DTC).>
P0710 Transmission fluid temperature sen- <Ref. to AT-46, DTC 27 ATF TEMPERATURE SENSOR, Diagnostic Proce-
sor circuit malfunction dure with Diagnostic Trouble Code (DTC).>
P0715 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).>
P0720 Output speed sensor (vehicle speed <Ref. to AT-57, DTC 33 FRONT VEHICLE SPEED SENSOR, Diagnostic
sensor 2) circuit malfunction Procedure with Diagnostic Trouble Code (DTC).>
P0725 Engine speed input circuit malfunc- <Ref. to AT-42, DTC 11 ENGINE SPEED SIGNAL, Diagnostic Procedure
tion with Diagnostic Trouble Code (DTC).>
P0731 Gear 1 incorrect ratio <Ref. to EN-226, DTC P0731 — GEAR 1 INCORRECT RATIO —, Diagnos-
tic Procedure with Diagnostic Trouble Code (DTC).>
P0741 Torque converter clutch system mal- <Ref. to EN-228, DTC P0741 — TORQUE CONVERTER CLUTCH SYS-
function TEM MALFUNCTION —, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P0743 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).>
EN-85
DTC
Item Index
No.
P0748 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).>
P0753 Shift solenoid A (Shift solenoid 1) <Ref. to AT-70, DTC 71 SHIFT SOLENOID 1, Diagnostic Procedure with
electrical Diagnostic Trouble Code (DTC).>
P0758 Shift solenoid B (Shift solenoid 2) <Ref. to AT-74, DTC 72 SHIFT SOLENOID 2, Diagnostic Procedure with
P0778 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).>
P0785 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).>
P1110 Atmospheric pressure sensor circuit <Ref. to EN-230, DTC P1110 — ATMOSPHERIC PRESSURE SENSOR
low input CIRCUIT LOW INPUT —, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
high input CIRCUIT HIGH INPUT —, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
range/performance problem RANGE/PERFORMANCE PROBLEM —, Diagnostic Procedure with Diag-
P1142 Throttle position sensor circuit range/ <Ref. to EN-242, DTC P1142 — THROTTLE POSITION SENSOR CIRCUIT
performance problem (low input) RANGE/PERFORMANCE PROBLEM (LOW INPUT) —, Diagnostic Proce-
P1146 Pressure sensor circuit range/perfor- <Ref. to EN-244, DTC P1146 — PRESSURE SENSOR CIRCUIT RANGE/
mance problem (high input) PERFORMANCE PROBLEM (HIGH INPUT) —, Diagnostic Procedure with
P1442 Fuel level sensor circuit range/perfor- <Ref. to EN-247, DTC P1442 — FUEL LEVEL SENSOR CIRCUIT RANGE/
mance problem 2 PERFORMANCE PROBLEM 2 —, Diagnostic Procedure with Diagnostic
P1480 Cooling fan relay 1 circuit high input <Ref. to EN-249, DTC P1480 — COOLING FAN RELAY 1 CIRCUIT HIGH
P1507 Idle control system malfunction (fail- <Ref. to EN-252, DTC P1507 — IDLE CONTROL SYSTEM MALFUNCTION
safe) (FAIL-SAFE) —, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P1510 Idle air control solenoid valve signal <Ref. to EN-254, DTC P1510 — IDLE AIR CONTROL SOLENOID VALVE
1 circuit low input SIGNAL 1 CIRCUIT LOW INPUT —, Diagnostic Procedure with Diagnostic
1 circuit high input SIGNAL 1 CIRCUIT HIGH INPUT —, Diagnostic Procedure with Diagnostic
EN-86
DTC
Item Index
No.
P1518 Starter switch circuit low input <Ref. to EN-262, DTC P1518 — STARTER SWITCH CIRCUIT LOW INPUT
P1540 Vehicle speed sensor malfunction 2 <Ref. to EN-264, DTC P1540 — VEHICLE SPEED SENSOR MALFUNC-
TION 2 —, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P1560 Back-up voltage circuit malfunction <Ref. to EN-266, DTC P1560 — BACK-UP VOLTAGE CIRCUIT MALFUNC-
TION —, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P1570 Antennna <Ref. to IM-24, DTC P1570 ANTENNA, Diagnostics Chart with Diagnostic
P1571 Reference code incompatibility <Ref. to IM-17, DTC P1571 REFERENCE CODE INCOMPATIBILITY, Diag-
nostics Chart with Diagnostic Trouble Code (DTC).>
P1572 IMM circuit failure except antenna <Ref. to IM-18, DTC P1572 IMM CIRCUIT FAILURE (EXCEPT ANTENNA
circuit CIRCUIT), Diagnostics Chart with Diagnostic Trouble Code (DTC).>
P1574 Key communication failure <Ref. to IM-21, DTC P1574 KEY COMMUNICATION FAILURE, Diagnostics
Chart with Diagnostic Trouble Code (DTC).>
P1576 EGI control module EEPROM <Ref. to IM-22, DTC P1576 EGI CONTROL MODULE EEPROM, Diagnos-
tics Chart with Diagnostic Trouble Code (DTC).>
P1577 IMM control module EEPROM <Ref. to IM-22, DTC P1577 IMM CONTROL MODULE EEPROM, Diagnos-
P1590 Neutral position switch circuit high <Ref. to EN-268, DTC P1590 — NEUTRAL POSITION SWITCH CIRCUIT
input (AT model) HIGH INPUT (AT MODEL) —, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P1591 Neutral position switch circuit low <Ref. to EN-272, DTC P1591 — NEUTRAL POSITION SWITCH CIRCUIT
input (AT model) LOW INPUT (AT MODEL) —, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P1592 Neutral position switch circuit low <Ref. to EN-274, DTC P1592 — NEUTRAL POSITION SWITCH CIRCUIT
input (MT model) LOW INPUT (MT MODEL) —, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P1594 Automatic transmission diagnosis <Ref. to EN-276, DTC P1594 — AUTOMATIC TRANSMISSION DIAGNO-
input signal circuit malfunction SIS INPUT SIGNAL CIRCUIT MALFUNCTION —, Diagnostic Procedure
input signal circuit low input SIS INPUT SIGNAL CIRCUIT LOW INPUT —, Diagnostic Procedure with
input signal circuit high input SIS INPUT SIGNAL CIRCUIT HIGH INPUT —, Diagnostic Procedure with
P1698 Engine torque control cut signal cir- <Ref. to EN-282, DTC P1698 — ENGINE TORQUE CONTROL CUT SIG-
cuit low input NAL CIRCUIT LOW INPUT —, Diagnostic Procedure with Diagnostic Trou-
ble Code (DTC).>
P1699 Engine torque control cut signal cir- <Ref. to EN-284, DTC P1699 — ENGINE TORQUE CONTROL CUT SIG-
cuit high input NAL CIRCUIT HIGH INPUT —, Diagnostic Procedure with Diagnostic Trou-
ble Code (DTC).>
P1700 Throttle position sensor circuit mal- <Ref. to AT-50, DTC 31 THROTTLE POSITION SENSOR, Diagnostic Pro-
function for automatic transmission cedure with Diagnostic Trouble Code (DTC).>
P1701 Cruise control set signal circuit mal- <Ref. to EN-286, DTC P1701 — CRUISE CONTROL SET SIGNAL CIRCUIT
function for automatic transmission MALFUNCTION FOR AUTOMATIC TRANSMISSION —, Diagnostic Proce-
P1703 Low clutch timing control solenoid <Ref. to AT-78, DTC 73 LOW CLUTCH TIMING SOLENOID, Diagnostic
valve circuit malfunction Procedure with Diagnostic Trouble Code (DTC).>
EN-87
DTC
Item Index
No.
P1711 Engine torque control signal 1 circuit <Ref. to EN-288, DTC P1711 — ENGINE TORQUE CONTROL SIGNAL 1
malfunction CIRCUIT MALFUNCTION —, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P1712 Engine torque control signal 2 circuit <Ref. to EN-290, DTC P1712 — ENGINE TORQUE CONTROL SIGNAL 2
malfunction CIRCUIT MALFUNCTION —, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
EN-88
EN-89
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)
19.Diagnostic Procedure with Diagnostic Trouble Code (DTC)

A: DTC P0031 — FRONT OXYGEN (A/F) SENSOR HEATER CIRCUIT LOW IN-
PUT —
• DTC DETECTING CONDITION:
• Immediately at fault recognition
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-49, OPERATION,
Clear Memory Mode.> and Inspection Mode <Ref. to EN-42, OPERATION, Inspection Mode.> .
• WIRING DIAGRAM:
MAIN RELAY BATTERY B47
RHD
RHD
SBF-5
1 2
6 LHD 2 LHD
3 4
4
B61 F44 5 6
5
3
2 B18
1
2
1 2 3
B47 FRONT OXYGEN 4 5 6
(A/F) SENSOR
B18
5
4
6
3
1
F44
1 2 3 4
5 6 7 8
B22
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
A22
A23
C20
C19
C23
C7
C6
A: B134
A: B134 1 2 3 4 5 6 7 8
ECM 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
C: B136 24 25 26 27 28 29 30 31 32 33 34 35
A34
A35
C: B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
B22 21 22 23 24 25 26 27 28 29 30
8
E3
EN1400
Step Check Yes No

1 CHECK ANY OTHER DIAGNOSTIC TROU- Does the Subaru Select Moni- Go to step 2. Go to step 5.
BLE CODE (DTC) ON DISPLAY. tor or OBD-II general scan tool
indicate DTC P0031 and
P0037 at the same time?
EN-90
Step Check Yes No

2 CHECK POWER SUPPLY TO FRONT OXY- Is the voltage more than 10 V? Go to step 3. Repair the power
GEN (A/F) SENSOR. supply line.
2)Disconnect the connector from front oxygen In this case, repair
(A/F) sensor. the following:
3)Turn the ignition switch to ON. • Open circuit in
4)Measure the voltage between front oxygen harness between
(A/F) sensor connector and engine ground. main relay and
Connector & terminal front oxygen (A/F)
(B18) No. 2 (+) — Engine ground (−): sensor connector
• Poor contact in
front oxygen (A/F)
sensor connector
• Poor contact in
main relay con-
nector
3 CHECK GROUND CIRCUIT OF ECM. Is the resistance less than 5 Go to step 4. Repair the har-
Measure the resistance of harness between Ω? ness and connec-
ECM connector and chassis ground. tor.
Connector & terminal NOTE:
(B134) No. 35 — Chassis ground: In this case, repair
(B134) No. 34 — Chassis ground: the following:
• Open circuit in
harness between
ECM and engine
ground terminal
• Poor contact in
ECM connector
Poor contact in
coupling connector
(B22)
4 CHECK CURRENT DATA. Is the value more than 0.2 A? Repair the poor Go to step 5.
1)Start the engine. contact in connec-
2)Read the data of front oxygen (A/F) sensor tor.
heater current using Subaru Select Monitor or NOTE:
OBD-II general scan tool. In this case, repair
NOTE: the following:
•Subaru Select Monitor • Poor contact in
For detailed operation procedure, refer to the front oxygen (A/F)
“READ CURRENT DATA FOR ENGINE”. sensor connector
<Ref. to EN-34, Subaru Select Monitor.> • Poor contact in
•OBD-II scan tool ECM connector
For detailed operation procedures, refer to the
5 CHECK OUTPUT SIGNAL FROM ECM. Is the voltage less than 1.0 V? Go to step 7. Go to step 6.
1)Start and idle the engine.
6 CHECK OUTPUT SIGNAL FROM ECM. Does the voltage change less Repair the poor Go to step 7.
Measure the voltage between ECM connector than 1.0 V by shaking harness contact in ECM
and chassis ground. and connector of ECM while connector.
Connector & terminal monitoring the value with volt-
(B134) No. 22 (+) — Chassis ground (−): age meter?
Measure the voltage between ECM connector
and chassis ground.
EN-91
Step Check Yes No

9 CHECK FRONT OXYGEN (A/F) SENSOR. Is the resistance less than 10 Repair the har- Replace the front
1)Turn the ignition switch to OFF. Ω? ness and connec- oxygen (A/F) sen-
2)Measure the resistance between front oxy- tor. sor. <Ref. to FU-
gen (A/F) sensor connector terminals. NOTE: 54, Fuel.>
Terminals In this case, repair
No. 2 — No. 5: the following:
• Open or ground
short circuit in har-
ness between
front oxygen (A/F)
sensor and ECM
connector
• Poor contact in
front oxygen (A/F)
sensor connector
• Poor contact in
ECM connector
EN-92
EN-93
B: DTC P0032 — FRONT OXYGEN (A/F) SENSOR HEATER CIRCUIT HIGH IN-
PUT —
CAUTION:
Clear Memory Mode.> and Inspection Mode <Ref. to EN-42, Inspection Mode.> .
• WIRING DIAGRAM:
RHD
RHD
SBF-5
1 2
6 LHD 2 LHD
3 4
4
B61 F44 5 6
5
3
2 B18
1
2
1 2 3
(A/F) SENSOR
B18
5
4
6
3
1
F44
1 2 3 4
5 6 7 8
B22
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
A22
A23
C20
C19
C23
C7
C6
A: B134
A: B134 1 2 3 4 5 6 7 8
ECM 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
C: B136 24 25 26 27 28 29 30 31 32 33 34 35
A34
A35
C: B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
B22 21 22 23 24 25 26 27 28 29 30
8
E3
EN1400
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.
EN-94
Step Check Yes No

and chassis ground.
3 CHECK FRONT OXYGEN (A/F) SENSOR Is the value more than 2.3 A? Replace the ECM. END
HEATER CURRENT. <Ref. to FU-51,
1)Turn the ignition switch to OFF. Engine Control
2)Repair the battery short circuit in harness Module.>
between ECM and front oxygen (A/F) sensor
connector.
4)Read the data of front oxygen (A/F) sensor
heater current using Subaru Select Monitor or
OBD-II general scan tool.
NOTE:
•Subaru Select Monitor
For detailed operation procedure, refer to the
“READ CURRENT DATA FOR ENGINE”.
<Ref. to EN-34, Subaru Select Monitor.>
•OBD-II general scan tool
4 CHECK OUTPUT SIGNAL FROM ECM. Does the voltage change more
Repair the battery Go to step 5.
Measure the voltage between ECM connector than 8 V by shaking harness
and chassis ground. and connector of ECM while
ness between
ECM and front
(B134) No. 23 (+) — Chassis ground (−): age meter? oxygen (A/F) sen-
sor connector.
5 CHECK OUTPUT SIGNAL FROM ECM. Does the voltage change more Repair the battery END
Measure the voltage between ECM connector than 8 V by shaking harness short circuit in har-
and chassis ground. and connector of ECM while ness between
Connector & terminal monitoring the value with volt- ECM and front
sor connector.
EN-95
C: DTC P0037 — REAR OXYGEN SENSOR HEATER CIRCUIT MALFUNCTION

—
• Two consecutive driving cycles with fault
CAUTION:
• WIRING DIAGRAM:
MAIN RELAY BATTERY B47 B19
RHD
RHD
1 2 1 2
6 LHD 2 LHD 3 4 3 4
4 5 6
B61 F44 (LHD)
5
3 2 1
4 3
2
(RHD)
1
2
B47 REAR OXYGEN

SENSOR B83
B19
1 2 3 4
1
B122
1 2 3
4 5 6
F44
5 LHD RHD 4
1 2 3 4
1 LHD RHD 1 5 6 7 8
B122 B83
B22
A21
C18
C16
C24
1 2 3 4
A: B134 5 6 7 8
ECM 9 10 11 12
C: B136 13 14 15 16
C22
A34
A35
C21
C: B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
B22
16
A: B134
8
E3
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25 26 27 28 29 30 31 32 33 34 35
EN1401
Step Check Yes No

1 CHECK GROUND CIRCUIT OF ECM. Is the resistance less than 5 Go to step 3. Go to step 2.
1)Turn the ignition switch to OFF. Ω?
2)Disconnect the connector from ECM.
EN-96
Step Check Yes No

1)Repair the harness and connector. Ω? ness and connec-
2)Measure the resistance of harness between tor.
ECM connector and chassis ground. NOTE:
• Open circuit in
harness between
ECM and engine
ground terminal
• Poor contact in
ECM connector
• Poor contact in
coupling connector
(B22)
3 CHECK CURRENT DATA. Is the value more than 0.2 A? Repair the con- Go to step 4.
1)Start the engine. nector.
2)Read the data of rear oxygen sensor heater NOTE:
current using Subaru Select Monitor or OBD-II In this case, repair
general scan tool. the following:
NOTE: • Poor contact in
•Subaru Select Monitor rear oxygen sen-
For detailed operation procedure, refer to the sor connector
“READ CURRENT DATA FOR ENGINE”. • Poor contact in
<Ref. to EN-34, Subaru Select Monitor.> rear oxygen sen-
•OBD-II scan tool sor connecting
For detailed operation procedures, refer to the harness connector
OBD-II General Scan Tool Instruction Manual. • Poor contact in
ECM connector
6 CHECK OUTPUT SIGNAL FROM ECM. Is the voltage less than 1.0 V? Contact with your Repair the battery
1)Disconnect the connector from rear oxygen Subaru distributor short circuit in har-
sensor. service. ness between
2)Measure the voltage between ECM connec- ECM and rear oxy-
tor and chassis ground. gen sensor con-
Connector & terminal nector.
7 CHECK POWER SUPPLY TO REAR OXY- Is the voltage more than 10 V? Go to step 8. Repair the power
GEN SENSOR. supply line.
2)Disconnect the connector from rear oxygen In this case, repair
sensor. the following:
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
(B19) No. 2 (+) — Chassis ground (−): • Poor contact in
rear oxygen sen-
sor connector
EN-97
Step Check Yes No

8 CHECK REAR OXYGEN SENSOR. Is the resistance less than 30 Repair the har- Replace the rear
1)Turn the ignition switch to OFF. Ω? ness and connec- oxygen sensor.
2)Measure the resistance between rear oxy- tor. <Ref. to FU-49,
gen sensor connector terminals. NOTE: Rear Oxygen Sen-
Terminals In this case, repair sor.>
No. 1 — No. 2: the following:
• 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
EN-98
EN-99
D: DTC P0038 — REAR OXYGEN SENSOR HEATER CIRCUIT HIGH INPUT —

CAUTION:
• WIRING DIAGRAM:
RHD
RHD
1 2 1 2
6 LHD 2 LHD 3 4 3 4
4 5 6
B61 F44 (LHD)
5
3 2 1
4 3
2
(RHD)
1
2
B47 REAR OXYGEN

SENSOR B83
B19
1 2 3 4
1
B122
1 2 3
4 5 6
F44
5 LHD RHD 4
1 2 3 4
1 LHD RHD 1 5 6 7 8
B122 B83
B22
A21
C18
C16
C24
1 2 3 4
A: B134 5 6 7 8
ECM 9 10 11 12
C: B136 13 14 15 16
C22
A34
A35
C21
C: B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
B22
16
A: B134
8
E3
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25 26 27 28 29 30 31 32 33 34 35
EN1401
Step Check Yes No

1 CHECK INPUT SIGNAL FOR ECM. Is the voltage more than 8 V? Go to step 2. Go to step 3.
and chassis ground.
EN-100
Step Check Yes No

2 CHECK CURRENT DATA. Is the value more than 7 A? Replace the ECM. END
1)Turn the ignition switch to OFF. <Ref. to FU-51,
2)Repair the battery short circuit in harness Engine Control
between ECM and rear oxygen sensor con- Module.>
nector.
4)Read the data of rear oxygen sensor heater
current using Subaru Select Monitor or OBD-II
general scan tool.
NOTE:
3 CHECK POOR CONTACT. Is there poor contact in ECM Repair the poor END
connector.
EN-101
E: DTC P0066 — AIR ASSIST INJECTOR SOLENOID VALVE CIRCUIT LOW IN-
PUT —
• Erroneous idling
• Engine stalls.
CAUTION:
• WIRING DIAGRAM:
MAIN RELAY
4 BATTERY
RHD
RHD
6
SBF-5
5 LHD 2 LHD
3
B61 F44
2
1 AIR ASSIST
INJECTOR
B47 SOLENOID
VALVE
2
1
E42
E3
1
7
B22
24
B134 ECM
E42 B47 F44 B22 B134
1 2 1 2 1 2 3 4 1 2 3 4 1 2 3 4 5 6 7 8
3 4 5 6 7 8 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
5 6 9 10 11 12 24 25 26 27 28 29 30 31 32 33 34 35
13 14 15 16
EN1402
EN-102
Step Check Yes No

1 CHECK OUTPUT SIGNAL FROM ECM. Is the voltage more than 10 V? Repair the poor Go to step 2.
1)Turn the ignition switch to ON. contact in ECM
2)Measure the voltage between ECM and connector.
chassis ground.
2 CHECK POWER SUPPLY TO AIR ASSIST IN- Is the voltage more than 10 V? Go to step 3. Repair the har-
JECTOR SOLENOID VALVE. ness and connec-
2)Disconnect the connector from air assist NOTE:
injector solenoid valve. In this case, repair
4)Measure the voltage between air assist • Open circuit in
injector solenoid valve and engine ground. harness between
Connector & terminal air assist injector
(E42) No. 2 (+) — Engine ground (−): solenoid valve and
main relay con-
nector
• Poor contact in
coupling connector
(B22)
3 CHECK HARNESS BETWEEN ECM AND AIR Is the resistance less than 1 Go to step 4. Repair the har-
ASSIST INJECTOR SOLENOID VALVE CON- Ω? ness and connec-
NECTOR. tor.
3)Measure the resistance of harness between the following:
ECM and air assist injector solenoid valve con- • Open circuit in
nector. harness between
Connector & terminal ECM and air assist
(B134) No. 24 — (E42) No. 1: injector solenoid
valve connector
• Poor contact in
coupling connector
(B22)
4 CHECK HARNESS BETWEEN ECM AND AIR Is the resistance less than 10 Repair the ground Go to step 5.
ASSIST INJECTOR SOLENOID VALVE CON- Ω? short circuit in har-
Measure the resistance of harness between ECM and air assist
ECM and chassis ground. injector solenoid
Connector & terminal valve connector.
5 CHECK POOR CONTACT. Is there poor contact in ECM Repair the poor Replace the air
Check poor contact in ECM and air assist and air assist injector solenoid contact in ECM assist injector
injector solenoid valve connectors. valve connectors? and air assist solenoid valve.
injector solenoid <Ref. to FU-40, Air
valve connectors. Assist Injector
Solenoid Valve.>
EN-103
F: DTC P0067 — AIR ASSIST INJECTOR SOLENOID VALVE CIRCUIT HIGH IN-
PUT —
• Engine stalls.
CAUTION:
• WIRING DIAGRAM:
MAIN RELAY
4 BATTERY
RHD
RHD
6
SBF-5
5 LHD 2 LHD
3
B61 F44
2
1 AIR ASSIST
INJECTOR
B47 SOLENOID
VALVE
2
1
E42
E3
1
7
B22
24
B134 ECM
E42 B47 F44 B22 B134
1 2 1 2 1 2 3 4 1 2 3 4 1 2 3 4 5 6 7 8
3 4 5 6 7 8 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
5 6 9 10 11 12 24 25 26 27 28 29 30 31 32 33 34 35
13 14 15 16
EN1402
EN-104
Step Check Yes No

2)Measure the voltage between ECM and
chassis ground.
2 CHECK OUTPUT SIGNAL FROM ECM. Is the voltage more than 10 V? Repair the 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 FU-40, Air
3)Turn the ignition switch to ON. injector solenoid Assist Injector
4)Measure the voltage between ECM and valve connector. Solenoid Valve.>
chassis ground. After repair, and ECM <Ref. to
Connector & terminal replace the ECM. FU-51, Engine
(B134) No. 24 (+) — Chassis ground (−): <Ref. to FU-51, Control Module.>
Engine Control
Module.>
3 CHECK OUTPUT SIGNAL FROM ECM. Does the voltage change more Repair the battery Contact with your
Measure the voltage between ECM and chas- than 10 V by shaking harness short circuit in har- Subaru distributor
sis ground. and connector of ECM while ness between service.
Connector & terminal monitoring the value with volt- ECM and air assist NOTE:
(B134) No. 24 (+) — Chassis ground (−): age meter? injector solenoid Inspection by DTM
valve connector. is required, be-
After repair, cause probable
replace the ECM. cause is deteriora-
<Ref. to FU-51, tion of multiple
Engine Control parts.
Module.>
EN-105
G: DTC P0106 — PRESSURE SENSOR CIRCUIT RANGE/PERFORMANCE

PROBLEM (LOW INPUT) —
CAUTION:
• WIRING DIAGRAM:
INTAKE AIR
TEMPERATURE E20
AND
PRESSURE 1 2 3 4
SENSOR
1
3
2
4
E20
LHD: B83
1 2 3
4 5 6
B122
E2
12
14
15
1 2 3
9
B21 4 5 6
B122 B83 RHD: B83
3 LHD RHD 2 1 2 3 4
1 LHD RHD 1
2 LHD
1 B21
B83 1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
25 LHD
17 18 19 20
16
15
13
B136 ECM
B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
EN1403
EN-106
Step Check Yes No

1 CHECK ANY OTHER DIAGNOSTIC TROU- Is any other DTC displayed? Inspect the rele- Go to step 2.
BLE CODE (DTC) ON DISPLAY. vant DTC using
“List of Diagnostic
Trouble Code
(DTC)”. <Ref. to
EN-83, List of
Diagnostic Trou-
ble Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0106.
2 CHECK AIR INTAKE SYSTEM. Are there holes, loose bolts or Repair the air Go to step 3.
disconnection of hose on air intake system.
intake system?
3 CHECK PRESSURE SENSOR. Is the value within the specifi- Go to step 4. Replace the intake
1)Start the engine and warm-up engine until cations? air temperature
coolant temperature is greater than 60°C sensor and pres-
(140°F). sure sensor. <Ref.
2)Place the shift lever in the selector lever in to FU-37, Intake
“N” or “P” position. Air Temperature
3)Turn the A/C switch to OFF. and Pressure Sen-
4)Turn all accessory switches to OFF. sor.>
5)Read the data of intake manifold pressure
sensor signal using Subaru Select Monitor or
NOTE:
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 Go to step 5. Adjust or replace
Read the data of throttle position signal using equal to or less than 5 % when the throttle posi-
Subaru Select Monitor or OBD-II general scan throttle is fully closed? tion sensor. <Ref.
tool. to FU-35, Throttle
NOTE: Position Sensor.>
EN-107
Step Check Yes No

5 CHECK THROTTLE POSITION. Is the throttle positioning ratio Replace the intake Replace the throt-
equal to or more than 85 % air temperature tle position sensor.
when throttle is fully open? and pressure sen- <Ref. to FU-35,
sor. <Ref. to FU- Throttle Position
37, Intake Air Sensor.>
Temperature and
Pressure Sensor.>
EN-108
EN-109
H: DTC P0107 — PRESSURE SENSOR CIRCUIT LOW INPUT —

CAUTION:
• WIRING DIAGRAM:
INTAKE AIR
TEMPERATURE E20
AND
PRESSURE 1 2 3 4
SENSOR
1
3
2
4
E20
LHD: B83
1 2 3
4 5 6
B122
E2
12
14
15
1 2 3
9
B21 4 5 6
B122 B83 RHD: B83
3 LHD RHD 2 1 2 3 4
1 LHD RHD 1
2 LHD
1 B21
B83 1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
25 LHD
17 18 19 20
16
15
13
B136 ECM
B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
EN1403
EN-110
Step Check Yes No

1 CHECK CURRENT DATA. Is the value less than 13.3 kPa Go to step 3. Go 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
NOTE:
2 CHECK POOR CONTACT. Is there poor contact in ECM or Repair the poor Even if MIL lights
Check poor contact in ECM and pressure sen- pressure sensor connector? contact in ECM or up, the circuit has
sor connector. pressure sensor returned to a nor-
connector. mal condition at
this time.
3 CHECK INPUT SIGNAL FOR ECM. Is the voltage more than 4.5 V? Go to step 5. Go to step 4.
and chassis ground.
4 CHECK INPUT SIGNAL FOR ECM. Does the voltage change more Repair the poor Contact with your
Measure the voltage between ECM connector than 4.5 V by shaking harness contact in ECM Subaru distributor
and chassis ground. and connector of ECM while connector. service.
Connector & terminal monitoring the value with volt- NOTE:
(B136) No. 15 (+) — Chassis ground (−): age meter? Inspection by DTM
is required, be-
cause probable
cause is deteriora-
tion of multiple
parts.
5 CHECK INPUT SIGNAL FOR ECM. Is the voltage less than 0.2 V? Go to step 7. Go to step 6.
Measure the voltage between ECM and chas-
sis ground.
6 CHECK INPUT SIGNAL FOR ECM. (USING Does the value change more Repair the poor Go to step 7.
SUBARU SELECT MONITOR.) than 13.3 kPa (100 mmHg, contact in ECM
Read the data of atmospheric absolute pres- 3.94 inHg) by shaking harness connector.
sure signal using Subaru Select Monitor. and connector of ECM while
NOTE: monitoring the value with Sub-
•Subaru Select Monitor aru Select Monitor?
7 CHECK HARNESS BETWEEN ECM AND IN- Is the voltage more than 4.5 V? Go to step 8. Repair the open
TAKE AIR TEMPERATURE AND PRESSURE circuit in harness
SENSOR CONNECTOR. between ECM and
1)Turn the ignition switch to OFF. intake air tempera-
2)Disconnect the connector from intake air ture and pressure
temperature and pressure sensor. sensor connector.
4)Measure the voltage between intake air tem-
perature sensor and pressure sensor connec-
tor and engine ground.
EN-111
Step Check Yes No

8 CHECK HARNESS BETWEEN ECM AND IN- Is the resistance less than 1 Go to step 9. Repair the open
TAKE AIR TEMPERATURE AND PRESSURE Ω? circuit in harness
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.
(B136) No. 16 — (E20) No. 1:
9 CHECK HARNESS BETWEEN ECM AND IN- Is the resistance more than Go to step 10. Repair the ground
TAKE AIR TEMPERATURE AND PRESSURE 500 kΩ? short circuit in har-
SENSOR CONNECTOR. 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:
10 CHECK POOR CONTACT. Is there poor contact in intake Repair the poor Replace the intake
Check poor contact in intake manifold pressure manifold pressure sensor con- contact in intake air temperature
sensor connector. nector? air temperature and pressure sen-
and pressure sensor. <Ref. to FU-
sor connector. 37, Intake Air
Temperature and
Pressure Sensor.>
EN-112
EN-113
I: DTC P0108 — PRESSURE SENSOR CIRCUIT HIGH INPUT —

CAUTION:
Clear Memory Mode.> and Inspection Mode <Ref. to EN-42, Operation.> .
• WIRING DIAGRAM:
INTAKE AIR
TEMPERATURE E20
AND
PRESSURE 1 2 3 4
SENSOR
1
3
2
4
E20
LHD: B83
1 2 3
4 5 6
B122
E2
12
14
15
1 2 3
9
B21 4 5 6
B122 B83 RHD: B83
3 LHD RHD 2 1 2 3 4
1 LHD RHD 1
2 LHD
1 B21
B83 1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
25 LHD
17 18 19 20
16
15
13
B136 ECM
B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
EN1403
EN-114
Step Check Yes No

1 CHECK CURRENT DATA. Is the value more than 119.5 Go to step 10. Go to step 2.
1)Start the engine. kPa (896.5 mmHg, 35.29
2)Read the data of intake manifold absolute inHg)?
NOTE:
and chassis ground.
is required, be-
cause probable
cause is deteriora-
tion of multiple
parts.
and chassis ground.
SUBARU SELECT MONITOR.) than 13.3 kPa (100 mmHg, contact in ECM
Read the data of atmospheric absolute pres- 3.94 inHg) by shaking harness connector.
sure signal using Subaru Select Monitor. and connector of ECM while
NOTE: monitoring the value with Sub-
•Subaru Select Monitor aru Select Monitor?
6 CHECK HARNESS BETWEEN ECM AND IN- Is the voltage more than 4.5 V? Go to step 7. Repair the open
TAKE AIR TEMPERATURE AND PRESSURE circuit in harness
temperature and pressure sensor. sensor connector.
4)Measure the voltage between intake air tem-
perature and pressure sensor connector and
engine ground.
EN-115
Step Check Yes No

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.
(B136) No. 5 — (E20) No. 4:
Measure the resistance of harness between intake air tempera-
ECM and intake air temperature and pressure ture and pressure
sensor connector. sensor connector.
(B136) No. 16 — (E20) No. 1:
9 CHECK POOR CONTACT. Is there poor contact in intake Repair the poor Replace the intake
Check poor contact in intake air temperature manifold pressure sensor con- contact in intake air temperature
and pressure sensor connector. nector? air temperature and pressure sen-
and pressure sensor. <Ref. to FU-
sor connector. 37, Intake Air
Temperature and
Pressure Sensor.>
10 CHECK HARNESS BETWEEN ECM AND IN- Is the value more than 119.5 Repair the battery Replace the intake
TAKE AIR TEMPERATURE AND PRESSURE kPa (896.5 mmHg, 35.29 short circuit in har- air temperature
SENSOR CONNECTOR. inHg)? ness between and pressure sen-
1)Turn the ignition switch to OFF and Subaru ECM and intake sor. <Ref. to FU-
Select Monitor or OBD-II general scan tool air temperature 37, Intake Air
switch to OFF. and pressure sen- Temperature and
2)Disconnect the connector from intake air sor connector. Pressure Sensor.>
temperature and pressure sensor.
3)Turn the ignition switch to ON and Subaru
Select Monitor or the OBD-II general scan tool
switch to ON.
NOTE:
EN-116
EN-117
J: DTC P0111 — INTAKE AIR TEMPERATURE SENSOR CIRCUIT RANGE/PER-

FORMANCE PROBLEM —
• Poor driving performance
CAUTION:
• WIRING DIAGRAM:
INTAKE AIR
TEMPERATURE E20
AND
PRESSURE 1 2 3 4
SENSOR
1
3
2
E20
LHD: B83
1 2 3
4 5 6
B122
E2
12
14
15
1 2 3
9
B21 4 5 6
B122 B83 RHD: B83
3 LHD RHD 2 1 2 3 4
1 LHD RHD 1
2 LHD
1 B21
B83 1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
25 LHD
17 18 19 20
16
15
13
B136 ECM
B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
EN1403
EN-118
Step Check Yes No

Trouble Code
(DTC)”. <Ref. to
EN-83, List of
Diagnostic Trou-
ble Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0111.
2 CHECK ENGINE COOLANT TEMPERA- Is the engine coolant tempera- Replace the intake Inspect the DTC
TURE. ture between 75°C (167°F) air temperature P0125 using “17.
1)Start the engine and warm it up completely. and 95°C (203°F)? and pressure sen- List of Diagnostic
2)Measure the engine coolant temperature sor. <Ref. to FU- Trouble Code
using Subaru Select Monitor or OBD-II general 37, Intake Air (DTC)”. <Ref. to
scan tool. Temperature and EN-83, List of
NOTE: Pressure Sensor.> Diagnostic Trou-
•Subaru Select Monitor ble Code (DTC).>
EN-119
K: DTC P0112 — INTAKE AIR TEMPERATURE SENSOR CIRCUIT LOW INPUT

—
CAUTION:
• WIRING DIAGRAM:
INTAKE AIR
TEMPERATURE E20
AND
PRESSURE 1 2 3 4
SENSOR
1
3
2
E20
LHD: B83
1 2 3
4 5 6
B122
E2
12
14
15
1 2 3
9
B21 4 5 6
B122 B83 RHD: B83
3 LHD RHD 2 1 2 3 4
1 LHD RHD 1
2 LHD
1 B21
B83 1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
25 LHD
17 18 19 20
16
15
13
B136 ECM
B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
EN1403
EN-120
Step Check Yes No

1 CHECK CURRENT DATA. Is the value greater than 120°C Go to step 2. Repair the poor
1)Start the engine. (248°F)? contact.
2)Read the data of intake air temperature sen- NOTE:
sor signal using Subaru Select Monitor or In this case, repair
OBD-II general scan tool. the following:
•Subaru Select Monitor intake air tempera-
For detailed operation procedure, refer to the ture and pressure
“READ CURRENT DATA FOR ENGINE”. sensor
•OBD-II general scan tool ECM
For detailed operation procedure, refer to the • Poor contact in
OBD-II General Scan Tool Instruction Manual. coupling connector
(B21)
• Poor contact in
joint connector
(B83), (B122)
2 CHECK HARNESS BETWEEN INTAKE AIR Is the value less than −40°C Replace the intake Repair the ground
TEMPERATURE AND PRESSURE SENSOR (−40°F)? air temperature short circuit in har-
AND ECM CONNECTOR. and pressure sen- ness between
1)Turn the ignition switch to OFF. sor. <Ref. to FU- intake air tempera-
2)Disconnect the connector from intake air 37, Intake Air ture sensor and
temperature and pressure sensor. Temperature and ECM connector.
3)Turn the ignition switch to ON. Pressure Sensor.>
4)Read the data of intake air temperature sen-
sor signal using Subaru Select Monitor or the
NOTE:
EN-121
L: DTC P0113 — INTAKE AIR TEMPERATURE SENSOR CIRCUIT HIGH INPUT

—
CAUTION:
• WIRING DIAGRAM:
INTAKE AIR
TEMPERATURE E20
AND
PRESSURE 1 2 3 4
SENSOR
1
3
2
E20
LHD: B83
1 2 3
4 5 6
B122
E2
12
14
15
1 2 3
9
B21 4 5 6
B122 B83 RHD: B83
3 LHD RHD 2 1 2 3 4
1 LHD RHD 1
2 LHD
1 B21
B83 1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
25 LHD
17 18 19 20
16
15
13
B136 ECM
B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
EN1403
EN-122
Step Check Yes No

1 CHECK CURRENT DATA. Is the value less than −40°C Go to step 2. Repair the poor
1)Start the engine. (−40°F)? contact.
sor signal using Subaru Select Monitor or In this case, repair
•Subaru Select Monitor intake air tempera-
For detailed operation procedure, refer to the ture and pressure
“READ CURRENT DATA FOR ENGINE”. sensor
For detailed operation procedure, refer to the • Poor contact in
(B21)
• Poor contact in
joint connector
(B83), (B122)
2 CHECK HARNESS BETWEEN INTAKE AIR Is the voltage more than 10 V? Repair the battery Go to step 3.
TEMPERATURE AND PRESSURE SENSOR short circuit in har-
AND ECM CONNECTOR. ness between
temperature and pressure sensor. sensor and ECM
3)Measure the voltage between intake air tem- connector.
perature and pressure sensor connector and
engine ground.
1)Turn the ignition switch to ON. intake air tempera-
2)Measure the voltage between intake air tem- ture and pressure
perature and pressure sensor connector and sensor and ECM
engine ground. connector.
EN-123
Step Check Yes No

4 CHECK HARNESS BETWEEN INTAKE AIR Is the voltage more than 3 V? Go to step 5. Repair the har-
TEMPERATURE AND PRESSURE SENSOR ness and connec-
AND ECM CONNECTOR. tor.
Measure the voltage between intake air tem- NOTE:
perature and pressure sensor connector and In this case, repair
engine ground. the following:
(E20) No. 2 (+) — Engine ground (−): harness between
intake air tempera-
ture and pressure
sensor and ECM
connector
• Poor contact in
intake air tempera-
ture and pressure
sensor
• Poor contact in
ECM
• Poor contact in
coupling connector
(B21)
• Poor contact in
joint connector
(B83) and (B122)
5 CHECK HARNESS BETWEEN INTAKE AIR Is the resistance less than 5 Replace the intake Repair the har-
TEMPERATURE AND PRESSURE SENSOR Ω? air temperature ness and connec-
AND ECM CONNECTOR. and pressure sen- tor.
1)Turn the ignition switch to OFF. sor. <Ref. to FU- NOTE:
2)Measure the resistance of harness between 37, Intake Air In this case, repair
intake air temperature and pressure sensor Temperature and the following:
connector and engine ground. Pressure Sensor.> • Open circuit in
Connector & terminal harness between
(E20) No. 1 — Engine ground: intake air tempera-
ture and pressure
sensor and ECM
connector
• Poor contact in
intake air tempera-
ture and pressure
sensor
• Poor contact in
ECM
• Poor contact in
coupling connector
(B21)
• Poor contact in
joint connector
(B83) and (B122)
EN-124
EN-125
M: DTC P0117 — ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT LOW

INPUT —
• Hard to start
CAUTION:
Clear Memory Mode.> and Inspection Mode <Ref. to EN-42, Operation.> .
• WIRING DIAGRAM:
ENGINE
COOLANT E8
TEMPERATURE
SENSOR 1 2
3
1
2
E8
B122
1 2 3
4 5 6
E2
13
9
B21 B83
1 2 3 4
B21
3 LHD RHD 2 1 2 3 4
5 6 7 8
9 10 11 12
1 LHD RHD 1 13 14 15 16
17 18 19 20
B122 B83
B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
14
16
B136 ECM
EN1404
EN-126
Step Check Yes No

2)Read the data of engine coolant temperature NOTE:
sensor signal using Subaru Select Monitor or In this case, repair
•Subaru Select Monitor engine coolant
For detailed operation procedure, refer to the temperature sen-
“READ CURRENT DATA FOR ENGINE”. sor
For detailed operation procedures, refer to the • Poor contact in
(B21)
• Poor contact in
joint connector
(B83) or (B122)
2 CHECK HARNESS BETWEEN ENGINE Is the value less than −40°C Replace the Repair the ground
COOLANT TEMPERATURE SENSOR AND (−40°F)? engine coolant short circuit in har-
ECM CONNECTOR. temperature sen- ness between
1)Turn the ignition switch to OFF. sor. <Ref. to FU- engine coolant
2)Disconnect the connector from engine cool- 31, Engine Cool- temperature sen-
ant temperature sensor. ant Temperature sor and ECM con-
3)Turn the ignition switch to ON. Sensor.> nector.
4)Read the data of engine coolant temperature
NOTE:
EN-127
N: DTC P0118 — ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT HIGH

INPUT —
• Hard to start
CAUTION:
• WIRING DIAGRAM:
ENGINE
COOLANT E8
TEMPERATURE
SENSOR 1 2
3
1
2
E8
B122
1 2 3
4 5 6
E2
13
9
B21 B83
1 2 3 4
B21
3 LHD RHD 2 1 2 3 4
5 6 7 8
9 10 11 12
1 LHD RHD 1 13 14 15 16
17 18 19 20
B122 B83
B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
14
16
B136 ECM
EN1404
EN-128
Step Check Yes No

(B21)
• Poor contact in
joint connector
(B83) or (B122)
2 CHECK HARNESS BETWEEN ENGINE Is the voltage more than 10 V? Repair the battery Go to step 3.
COOLANT TEMPERATURE SENSOR AND short circuit in har-
ECM CONNECTOR. ness between
1)Turn the 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.
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.
EN-129
Step Check Yes No

4 CHECK HARNESS BETWEEN ENGINE Is the voltage more than 4 V? Go to step 5. Repair the har-
COOLANT TEMPERATURE SENSOR AND ness and connec-
ECM CONNECTOR. tor.
Measure the voltage between engine coolant NOTE:
temperature sensor connector and engine In this case, repair
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
coupling connector
(B21)
• Poor contact in
joint connector
(B83) or (B122)
5 CHECK HARNESS BETWEEN ENGINE Is the resistance less than 5 Replace the Repair the har-
COOLANT TEMPERATURE SENSOR AND Ω? engine coolant ness and connec-
ECM CONNECTOR. temperature sen- tor.
1)Turn the ignition switch to OFF. sor. <Ref. to FU- NOTE:
2)Measure the resistance of harness between 31, Engine Cool- In this case, repair
engine coolant temperature sensor connector ant Temperature the following:
and engine ground. Sensor.> • Open circuit in
(E8) No. 2 — 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
coupling connector
(B21)
• Poor contact in
joint connector
(B83) or (B122)
EN-130
EN-131
O: DTC P0121 — THROTTLE POSITION SENSOR CIRCUIT RANGE/PERFOR-

MANCE PROBLEM (HIGH INPUT) —
• Engine stalls.
CAUTION:
• WIRING DIAGRAM:
THROTTLE
POSITION
SENSOR E13
1 2 3 4
4
3
2
E13
B122
1 2 3
4 5 6
E2
12
11
9
B21 B83
1 2 3 4
B21
3 LHD RHD 2 1 2 3 4
5 6 7 8
9 10 11 12
1 LHD RHD 1
13 14 15 16
17 18 19 20
B122 B83
B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
15
17
16
21 22 23 24 25 26 27 28 29 30
B136 ECM
EN1405
EN-132
Step Check Yes No

1 CHECK ANY OTHER DIAGNOSTIC TROU- Is any other DTC displayed? Inspect the rele- Replace the throt-
BLE CODE (DTC) ON DISPLAY. vant DTC using tle position sensor.
“List of Diagnostic <Ref. to FU-35,
Trouble Code Throttle Position
(DTC)”. <Ref. to Sensor.>
EN-83, List of
Diagnostic Trou-
ble Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0121.
EN-133
P: DTC P0122 — THROTTLE POSITION SENSOR CIRCUIT LOW INPUT —

• Engine stalls.
CAUTION:
• WIRING DIAGRAM:
THROTTLE
POSITION
SENSOR E13
1 2 3 4
4
3
2
E13
B122
1 2 3
4 5 6
E2
12
11
9
B21 B83
1 2 3 4
B21
3 LHD RHD 2 1 2 3 4
5 6 7 8
9 10 11 12
1 LHD RHD 1
13 14 15 16
17 18 19 20
B122 B83
B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
15
17
16
21 22 23 24 25 26 27 28 29 30
B136 ECM
EN1405
EN-134
Step Check Yes No

1 CHECK CURRENT DATA. Is the value less than 0.1 V? Go 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-II 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”. NOTE:
<Ref. to EN-34, Subaru Select Monitor.> In this case, repair
•OBD-II general scan tool the following:
OBD-II General Scan Tool Instruction Manual. throttle position
sensor connector
• Poor contact in
ECM connector
• Poor contact in
coupling connector
(B21)
and chassis ground while throttle valve is fully
closed.
is required, be-
cause probable
cause is deteriora-
tion of multiple
parts.
and chassis ground.
5 CHECK INPUT SIGNAL FOR ECM. (USING Does the voltage change more Repair the poor Go to step 6.
SUBARU SELECT MONITOR.) than 0.1 V by shaking harness contact in ECM
Measure the voltage between ECM connector and connector of ECM while connector.
and chassis ground. monitoring the value with Sub-
aru Select Monitor?
EN-135
Step Check Yes No

6 CHECK HARNESS BETWEEN ECM AND Is the voltage more than 4.5 V? Go to step 7. Repair the har-
THROTTLE POSITION SENSOR CONNEC- ness and connec-
TOR. tor.
2)Disconnect the connectors from throttle posi- In this case, repair
tion sensor. the following:
4)Measure the voltage between throttle posi- harness between
tion sensor connector and engine ground. throttle position
Connector & terminal sensor and ECM
• Poor contact in
throttle position
sensor connector
• Poor contact in
ECM connector
• Poor contact in
coupling connector
(B21)
• Poor contact in
joint connector
(B83) or (B122)
7 CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Go to step 8. Repair the har-
THROTTLE POSITION SENSOR CONNEC- Ω? ness and connec-
TOR. tor.
ECM connector and throttle position sensor the following:
connector. • Open circuit in
(B136) No. 17 — (E13) No. 3: throttle position
sensor and ECM
connector
• Poor contact in
ECM connector
• Poor contact in
throttle position
sensor connector
• Poor contact in
coupling connector
(B21)
THROTTLE POSITION SENSOR CONNEC- Ω? 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.
9 CHECK POOR CONTACT. Is there poor contact in throttle Repair the poor Replace the throt-
Check poor contact in throttle position sensor position sensor connector? contact in throttle tle position sensor.
connector. position sensor <Ref. to FU-35,
connector. Throttle Position
Sensor.>
EN-136
EN-137
Q: DTC P0123 — THROTTLE POSITION SENSOR CIRCUIT HIGH INPUT —

• Engine stalls.
CAUTION:
• WIRING DIAGRAM:
THROTTLE
POSITION
SENSOR E13
1 2 3 4
4
3
2
E13
B122
1 2 3
4 5 6
E2
12
11
9
B21 B83
1 2 3 4
B21
3 LHD RHD 2 1 2 3 4
5 6 7 8
9 10 11 12
1 LHD RHD 1
13 14 15 16
17 18 19 20
B122 B83
B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
15
17
16
21 22 23 24 25 26 27 28 29 30
B136 ECM
EN1405
EN-138
Step Check Yes No

1 CHECK CURRENT DATA. Is the value more than 4.9 V? Go to step 2. Even if MIL lights
<Ref. to EN-34, Subaru Select Monitor.> In this case, repair
•OBD-II general scan tool the following:
OBD-II General Scan Tool Instruction Manual. throttle position
sensor connector
• Poor contact in
ECM connector
• Poor contact in
coupling connector
(B21)
2 CHECK HARNESS BETWEEN THROTTLE Is the resistance less than 5 Go to step 3. Repair the har-
POSITION SENSOR AND ECM CONNEC- Ω? ness and connec-
TOR. tor.
2)Disconnect the connector from throttle posi- In this case, repair
3)Measure the resistance of harness between • Open circuit in
throttle position sensor connector and engine harness between
ground. throttle position
(E13) No. 2 — Engine ground: connector
• Poor contact in
coupling connector
(B21)
• Poor contact in
joint connector
(B83) or (B122)
3 CHECK HARNESS BETWEEN THROTTLE Is the voltage more than 4.9 V? Repair the battery Replace the throt-
POSITION SENSOR AND ECM CONNEC- short circuit in har- tle position sensor.
TOR. ness between <Ref. to FU-35,
1)Turn the ignition switch to ON. throttle position Throttle Position
2)Measure the voltage between throttle posi- sensor and ECM Sensor.>
tion sensor connector and engine ground. connector. After
Connector & terminal repair, replace the
(E13) No. 3 (+) — Engine ground (−): ECM. <Ref. to FU-
51, Engine Con-
trol Module.>
EN-139
R: DTC P0125 — INSUFFICIENT COOLANT TEMPERATURE FOR CLOSED

LOOP FUEL CONTROL —
• Engine would not return to idling.
CAUTION:
• WIRING DIAGRAM:
ENGINE
COOLANT E8
TEMPERATURE
SENSOR 1 2
3
1
2
E8
B122
1 2 3
4 5 6
E2
13
9
B21 B83
1 2 3 4
B21
3 LHD RHD 2 1 2 3 4
5 6 7 8
9 10 11 12
1 LHD RHD 1 13 14 15 16
17 18 19 20
B122 B83
B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
14
16
B136 ECM
EN1404
EN-140
Step Check Yes No

Trouble Code
(DTC)”. <Ref. to
EN-83, List of
Diagnostic Trou-
ble Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect P0125.
2 CHECK THERMOSTAT. Does thermostat remain Replace the ther- Replace the
opened? mostat. <Ref. to engine coolant
CO-37, Thermo- temperature sen-
stat.> sor. <Ref. to FU-
31, Engine Cool-
ant Temperature
Sensor.>
EN-141
S: DTC P0130 — FRONT OXYGEN (A/F) SENSOR CIRCUIT RANGE/PERFOR-

MANCE PROBLEM (LEAN) —
CAUTION:
• WIRING DIAGRAM:
RHD
RHD
SBF-5
1 2
6 LHD 2 LHD
3 4
4
B61 F44 5 6
5
3
2 B18
1
2
1 2 3
(A/F) SENSOR
B18
5
4
6
3
1
F44
1 2 3 4
5 6 7 8
B22
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
A22
A23
C20
C19
C23
C7
C6
A: B134
A: B134 1 2 3 4 5 6 7 8
ECM 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
C: B136 24 25 26 27 28 29 30 31 32 33 34 35
A34
A35
C: B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
B22 21 22 23 24 25 26 27 28 29 30
8
E3
EN1400
Step Check Yes No

Trouble Code
(DTC)”. <Ref. to
EN-83, List of
Diagnostic Trou-
ble Code (DTC).>
EN-142
Step Check Yes No

2 CHECK FRONT OXYGEN (A/F) SENSOR DA- Is the value equal to or more Go to step 3. Go to step 4.
TA. than 0.85 and equal to less
1)Start the engine. than 1.15 in idling?
2)While observing the Subaru Select Monitor
or OBD-II general scan tool screen, warm-up
the engine until coolant temperature is above
70°C (160°F).
If the engine is already warmed-up, operate at
idle speed for at least 1 minute.
signal using Subaru Select Monitor or OBD-II
general scan tool.
NOTE:
3 CHECK FRONT OXYGEN (A/F) SENSOR DA- Is the value more than 1.1 for a Go to step 6. Go to step 4.
TA. moment?
Race the engine at speeds from idling to 5,000
rpm for a total of 5 cycles.
NOTE:
To increase the engine speed to 5,000 rpm,
slowly depress accelerator pedal, taking ap-
proximately 5 seconds, and quickly release ac-
celerator pedal to decrease engine speed.
FRONT OXYGEN (A/F) SENSOR. Ω? circuit between
1)Turn the ignition switch to OFF. ECM and front
2)Disconnect the connector from ECM and oxygen (A/F) sen-
front oxygen (A/F) sensor connector. sor.
3)Measure the resistance between ECM and
front oxygen (A/F) sensor.
Connector & terminals
(B136) No. 6 — (E24) No. 3:
(B136) No. 7 — (E24) No. 4:
(B136) No. 19 — (E24) No. 1:
(B136) No. 20 — (E24) No. 6:
FRONT OXYGEN (A/F) SENSOR. MΩ? short circuit
Measure the resistance between ECM and between ECM and
chassis ground. front oxygen (A/F)
Connector & terminals sensor.
6 CHECK EXHAUST SYSTEM. Is there a fault in exhaust sys- Repair or replace Replace the front
Check the exhaust system parts. tem? the faulty parts. oxygen (A/F) sen-
NOTE: sor. <Ref. to FU-
Check the following items. 47, Front Oxygen
•Loose installation of portions (A/F) Sensor.>
•Damage (crack, hole etc.) of parts
•Looseness of front oxygen (A/F) sensor
•Looseness and ill fitting of parts between front
oxygen (A/F) sensor and rear oxygen sensor
EN-143
T: DTC P0131 — FRONT OXYGEN (A/F) SENSOR CIRCUIT MALFUNCTION

(OPEN CIRCUIT) —
CAUTION:
• WIRING DIAGRAM:
RHD
RHD
SBF-5
1 2
6 LHD 2 LHD
3 4
4
B61 F44 5 6
5
3
2 B18
1
2
1 2 3
(A/F) SENSOR
B18
5
4
6
3
1
F44
1 2 3 4
5 6 7 8
B22
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
A22
A23
C20
C19
C23
C7
C6
A: B134
A: B134 1 2 3 4 5 6 7 8
ECM 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
C: B136 24 25 26 27 28 29 30 31 32 33 34 35
A34
A35
C: B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
B22 21 22 23 24 25 26 27 28 29 30
8
E3
EN1400
EN-144
Step Check Yes No

FRONT OXYGEN (A/F) SENSOR CONNEC- Ω? ness and connec-
TOR. tor.
2)Disconnect the connectors from ECM and In this case, repair
front oxygen (A/F) sensor connector. the following:
ECM and front oxygen (A/F) sensor connector. harness between
Connector & terminal ECM and front
(B136) No. 6 — (E24) No. 3: oxygen (A/F) sen-
(B136) No. 7 — (E24) No. 4: sor connector
(B136) No. 20 — (E24) No. 6: front oxygen (A/F)
sensor connector
• Poor contact in
ECM connector
2 CHECK POOR CONTACT. Is there poor contact in front Repair the poor Replace the front
Check poor contact in front oxygen (A/F) sen- oxygen (A/F) sensor connec- contact in front oxygen (A/F) sen-
sor connector. tor? oxygen (A/F) sensor. <Ref. to FU-
sor connector. 47, Front Oxygen
(A/F) Sensor.>
EN-145
U: DTC P0132 — FRONT OXYGEN (A/F) SENSOR CIRCUIT MALFUNCTION

(SHORT CIRCUIT) —
CAUTION:
• WIRING DIAGRAM:
RHD
RHD
SBF-5
1 2
6 LHD 2 LHD
3 4
4
B61 F44 5 6
5
3
2 B18
1
2
1 2 3
(A/F) SENSOR
B18
5
4
6
3
1
F44
1 2 3 4
5 6 7 8
B22
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
A22
A23
C20
C19
C23
C7
C6
A: B134
A: B134 1 2 3 4 5 6 7 8
ECM 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
C: B136 24 25 26 27 28 29 30 31 32 33 34 35
A34
A35
C: B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
B22 21 22 23 24 25 26 27 28 29 30
8
E3
EN1400
EN-146
Step Check Yes No

1 CHECK HARNESS BETWEEN ECM AND Is the resistance more than 10 Replace the front Repair the ground
FRONT OXYGEN (A/F) SENSOR CONNEC- Ω? oxygen (A/F) sen- short circuit in har-
TOR. sor. <Ref. to FU- ness between
1)Turn the ignition switch to OFF. 47, Front Oxygen ECM and front
2)Disconnect the connector from ECM. (A/F) Sensor.> oxygen (A/F) sen-
3)Measure the resistance of harness between sor connector.
EN-147
V: DTC P0133 — FRONT OXYGEN (A/F) SENSOR CIRCUIT SLOW RESPONSE

—
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN-49, Operation.>
and Inspection Mode <Ref. to EN-42, OPERATION, Inspection Mode.> .
• WIRING DIAGRAM:
RHD
RHD
SBF-5
1 2
6 LHD 2 LHD
3 4
4
B61 F44 5 6
5
3
2 B18
1
2
1 2 3
(A/F) SENSOR
B18
5
4
6
3
1
F44
1 2 3 4
5 6 7 8
B22
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
A22
A23
C20
C19
C23
C7
C6
A: B134
A: B134 1 2 3 4 5 6 7 8
ECM 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
C: B136 24 25 26 27 28 29 30 31 32 33 34 35
A34
A35
C: B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
B22 21 22 23 24 25 26 27 28 29 30
8
E3
EN1400
EN-148
Step Check Yes No

Trouble Code
(DTC)”. <Ref. to
EN-83, List of
Diagnostic Trou-
ble Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0133.
2 CHECK EXHAUST SYSTEM. Is there a fault in exhaust sys- Repair the exhaust Replace the front
NOTE: tem? system. oxygen (A/F) sen-
Check the following items. sor. <Ref. to FU-
•Loose installation of front portion of exhaust 47, Front Oxygen
pipe onto cylinder heads (A/F) Sensor.>
•Loose connection between front exhaust pipe
and front catalytic converter
•Damage of exhaust pipe resulting in a hole
EN-149
W: DTC P0136 — REAR OXYGEN SENSOR CIRCUIT MALFUNCTION —

CAUTION:
• WIRING DIAGRAM:
RHD
RHD
1 2 1 2
6 LHD 2 LHD 3 4 3 4
4 5 6
B61 F44 (LHD)
5
3 2 1
4 3
2
(RHD)
1
2
B47 REAR OXYGEN

SENSOR B83
B19
1 2 3 4
1
B122
1 2 3
4 5 6
F44
5 LHD RHD 4
1 2 3 4
1 LHD RHD 1 5 6 7 8
B122 B83
B22
A21
C18
C16
C24
1 2 3 4
A: B134 5 6 7 8
ECM 9 10 11 12
C: B136 13 14 15 16
C22
A34
A35
C21
C: B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
B22
16
A: B134
8
E3
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25 26 27 28 29 30 31 32 33 34 35
EN1401
Step Check Yes No

indicate DTC P0131 or P0132?
EN-150
Step Check Yes No

2 CHECK FAILURE CAUSE OF P0131 or Is the failure cause of P0131 or Check the fuel Go to step 3.
P0132. P0132 in the fuel system? system.
Inspect the DTC P0131 or P0132 using “17. NOTE:
List of Diagnostic Trouble Code (DTC)”. <Ref. In this case, it is
to EN-83, List of Diagnostic Trouble Code not necessary to
(DTC).> inspect DTC
P0136.
3 CHECK REAR OXYGEN SENSOR DATA. Does the value fluctuate? Go to step 7. Go to step 4.
1)Warm-up the engine until engine coolant
temperature is above 70°C (158°F), and keep
the engine speed at 2,000 rpm to 3,000 rpm for
2 minutes.
2)Read the data of rear oxygen sensor signal
using Subaru Select Monitor or OBD-II general
scan tool.
NOTE:
“READ CURRENT DATA SHOWN ON DIS-
PLAY FOR ENGINE”. <Ref. to EN-34, Subaru
Select Monitor.>
4 CHECK REAR OXYGEN SENSOR DATA. Is the value fixed between 0.2 Go to step 5. Replace the rear
Read the data of rear oxygen sensor signal and 0.4 V? oxygen sensor.
using Subaru Select Monitor or OBD-II general <Ref. to FU-47,
scan tool. Front Oxygen (A/
1)Keep the engine speed at 4,500 rpm for 5 F) Sensor.>
seconds.
2)Release the accelerator quickly and idle the
engine for 10 seconds.
3)Repeat this cycle for three times.
5 CHECK HARNESS BETWEEN ECM AND Is the resistance more than 3 Repair the open Go to step 6.
REAR OXYGEN SENSOR CONNECTOR. Ω? circuit in harness
1)Turn the ignition switch to OFF. between ECM and
2)Disconnect the connectors from ECM and rear oxygen sen-
rear oxygen sensor. sor connector.
ECM and rear oxygen sensor connector.
(B136) No. 16 — (B19) No. 3:
6 CHECK GROUND CIRCUIT ON ECM. Is the resistance less than 5 Go to step 8. Go to step 7.
1)Turn the ignition switch to OFF. Ω?
EN-151
Step Check Yes No

1)Repair the harness and connector. Ω? ness and connec-
ECM connector and chassis ground. NOTE:
• Open circuit in
harness between
ECM and engine
ground terminal
• Poor contact in
ECM connector
• Poor contact in
coupling connector
(B22)
8 CHECK HARNESS BETWEEN REAR OXY- Is the voltage more than 0.2 V? Replace the rear Repair the har-
GEN SENSOR AND ECM CONNECTOR. oxygen sensor. ness and connec-
1)Turn the ignition switch to OFF. <Ref. to FU-47, tor.
2)Disconnect the connector from rear oxygen Front Oxygen (A/ NOTE:
sensor. F) Sensor.> In this case, repair
4)Measure the voltage between rear oxygen • Open circuit in
sensor harness connector and engine ground harness between
or chassis ground. rear oxygen sen-
Connector & terminal sor and ECM con-
(B19) No. 4 (+) — Engine ground (−): nector
• Poor contact in
rear oxygen sen-
sor connector
• Poor contact in
ECM connector
9 CHECK EXHAUST SYSTEM. Is there a fault in exhaust sys- Repair or replace Replace the rear
Check the exhaust system parts. tem? the faulty parts. oxygen sensor.
NOTE: <Ref. to FU-47,
Check the following items. Front Oxygen (A/
•Loose installation of portions F) Sensor.>
EN-152
EN-153
X: DTC P0139 — REAR OXYGEN SENSOR CIRCUIT SLOW RESPONSE —

CAUTION:
• WIRING DIAGRAM:
RHD
RHD
1 2 1 2
6 LHD 2 LHD 3 4 3 4
4 5 6
B61 F44 (LHD)
5
3 2 1
4 3
2
(RHD)
1
2
B47 REAR OXYGEN

SENSOR B83
B19
1 2 3 4
1
B122
1 2 3
4 5 6
F44
5 LHD RHD 4
1 2 3 4
1 LHD RHD 1 5 6 7 8
B122 B83
B22
A21
C18
C16
C24
1 2 3 4
A: B134 5 6 7 8
ECM 9 10 11 12
C: B136 13 14 15 16
C22
A34
A35
C21
C: B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
B22
16
A: B134
8
E3
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25 26 27 28 29 30 31 32 33 34 35
EN1401
EN-154
Step Check Yes No

1 CHECK ANY OTHER DIAGNOSTIC TROU- Is any other DTC displayed? Inspect the rele- Replace the rear
BLE CODE (DTC) ON DISPLAY. vant DTC using oxygen sensor.
Trouble Code Front Oxygen (A/
(DTC)”. <Ref. to F) Sensor.>
EN-83, List of
Diagnostic Trou-
ble Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0139.
EN-155
Y: DTC P0170 — FUEL TRIM MALFUNCTION —

• Engine stalls.
CAUTION:
Step Check Yes No

1 CHECK EXHAUST SYSTEM. Are there holes or loose bolts Repair the exhaust Go to step 2.
on exhaust system? system.
intake system?
3 CHECK FUEL PRESSURE. Is the fuel pressure between Go to step 4. Repair the follow-
Warning: 284 — 314 kPa (2.9 — 3.2 ing items.
•Place “NO FIRE” signs near the working kg/cm2, 41 — 46 psi)? Fuel pressure too
area. high:
•Be careful not to spill fuel on the floor. • Clogged fuel
1)Release the 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 5 • Clogged fuel
more seconds. supply line
(4) Turn the ignition switch to OFF. • Improper fuel
2)Connect the connector to fuel pump relay. pump discharge
3)Disconnect the fuel delivery hose from fuel
filter, and connect fuel pressure gauge.
4)Install the fuel filler cap.
5)Start the engine and idle while gear position
is neutral.
6)Measure the fuel pressure while disconnect-
ing pressure regulator vacuum hose from
intake manifold.
Warning:
Before removing the fuel pressure gauge,
release the fuel pressure.
NOTE:
If the fuel pressure does not increase, squeeze
the fuel return hose 2 to 3 times, then measure
fuel pressure again.
EN-156
Step Check Yes No

After connecting the pressure regulator vac- 206 — 235 kPa (2.1 — 2.4 ing items.
uum hose, measure the fuel pressure. kg/cm2, 30 — 34 psi)? Fuel pressure too
Warning: high:
Before removing the fuel pressure gauge, • Faulty pres-
release fuel pressure. sure regulator
NOTE: • Clogged fuel
•If the fuel pressure does not increase, return line or
squeeze the fuel return hose 2 to 3 times, then bent hose
measure fuel pressure again. Fuel pressure too
•If out of specification as measured at this low:
step, check or replace the pressure regulator • Faulty pres-
and pressure regulator vacuum hose. sure regulator
• Improper fuel
pump discharge
• Clogged fuel
supply line
5 CHECK ENGINE COOLANT TEMPERATURE Is the temperature between Go to step 6. Replace the
SENSOR. 70°C (158°F) and 100°C engine coolant
1)Start the engine and warm-up completely. (212°F)? temperature sen-
2)Read the data of engine coolant temperature sor. <Ref. to FU-
sensor signal using Subaru Select Monitor or 31, Engine Cool-
OBD-II general scan tool. ant Temperature
NOTE: Sensor.>
6 CHECK INTAKE MANIFOLD PRESSURE Is the voltage within the speci- Contact with your Replace the intake
SENSOR SIGNAL. fications? Subaru distributor air temperature
1)Start the engine and warm-up engine until service. and pressure sen-
coolant temperature is greater than 60°C NOTE: sor. <Ref. to FU-
(140°F). Inspection by DTM 37, Intake Air
2)Place the selector lever in “N” or “P” position. is required, be- Temperature and
3)Turn the A/C switch to OFF. cause probable Pressure Sensor.>
4)Turn all accessory switches to OFF. cause is deteriora-
5)Read the data of intake manifold pressure tion of multiple
sensor signal using Subaru Select Monitor or parts.
NOTE:
Specification:
Idling
24.0 — 41.3 kPa (180 — 310 mmHg, 7.09
— 12.20 inHg)
Ignition ON
73.3 — 106.6 kPa (550 — 800 mmHg,
21.65 — 31.50 inHg)
EN-157
Z: DTC P0301 — CYLINDER 1 MISFIRE DETECTED —

NOTE:
For the diagnostic procedure, refer to DTC P0304. <Ref. to EN-160, DTC P0304 — CYLINDER 4 MISFIRE
DETECTED —, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
AA:DTC P0302 — CYLINDER 2 MISFIRE DETECTED —
NOTE:
AB:DTC P0303 — CYLINDER 3 MISFIRE DETECTED —
NOTE:
EN-158
EN-159
AC:DTC P0304 — CYLINDER 4 MISFIRE DETECTED —

• Immediately at fault recognition (A misfire which could damage catalyst occurs.)
• Engine stalls.
• Rough driving
CAUTION:
• WIRING DIAGRAM:
MAIN RELAY
4 RHD
BATTERY
RHD
6
SBF-5
5 LHD 2 LHD
3
B61 F44
2
1
B47
C2
C1
A: B134 C: B136 ECM

A13
A14
A15
A4
B22
10
11
12
1
E3
E5 E16 E6 E17
2

No.1 No.2 No.3 No.4
E5 E16 B47 F44 B22
E6 E17 1 2 1 2 3 4 1 2 3 4
3 4 5 6 7 8 5 6 7 8
1 2 5 6 9 10 11 12
13 14 15 16
C: B136 A: B134
1 2 3 4 5 6 7 1 2 3 4 5 6 7 8
8 9 10 11 12 13 14 15 16 17 18 19 20 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
21 22 23 24 25 26 27 28 29 30 24 25 26 27 28 29 30 31 32 33 34 35
EN0866
EN-160
Step Check Yes No

Trouble Code
(DTC)”. <Ref. to
EN-83, List of
Diagnostic Trou-
ble Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect P0301,
P0302, P0303,
P0304.
tor and chassis ground on faulty cylinders.
#1 (B134) No. 4 (+) — Chassis ground
(−):
(−):
(−):
(−):
3 CHECK HARNESS BETWEEN FUEL INJEC- Is the resistance less than 10 Repair the ground Go to step 4.
TOR AND ECM CONNECTOR. Ω? short circuit in har-
1)Turn the ignition switch to OFF. ness between fuel
2)Disconnect the connector from fuel injector injector and ECM
on faulty cylinders. connector.
3)Measure the resistance between ECM con-
nector and engine ground on faulty cylinders.
#1 (E5) No. 1 — Engine ground:
4 CHECK HARNESS BETWEEN FUEL INJEC- Is the resistance less than 1 Go to step 5. Repair the har-
TOR AND ECM CONNECTOR. Ω? ness and connec-
Measure the resistance of harness connector tor.
between ECM connector and fuel injector on NOTE:
faulty cylinders. In this case, repair
#1 (B134) No. 4 — (E5) No. 1: • Open circuit in
#2 (B134) No. 13 — (E16) No. 1: harness between
#3 (B134) No. 14 — (E6) No. 1: ECM and fuel
#4 (B134) No. 15 — (E17) No. 1: injector connector
• Poor contact in
coupling connector
(B22)
5 CHECK FUEL INJECTOR. Is the resistance between 5 Go to step 6. Replace the faulty
Measure the resistance between fuel injector and 20 Ω? fuel injector. <Ref.
terminals on faulty cylinder. to FU-41, Fuel
Terminals Injector.>
No. 1 — No. 2:
EN-161
Step Check Yes No

6 CHECK POWER SUPPLY LINE. Is the voltage more than 10 V? Repair the poor Repair the har-
1)Turn the ignition switch to ON. contact in all con- ness and connec-
2)Measure the voltage between fuel injector nectors in fuel tor.
and engine ground on faulty cylinders. injector circuit. NOTE:
#1 (E5) No. 2 (+) — Engine ground (−): the following:
#2 (E16) No. 2 (+) — Engine ground (−): • Open circuit in
#3 (E6) No. 2 (+) — Engine ground (−): harness between
#4 (E17) No. 2 (+) — Engine ground (−): main relay and fuel
injector connector
on faulty cylinders
• Poor contact in
coupling connector
• Poor contact in
main relay con-
nector
• Poor contact in
fuel injector con-
nector on faulty
cylinders
7 CHECK HARNESS BETWEEN FUEL INJEC- Is the voltage more than 10 V? Repair the battery Go to step 8.
TOR AND ECM CONNECTOR. short circuit in har-
2)Disconnect the connector from fuel injector ECM and fuel
on faulty cylinder. injector. After
3)Turn the ignition switch to ON. repair, replace
4)Measure the voltage between ECM connec- ECM. <Ref. to FU-
tor and chassis ground on faulty cylinders. 51, Engine Con-
Connector & terminal trol Module.>
(−):
(−):
(−):
(−):
8 CHECK FUEL INJECTOR. Is the resistance less than 1 Replace the faulty Go to step 9.
1)Turn the ignition switch to OFF. Ω? fuel injector <Ref.
2)Measure the resistance between fuel injector to FU-41, Fuel
terminals on faulty cylinder. Injector.> and
Terminals ECM <Ref. to FU-
No. 1 — No. 2: 51, Engine Con-
trol Module.>
9 CHECK INSTALLATION OF CAMSHAFT PO- Is the camshaft position sensor Tighten the cam- Go to step 10.
SITION SENSOR/CRANKSHAFT POSITION or crankshaft position sensor shaft position sen-
SENSOR. loosely installed? sor or crankshaft
position sensor.
10 CHECK CRANKSHAFT SPROCKET. Is the crankshaft sprocket Replace the crank- Go to step 11.
Remove the timing belt cover. rusted or does it have broken shaft sprocket.
teeth? <Ref. to ME-56,
Crankshaft
Sprocket.>
11 CHECK INSTALLATION CONDITION OF Is the timing belt dislocated Repair the installa- Go to step 12.
TIMING BELT. from its proper position? tion condition of
Turn the crankshaft using ST, and align the timing belt. <Ref.
alignment mark on crankshaft sprocket with to ME-49, Timing
alignment mark on cylinder block. Belt Assembly.>
EN-162
Step Check Yes No

12 CHECK FUEL LEVEL. Is the fuel meter indication Go to step 13. Replenish the fuel
higher than the “Lower” level? so fuel meter indi-
cation is higher
than the “Lower”
level. After replen-
ishing fuel; Go to
step 13.
13 CHECK STATUS OF CHECK ENGINE MAL- Is the MIL coming on or blink- Go to step 15. Go to step 14.
FUNCTION INDICATOR LAMP (MIL). ing?
1)Clear the memory using Subaru Select Mon-
itor.
<Ref. to EN-49, Clear Memory Mode.>
2)Start engine, and drive the vehicle more than
10 minutes.
14 CHECK CAUSE OF MISFIRE DIAGNOSED. Was the cause of misfire diag- Finish the diag- Repair the poor
nosed when the engine is run- nostics operation, contact.
ning? if the engine has NOTE:
no abnormality. In this case, repair
Ex. Remove spark • Poor contact in
plug cord, etc. ignitor connector
• 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 connector
15 CHECK AIR INTAKE SYSTEM. Is there a fault in air intake sys- Repair the air Go to step 16.
tem? intake 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?
16 CHECK MISFIRE SYMPTOM. Does the Subaru Select Moni- Go to step 21. Go to step 17.
1)Turn the ignition switch to ON. tor or OBD-II general scan tool
2)Read the DTC. indicate only one DTC?
OBD-II General Scan Tool Operation Manual.
NOTE:
Perform diagnosis according to the items listed
below.
17 CHECK DIAGNOSTIC TROUBLE CODE Does the Subaru Select Moni- Go to step 22. Go to step 18.
(DTC) ON DISPLAY. tor or OBD-II general scan tool
P0302?
EN-163
Step Check Yes No

P0304?
P0303?
P0304?
21 ONLY ONE CYLINDER Is there a fault in that cylinder? Repair or replace Go to DTC P0170.
the faulty parts. <Ref. to EN-156,
NOTE: DTC P0170 —
Check the follow- FUEL TRIM MAL-
ing items. FUNCTION —,
• Spark plug Diagnostic Proce-
• Spark plug cord dure with Diagnos-
• Fuel injector tic Trouble Code
• Compression (DTC).>
ratio
22 GROUP OF #1 AND #2 CYLINDERS Are there faults in #1 and #2 Repair or replace Go to DTC P0170.
cylinders? the faulty parts. <Ref. to EN-156,
NOTE: DTC P0170 —
• Check the fol- FUEL TRIM MAL-
lowing items. FUNCTION —,
• Spark plugs Diagnostic Proce-
• Fuel injectors dure with Diagnos-
• Ignition coil tic Trouble Code
• Compres- (DTC).>
sion ratio
• If no abnormal is
discovered, check
for “IGNITION
CONTROL SYS-
TEM” of #1 and #2
cylinders side.
<Ref. to EN-72,
IGNITION CON-
TROL SYSTEM,
Diagnostics for
Engine Starting
Failure.>
EN-164
Step Check Yes No

NOTE: DTC P0170 —
• Check the fol- FUEL TRIM MAL-
lowing items. FUNCTION —,
• Ignition coil tic Trouble Code
• If no abnormal is (DTC).>
discovered, check
for “16. D: IGNI-
TION CONTROL
SYSTEM” of #3
and #4 cylinders
side. <Ref. to EN-
72, IGNITION
CONTROL SYS-
TEM, Diagnostics
for Engine Start-
ing Failure.>
NOTE: DTC P0170 —
• Skipping timing tic Trouble Code
belt teeth (DTC).>
NOTE: DTC P0170 —
• Compression tic Trouble Code
ratio (DTC).>
• Skipping timing
belt teeth
26 CYLINDER AT RANDOM Is the engine idle rough? Go to DTC P0170. Repair or replace
<Ref. to EN-156, the faulty parts.
DTC P0170 — NOTE:
FUEL TRIM MAL- Check the follow-
FUNCTION —, ing items.
Diagnostic Proce- • Spark plugs
dure with Diagnos- • Fuel injectors
tic Trouble Code • Compression
(DTC).> ratio
EN-165
AD:DTC P0327 — KNOCK SENSOR CIRCUIT LOW INPUT —

• Knocking occurs.
CAUTION:
• WIRING DIAGRAM:
E14
1 2
KNOCK
SENSOR
B83
2
E14
1 2 3
4 5 6
B21
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
17 18 19 20
E2
16
B21
B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
1
4
B83
LHD
LHD
RHD RHD
25
4
B136 ECM
EN1406
EN-166
Step Check Yes No

1 CHECK HARNESS BETWEEN KNOCK SEN- Is the resistance more than Go to step 2. Repair the har-
SOR AND ECM CONNECTOR. 700 kΩ? ness and connec-
3)Measure the resistance between ECM har- In this case, repair
ness connector and chassis ground. the following:
knock sensor and
ECM connector
• Poor contact in
knock sensor con-
nector
• Poor contact in
coupling connector
(B21)
2 CHECK KNOCK SENSOR. Is the resistance more than Go to step 3. Repair the har-
1)Disconnect the connector from knock sen- 700 kΩ? ness and connec-
sor. tor.
2)Measure the resistance between knock sen- NOTE:
sor connector terminal and engine ground. In this case, repair
Terminal the following:
No. 2 — Engine ground: • Open circuit in
harness between
knock sensor and
ECM connector
• Poor contact in
knock sensor con-
nector
• Poor contact in
coupling connector
(B21)
3 CHECK CONDITION OF KNOCK SENSOR Is the knock sensor installa- Replace the knock Tighten the knock
INSTALLATION. tion bolt tightened securely? sensor. <Ref. to sensor installation
FU-34, Knock bolt securely.
Sensor.>
EN-167
AE:DTC P0328 — KNOCK SENSOR CIRCUIT HIGH INPUT —

CAUTION:
• WIRING DIAGRAM:
E14
1 2
KNOCK
SENSOR
B83
2
E14
1 2 3
4 5 6
B21
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
17 18 19 20
E2
16
B21
B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
1
4
B83
LHD
LHD
RHD RHD
25
4
B136 ECM
EN1406
Step Check Yes No

1 CHECK HARNESS BETWEEN KNOCK SEN- Is the resistance less than 400 Go to step 2. Go to step 3.
SOR AND ECM CONNECTOR. kΩ?
Measure the resistance of harness between
EN-168
Step Check Yes No

2 CHECK KNOCK SENSOR. Is the resistance less than 400 Replace the knock Repair the ground
1)Disconnect the connector from knock sen- kΩ? sensor. <Ref. to short circuit in har-
sor. FU-34, Knock ness between
2)Measure the resistance between knock sen- Sensor.> knock sensor con-
sor connector terminal and engine ground. nector and ECM
Terminal connector.
No. 2 — Engine ground: NOTE:
The harness be-
tween both con-
nectors is
shielded. Repair
the short circuit of
harness together
with shield.
3 CHECK INPUT SIGNAL FOR ECM. Is the voltage more than 2 V? Even if MIL lights Repair the poor
1)Connect the connectors to ECM and knock up, the circuit has contact in ECM
sensor. returned to a nor- connector.
2)Turn the ignition switch to ON. mal condition at
3)Measure the voltage between ECM and this time. (How-
chassis ground. ever, the possibil-
Connector & terminal ity of poor contact
(B136) No. 4 (+) — Chassis ground (−): still remains.)
NOTE:
In this case, repair
the following:
• Poor contact in
knock sensor con-
nector
• Poor contact in
ECM connector
• Poor contact in
coupling connector
(B21)
EN-169
AF:DTC P0335 — CRANKSHAFT POSITION SENSOR CIRCUIT MALFUNCTION

—
• Engine stalls.
• Failure of engine to start
CAUTION:
• WIRING DIAGRAM:
1 WITH E10
CRANKSHAFT
IMMOBILIZER:2
POSITION
WITHOUT 1 2
SENSOR
IMMOBILIZER:1
2 LHD:19
RHD:20
2
1
E10
B21
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
E2 17 18 19 20
2
17
B21
B135
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 28
1
10
9
B135 ECM
EN1407
EN-170
Step Check Yes No

1 CHECK HARNESS BETWEEN CRANK- Is the resistance more than Repair the har- Go to step 2.
SHAFT POSITION SENSOR AND ECM CON- 100 kΩ? ness and connec-
NECTOR. tor.
2)Disconnect the connector from crankshaft In this case, repair
position sensor. the following:
crankshaft position sensor connector and harness between
engine ground. crankshaft posi-
Connector & terminal tion sensor and
(E10) No. 1 — Engine ground: ECM connector
• Poor contact in
ECM connector
• Poor contact in
coupling connector
(B21)
2 CHECK HARNESS BETWEEN CRANK- Is the resistance less than 10 Repair the ground Go to step 3.
SHAFT POSITION SENSOR AND ECM CON- Ω? short circuit in har-
Measure the resistance of harness between crankshaft posi-
crankshaft position sensor connector and tion sensor and
engine ground. ECM connector.
(E10) No. 1 — Engine ground: The harness be-
tween both con-
nectors are
shielded. Repair
ground short circuit
in harness togeth-
er with shield.
3 CHECK HARNESS BETWEEN CRANK- Is the resistance less than 5 Go to step 4. Repair the har-
SHAFT POSITION SENSOR AND ECM CON- Ω? ness and connec-
NECTOR. tor.
crankshaft position sensor connector and In this case, repair
crankshaft posi-
tion sensor and
ECM connector
• Poor contact in
ECM connector
• Poor contact in
coupling connector
(B21)
4 CHECK CONDITION OF CRANKSHAFT PO- Is the crankshaft position sen- Go to step 5. Tighten the crank-
SITION SENSOR. sor installation bolt tightened shaft position sen-
securely? sor installation bolt
securely.
5 CHECK CRANKSHAFT POSITION SENSOR. Is the resistance between 1 Repair the poor Replace the crank-
1)Remove the crankshaft position sensor. and 4 kΩ? contact in crankshaft position sen-
2)Measure the resistance between connector shaft position sensor. <Ref. to FU-
terminals of crankshaft position sensor. sor connector. 32, Crankshaft
Terminals Position Sensor.>
No. 1 — No. 2:
EN-171
AG:DTC P0336 — CRANKSHAFT POSITION SENSOR CIRCUIT RANGE/PER-

• Engine stalls.
CAUTION:
• WIRING DIAGRAM:
1 WITH E10
CRANKSHAFT
IMMOBILIZER:2
POSITION
WITHOUT 1 2
SENSOR
IMMOBILIZER:1
2 LHD:19
RHD:20
2
1
E10
B21
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
E2 17 18 19 20
2
17
B21
B135
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 28
1
10
9
B135 ECM
EN1407
EN-172
Step Check Yes No

1 CHECK ANY OTHER DIAGNOSTIC TROU- Does the Subaru Select Moni- Inspect DTC Go to step 2.
BLE CODE (DTC) ON DISPLAY. tor or OBD-II general scan tool P0335 using “List
indicate DTC P0335? of Diagnostic
Trouble Code
(DTC)”. <Ref. to
EN-83, List of
Diagnostic Trou-
ble Code (DTC).>
Turn the ignition switch to OFF. securely? sor installation bolt
securely.
3 CHECK CRANKSHAFT SPROCKET. Are the crankshaft sprocket Replace the crank- Go to step 4.
Remove the front belt cover. teeth cracked or damaged? shaft sprocket.
<Ref. to ME-56,
Crankshaft
Sprocket.>
4 CHECK INSTALLATION CONDITION OF Is the timing belt dislocated Repair the installa- Replace the crank-
TIMING BELT. from its proper position? tion condition of shaft position sen-
Turn the crankshaft using ST, and align the timing belt. <Ref. sor. <Ref. to <Ref.
alignment mark on crankshaft sprocket with to ME-49, Timing to FU-32, Crank-
alignment mark on cylinder block. Belt Assembly.> shaft Position Sen-
ST 499987500 CRANKSHAFT SOKET sor.>
EN-173
AH:DTC P0340 — CAMSHAFT POSITION SENSOR CIRCUIT MALFUNCTION —

• Engine stalls.
CAUTION:
• WIRING DIAGRAM:
CAMSHAFT 1 WITH IMMOBILIZER:1

POSITION WITHOUT IMMOBILIZER:2
SENSOR
2 LHD:20 E15
RHD:19
1 2
1
2
E15
B21
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
17 18 19 20
E2
2
18
B21
B135
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 28
1
10
8
B135 ECM
EN1408
EN-174
Step Check Yes No

1 CHECK HARNESS BETWEEN CAMSHAFT Is the resistance more than Repair the har- Go to step 2.
POSITION SENSOR AND ECM CONNEC- 100 kΩ? ness and connec-
TOR. tor.
2)Disconnect the connector from camshaft In this case, repair
camshaft position sensor connector and harness between
engine ground. camshaft position
• Poor contact in
ECM connector
• Poor contact in
coupling connector
(B21)
2 CHECK HARNESS BETWEEN CAMSHAFT Is the resistance less than 10 Repair the ground Go to step 3.
POSITION SENSOR AND ECM CONNEC- Ω? short circuit in har-
TOR. ness between
Measure the resistance of harness between camshaft position
camshaft position sensor connector and sensor and ECM
tween both con-
nectors are
shielded. Repair
in harness togeth-
er with shield.
3 CHECK HARNESS BETWEEN CAMSHAFT Is the resistance less than 5 Go to step 4. Repair the har-
TOR. tor.
camshaft position sensor connector and In this case, repair
camshaft position
sensor and ECM
connector
• Poor contact in
ECM connector
• Poor contact in
coupling connector
(B21)
4 CHECK CONDITION OF CAMSHAFT POSI- Is the camshaft position sensor Go to step 5. Tighten the cam-
TION SENSOR. installation bolt tightened shaft position sen-
securely.
5 CHECK CAMSHAFT POSITION SENSOR. Is the resistance between 1 Repair the poor Replace the cam-
1)Remove the camshaft position sensor. and 4 kΩ? contact in camshaft position sen-
2)Measure the resistance between connector shaft position sensor. <Ref. to FU-
terminals of camshaft position sensor. sor connector. 33, Camshaft
No. 1 — No. 2:
EN-175
AI: DTC P0341 — CAMSHAFT POSITION SENSOR CIRCUIT RANGE/PERFOR-

MANCE PROBLEM —
• Engine stalls.
CAUTION:
• WIRING DIAGRAM:
CAMSHAFT 1 WITH IMMOBILIZER:1

POSITION WITHOUT IMMOBILIZER:2
SENSOR
2 LHD:20 E15
RHD:19
1 2
1
2
E15
B21
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
17 18 19 20
E2
2
18
B21
B135
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 28
1
10
8
B135 ECM
EN1408
EN-176
Step Check Yes No

1 CHECK ANY OTHER DIAGNOSTIC TROU- Does the Subaru Select Moni- Inspect DTC Go to step 2.
BLE CODE (DTC) ON DISPLAY. tor or OBD-II general scan tool P0340 using “List
Trouble Code
(DTC)”. <Ref. to
EN-83, List of
Diagnostic Trou-
ble Code (DTC).>
TOR. tor.
• Poor contact in
ECM connector
• Poor contact in
coupling connector
(B21)
TOR. ness between
tween both con-
nectors are
shielded. Repair
in harness togeth-
er with shield.
TOR. tor.
camshaft position
sensor and ECM
connector
• Poor contact in
ECM connector
• Poor contact in
coupling connector
(B21)
securely.
EN-177
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 kΩ? shaft position sen-
2)Measure the resistance between connector sor. <Ref. to FU-
terminals of camshaft position sensor. 33, Camshaft
No. 1 — No. 2:
securely.
8 CHECK CAMSHAFT SPROCKET. Are the camshaft sprocket Replace the cam- Go to step 9.
Remove the front belt cover. <Ref. to ME-48, teeth cracked or damaged? shaft sprocket.
Belt Cover.> <Ref. to ME-54,
Camshaft
Sprocket.>
9 CHECK INSTALLATION CONDITION OF Is the timing belt dislocated Repair the installa- Replace the cam-
Turn the camshaft using ST, and align the timing belt. <Ref. sor. <Ref. to FU-
alignment mark on camshaft sprocket with to ME-49, Timing 33, Camshaft
alignment mark on timing belt cover LH. Belt Assembly.> Position Sensor.>
WRENCH
NOTE:
(499207100) can be used.
EN-178
AJ:DTC P0420 — CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD —

• Engine stalls.
• Idle mixture is out of specifications.
CAUTION:
EN-179
• WIRING DIAGRAM:
MAIN RELAY BATTERY
RHD
RHD
SBF-5
6 LHD 2 LHD
4
B61 F44
5
3
2
1
B47
2
2
REAR FRONT OXYGEN

OXYGEN (A/F) SENSOR
SENSOR E18
B19
3
1
4
6
3
1
5 LHD RHD 4
1 LHD RHD 1
B122 B83
C16
A21
C18
C24
A22
A23
C20
C19
C23
C7
C6
A: B134 C: B136 ECM

C21
C22
B22
16
E3
B19 B18 B122 B47 F44 E1 B83
1 2 1 2 3 1 2 1 2 3 4 1 2 3 4
1 2 3 1 2 3 4
3 4 4 5 6 3 4 5 6 7 8
4 5 6 5 6 7
5 6
(LHD) 8 9 10
C: B136 A: B134 B22

2 1
4 3 1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 1 2 3 4
(RHD) 8 9 10 11 12 13 14 15 16 17 18 19 20 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 5 6 7 8
21 22 23 24 25 26 27 28 29 30 24 25 26 27 28 29 30 31 32 33 34 35 9 10 11 12
13 14 15 16
EN1409
EN-180
Step Check Yes No

Trouble Code
(DTC)”. <Ref. to
EN-83, List of
Diagnostic Trou-
ble Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0420.
2 CHECK EXHAUST SYSTEM. Is there a fault in exhaust sys- Repair or replace Go to step 3.
Check for gas leaks or air suction caused by tem? the exhaust sys-
loose or dislocated nuts and bolts, and open tem. <Ref. to EX-
hole at exhaust pipes. 2, General
NOTE: Description.>
Check the following positions.
•Between cylinder head and front exhaust pipe
•Between front exhaust pipe and front catalytic
converter
•Between front catalytic converter and rear cat-
alytic converter
3 CHECK REAR CATALYTIC CONVERTER. Is there damage at rear face of Replace the front Go to step 4.
Separate the rear catalytic converter from rear rear catalyst? catalytic converter
exhaust pipe. <Ref. to EC-3,
Front Catalytic
Converter.> and
rear catalytic con-
verter <Ref. to EC-
6, Rear Catalytic
Converter.>.
4 CHECK FRONT CATALYTIC CONVERTER. Is there damage at rear face or Replace the front Go to step 5.
Remove the front catalytic converter. front face of front catalyst? catalytic con-
verter. <Ref. to
EC-3, Front Cata-
lytic Converter.>
5 CHECK REAR OYXGEN SENSOR HARNESS Is there damage or open on Repair the har- Go to step 6.
SHIELD. the rear oxygen sensor harness and connec-
Visually check the rear oxygen sensor harness ness shield? tor
shield for damage or open.
6 CHECK GROUND CIRCUIT ON ECM. Is the resistance less than 5 Go to step 7. Repair the har-
ECM connector and chassis ground. In this case, repair
(B136) No. 21 — Chassis ground: • Open circuit in
harness between
ECM and engine
ground terminal
• Poor contact in
ECM connector
• Poor contact in
coupling connector
(B22)
EN-181
Step Check Yes No

7 CHECK GROUND CIRCUIT OF ECM. Is the resistance less than 5 Contact with your Repair the har-
1)Repair the harness and connector. Ω? Subaru distributor ness and connec-
2)Measure the resistance of harness between service. tor.
ECM connector and chassis ground. NOTE: NOTE:
Connector & terminal Inspection by DTM In this case, repair
(B136) No. 22 — Chassis ground: is required, be- the following:
cause probable • Open circuit in
cause is deteriora- harness between
tion of multiple ECM and engine
parts. ground terminal
• Poor contact in
ECM connector
• Poor contact in
coupling connector
(B22)
EN-182
EN-183
AK:DTC P0444 — EVAPORATIVE EMISSION CONTROL SYSTEM PURGE CON-

TROL VALVE CIRCUIT LOW INPUT —
CAUTION:
• WIRING DIAGRAM:
MAIN RELAY
4 BATTERY
RHD
RHD
6
SBF-5
E4
5 LHD 2 LHD
3
B61 F44 1 2
2
1
B47
F44
1 2 3 4
5 6 7 8
B134 ECM B47
1 2
3 4
5 6
2
B22
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
B22
1
2
E3
B134
E4 1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
1
2
24 25 26 27 28 29 30 31 32 33 34 35
PURGE CONTROL
SOLENOID VALVE
EN1410
EN-184
Step Check Yes No

1 CHECK OUTPUT SIGNAL FROM ECM. Is the voltage more than 10 V? Even if MIL lights Go 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
(B134) No. 2 (+) — Chassis ground (−): with your Subaru
distributor service.
NOTE:
Inspection by DTM
is required, be-
cause probable
cause is deteriora-
tion of multiple
parts.
2 CHECK HARNESS BETWEEN PURGE CON- Is the resistance less than 10 Repair the ground Go to step 3.
TROL SOLENOID VALVE AND ECM CON- Ω? short circuit in har-
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.
purge control solenoid valve connector and
engine ground.
3 CHECK HARNESS BETWEEN PURGE CON- Is the resistance less than 1 Go to step 4. Repair the open
TROL SOLENOID VALVE AND ECM CON- Ω? circuit in harness
NECTOR. between ECM and
Measure the resistance of harness between purge control sole-
ECM and purge control solenoid valve of har- noid valve connec-
ness connector. tor.
(B134) No. 2 — (E4) No. 2: In this case, repair
the following:
• Open circuit in
harness between
ECM and purge
control solenoid
valve connector
• Poor contact in
coupling connector
(B22)
4 CHECK PURGE CONTROL SOLENOID Is the resistance between 10 Go to step 5. Replace the purge
VALVE. and 100 Ω? control solenoid
1)Remove the purge control solenoid valve. valve. <Ref. to EC-
2)Measure the resistance between purge con- 8, Purge Control
trol solenoid valve terminals. Solenoid Valve.>
Terminals
No. 1 — No. 2:
5 CHECK POWER SUPPLY TO PURGE CON- Is the voltage more than 10 V? Go to step 6. Repair the open
TROL SOLENOID VALVE. circuit in harness
1)Turn the ignition switch to ON. between main
2)Measure the voltage between purge control relay and purge
solenoid valve and engine ground. control solenoid
EN-185
Step Check Yes No

6 CHECK POOR CONTACT. Is there poor contact in purge Repair the poor Contact with your
Check poor contact in purge control solenoid control solenoid valve connec- contact in purge Subaru distributor
valve connector. tor? control solenoid service.
valve connector. NOTE:
Inspection by DTM
is required, be-
cause probable
cause is deteriora-
tion of multiple
parts.
EN-186
EN-187
AL:DTC P0445 — EVAPORATIVE EMISSION CONTROL SYSTEM PURGE CON-

TROL VALVE CIRCUIT HIGH INPUT —
CAUTION:
• WIRING DIAGRAM:
MAIN RELAY
4 BATTERY
RHD
RHD
6
SBF-5
E4
5 LHD 2 LHD
3
B61 F44 1 2
2
1
B47
F44
1 2 3 4
5 6 7 8
B134 ECM B47
1 2
3 4
5 6
2
B22
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
B22
1
2
E3
B134
E4 1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
1
2
24 25 26 27 28 29 30 31 32 33 34 35
PURGE CONTROL
SOLENOID VALVE
EN1410
EN-188
Step Check Yes No

1 CHECK OUTPUT SIGNAL FROM ECM. Does voltage change between Go to step 2. Even if MIL light
1)Turn the ignition switch to OFF. 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). this time. In this
3)Turn the ignition switch to ON. case, repair the
4)While operating the purge control solenoid poor contact in
valve, measure the voltage between ECM and ECM connector.
chassis ground.
NOTE:
Purge control solenoid valve operation can be
executed using the Subaru Select Monitor. For
procedure, refer to “Compulsory Valve Opera-
tion Check Mode”. <Ref. to EN-50, Compulsory
Valve Operation Check Mode.>
chassis ground.
Module.>
4 CHECK HARNESS BETWEEN PURGE CON- Is the voltage more than 10 V? Repair the battery Go to step 5.
TROL SOLENOID VALVE AND ECM CON- short circuit in har-
2)Disconnect the 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-51,
Connector & terminal Engine Control
(B134) No. 2 (+) — Chassis ground (−): Module.>
5 CHECK PURGE CONTROL SOLENOID Is the resistance less than 1 Replace the purge Go to step 6.
VALVE. Ω? control solenoid
1)Turn the ignition switch to OFF. valve <Ref. to EC-
2)Measure the resistance between purge con- 8, Purge Control
trol solenoid valve terminals. Solenoid Valve.>
Terminals and ECM <Ref. to
No. 1 — No. 2: FU-51, Engine
Control Module.>
Module.>
EN-189
AM:DTC P0461 — FUEL LEVEL SENSOR CIRCUIT RANGE/PERFORMANCE

PROBLEM —
CAUTION:
• WIRING DIAGRAM:
LHD model BATTERY B72

No.13 SBF-4 SBF-1
4 1 1 2
3 4
IGNITION
B36 B72
SWITCH
23
R58
i1
1 2 3
4 5 6
A7
R59
COMBINATION
METER 1 2
1 : 1.6L AND 2.0L MODEL
A: i10
R15
C: i12 2 : 2.5L MODEL
1 2
A6
C2
3 4 5 6
A: i10
i2
24
1 2 3 4 5 6 7 8 9 10
B37
C: i12
27 B136 ECM
1 2 3 4 5 6
7 8 9 10 11 12 13 14
B99 B36
11
R3 1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
R15
B99 i2
2
R57
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
1
B22
2
B22
16
1
E3
1 2 3 4
2 5 6 7 8
9 10 11 12
13 14 15 16
3
5
R58
1
2
R59
FUEL SUB FUEL
LEVEL LEVEL
SENSOR SENSOR B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
EN1411
EN-190
RHD model BATTERY B72

No.13 SBF-4 SBF-1
4 1 1 2
3 4
MT AT IGNITION
B72
SWITCH R15
B36 B38
1 2
22
4
i1 i3 3 4 5 6
MT AT R58
1 2 3
A7
4 5 6
COMBINATION R59
METER 2 : 2.5L MODEL
1 2
A: i10
C: i12 A: i10
A6
C2
1 2 3 4 5 6 7 8 9 10
B22
i2
21
1 2 3 4
B37 5 6 7 8
27 B136 ECM 9 10 11 12
13 14 15 16
B99
i1 C: i12
5
R3
1 2 3 4 5 6
7 8 9 10 11 12 13 14
R15
2
R57 B99 i3
1 1 2 3 4 5 6 7 8 9 10
B22 11 12 13 14 15 16 17 18 19 20 21 22
16
2
E3
1
B136
2
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
3
5
R58
1
2
R59 21 22 23 24 25 26 27 28 29 30
FUEL SUB FUEL
LEVEL LEVEL
SENSOR SENSOR i2
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
EN1412
Step Check Yes No

1 CHECK ANY OTHER DIAGNOSTIC TROU- Is any other DTC displayed? Inspect the rele- Replace the fuel
BLE CODE (DTC) ON DISPLAY. vant DTC using level sensor <Ref.
“List of Diagnostic to FU-65, Fuel
Trouble Code Level Sensor.>
(DTC)”. <Ref. to
EN-83, List of
Diagnostic Trou-
ble Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect P0461.
EN-191
AN:DTC P0462 — FUEL LEVEL SENSOR CIRCUIT LOW INPUT —

CAUTION:
• WIRING DIAGRAM:

No.13 SBF-4 SBF-1
4 1 1 2
3 4
IGNITION
B36 B72
SWITCH
23
R58
i1
1 2 3
4 5 6
A7
R59
COMBINATION
METER 1 2
A: i10
R15
C: i12 2 : 2.5L MODEL
1 2
A6
C2
3 4 5 6
A: i10
i2
24
1 2 3 4 5 6 7 8 9 10
B37
C: i12
27 B136 ECM
1 2 3 4 5 6
7 8 9 10 11 12 13 14
B99 B36
11
R3 1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
R15
B99 i2
2
R57
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
1
B22
2
B22
16
1
E3
1 2 3 4
2 5 6 7 8
9 10 11 12
13 14 15 16
3
5
R58
1
2
R59
FUEL SUB FUEL
LEVEL LEVEL
SENSOR SENSOR B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
EN1411
EN-192

No.13 SBF-4 SBF-1
4 1 1 2
3 4
MT AT IGNITION
B72
SWITCH R15
B36 B38
1 2
22
4
i1 i3 3 4 5 6
MT AT R58
1 2 3
A7
4 5 6
COMBINATION R59
1 2
A: i10
C: i12 A: i10
A6
C2
1 2 3 4 5 6 7 8 9 10
B22
i2
21
1 2 3 4
B37 5 6 7 8
27 B136 ECM 9 10 11 12
13 14 15 16
B99
i1 C: i12
5
R3
1 2 3 4 5 6
7 8 9 10 11 12 13 14
R15
2
R57 B99 i3
1 1 2 3 4 5 6 7 8 9 10
B22 11 12 13 14 15 16 17 18 19 20 21 22
16
2
E3
1
B136
2
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
3
5
R58
1
2
R59 21 22 23 24 25 26 27 28 29 30
FUEL SUB FUEL
LEVEL LEVEL
SENSOR SENSOR i2
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
EN1412
Step Check Yes 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.>
2 CHECK INPUT SIGNAL FOR ECM. Is the voltage less than 0.12 Go to step 6. Go to step 3.
1)Turn the ignition switch to ON. (engine OFF) V?
EN-193
Step Check Yes No

3 CHECK INPUT SIGNAL FOR ECM. (USING Does the value change less Repair the poor Even if MIL lights
SUBARU SELECT MONITOR.) than 0.12 V by shaking har- contact in ECM up, the circuit has
Read the data of fuel level sensor signal using ness and connector of ECM connector. returned to a nor-
Subaru Select Monitor. while monitoring the value with mal condition at
NOTE: Subaru Select Monitor? this time. A tempo-
•Subaru Select Monitor rary poor contact
For detailed operation procedure, refer to the of the connector
“READ CURRENT DATA FOR ENGINE”. may be the cause.
<Ref. to EN-34, Subaru Select Monitor.> NOTE:
the following:
• Poor contact in
combination meter
connector
• Poor contact in
ECM connector
• Poor contact in
coupling connec-
tors (B99)
4 CHECK INPUT VOLTAGE OF ECM. Is the voltage more than 0.12 Go to step 4. Go to step 8.
1)Turn the ignition switch to OFF. V?
2)Separate the fuel tank cord connector (R57)
and rear wiring harness connector (R15).
4)Measure the voltage of harness between
COMBINATION METER. MΩ? short circuit in har-
2)Disconnect the connector from connector ECM and combi-
(i10) and ECM connector. nation meter con-
3)Measure the resistance between ECM and nector.
chassis ground.
6 CHECK HARNESS BETWEEN ECM AND Is the resistance less than 10 Repair or replace Repair the open
COMBINATION METER. Ω? the combination circuit between
Measure the resistance between ECM and meter. <Ref. to ECM and combi-
combination meter connector. IDI-4, Combina- nation meter con-
Connector & terminal tion Meter Sys- nector.
(B136) No. 27 — (i12) No. 2: tem.> NOTE:
the following:
Poor contact in
coupling connector
(i2)
7 CHECK ENGINE DISPLACEMENT. Is the engine displacement 2.5 Go to step 10. Go to step 8.
L?
8 CHECK FUEL TANK CORD. Is the resistance more than 1 Go to step 9. Repair the ground
1)Disconnect the connector from fuel pump MΩ? short circuit in fuel
assembly. tank cord.
2)Measure the resistance between fuel pump
assembly and chassis ground.
(R58) No. 3 — Chassis ground:
EN-194
Step Check Yes No

9 CHECK FUEL LEVEL SENSOR. Is the resistance between 0.5 Repair the poor Replace the fuel
1)Remove the fuel pump assembly. <Ref. to and 2.5 Ω? contact in harness level sensor.
FU-62, Fuel Pump.> between ECM and
2)Measure the resistance between fuel level combination meter
sensor and terminals with its float set to the full connector.
position.
Terminals
No. 5 — No. 3:
1)Turn the ignition switch to OFF. MΩ? 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.
12 CHECK FUEL LEVEL SENSOR. Is the resistance between 0.5 Go to step 13. Replace the fuel
1)Remove the fuel pump assembly. <Ref. to and 2.5 Ω? level sensor.
FU-62, Fuel Pump.>
2)Measure the resistance between fuel level
sensor and terminals with its float set to the full
position.
Terminals
No. 3 — No. 5:
13 CHECK FUEL SUB LEVLE SENSOR. Is the resistance between 0.5 Repair the poor Replace the fuel
1)Remove the fuel sub level sensor. <Ref. to and 2.5 Ω? contact in harness sub level sensor.
FU-66, Fuel Sub Level Sensor.> between ECM and
2)Measure the resistance between fuel sub combination meter
level sensor and terminals with its float set to connector.
the full position.
Terminals
No. 1 — No. 2:
EN-195
AO:DTC P0463 — FUEL LEVEL SENSOR CIRCUIT HIGH INPUT —

CAUTION:
• WIRING DIAGRAM:

No.13 SBF-4 SBF-1
4 1 1 2
3 4
IGNITION
B36 B72
SWITCH
23
R58
i1
1 2 3
4 5 6
A7
R59
COMBINATION
METER 1 2
A: i10
R15
C: i12 2 : 2.5L MODEL
1 2
A6
C2
3 4 5 6
A: i10
i2
24
1 2 3 4 5 6 7 8 9 10
B37
C: i12
27 B136 ECM
1 2 3 4 5 6
7 8 9 10 11 12 13 14
B99 B36
11
R3 1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
R15
B99 i2
2
R57
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
1
B22
2
B22
16
1
E3
1 2 3 4
2 5 6 7 8
9 10 11 12
13 14 15 16
3
5
R58
1
2
R59
FUEL SUB FUEL
LEVEL LEVEL
SENSOR SENSOR B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
EN1411
EN-196

No.13 SBF-4 SBF-1
4 1 1 2
3 4
MT AT IGNITION
B72
SWITCH R15
B36 B38
1 2
22
4
i1 i3 3 4 5 6
MT AT R58
1 2 3
A7
4 5 6
COMBINATION R59
1 2
A: i10
C: i12 A: i10
A6
C2
1 2 3 4 5 6 7 8 9 10
B22
i2
21
1 2 3 4
B37 5 6 7 8
27 B136 ECM 9 10 11 12
13 14 15 16
B99
i1 C: i12
5
R3
1 2 3 4 5 6
7 8 9 10 11 12 13 14
R15
2
R57 B99 i3
1 1 2 3 4 5 6 7 8 9 10
B22 11 12 13 14 15 16 17 18 19 20 21 22
16
2
E3
1
B136
2
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
3
5
R58
1
2
R59 21 22 23 24 25 26 27 28 29 30
FUEL SUB FUEL
LEVEL LEVEL
SENSOR SENSOR i2
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
EN1412
Step Check Yes No

IDI-4, Combina-
tion Meter Sys-
tem.>
EN-197
Step Check Yes No

2 CHECK INPUT SIGNAL FOR ECM. Is the voltage more than 4.75 Go to step 3. Even if MIL lights
1)Turn the ignition switch to ON. (engine OFF) V? 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-
(B136) No. 27 (+) — Chassis ground (−): rary poor contact
of the connector
may be the cause.
NOTE:
the following:
• Poor contact in
fuel pump connec-
tor
• Poor contact in
coupling connector
(B22, B99 and
R15)
3 CHECK INPUT VOLTAGE OF ECM. Is the voltage more than 4.75 Go to step 4. Repair the battery
1)Turn the ignition switch to OFF. V? 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.
ECM and chassis ground.
FUEL TANK CORD. Ω? circuit between
1)Turn the ignition switch to OFF. ECM and fuel tank
2)Separate the fuel tank cord connector (R57) cord.
fuel tank cord.
(B136) No. 27 — (R15) No. 2:
5 CHECK HARNESS BETWEEN FUEL TANK Is the resistance less than 5 Go to step 6. Repair the open
CORD AND CHASSIS GROUND. Ω? circuit between
Measure the resistance between fuel tank cord fuel tank cord and
and chassis ground. chassis ground.
(R15) No. 6 — Chassis ground: In this case, repair
the following:
Poor contact in
coupling connec-
tors (B22 and B99)
6 CHECK FUEL TANK CORD. Is the resistance less than 10 Go to step 7. Repair the open
1)Disconnect the connector from fuel level Ω? circuit between
sensor. coupling connector
2)Measure the resistance between fuel level and fuel level sen-
sensor and coupling connector. sor.
(R57) No. 6 — (R58) No. 5:
7 CHECK ENGINE DISPLACEMENT. Is the engine displacement 2.5 Go to step 10. Go to step 7.
L?
EN-198
Step Check Yes No

(R57) No. 2 — (R58) No. 3:
9 CHECK FUEL LEVEL SENSOR. Is the resistance more than Replace the fuel Replace the com-
1)Remove the fuel pump assembly. <Ref. to 100 Ω? level sensor. <Ref. bination meter.
FU-62, Fuel Pump.> to FU-65, Fuel <Ref. to IDI-15,
2)While moving the fuel level sensor float up Level Sensor.> Combination
and down, measure the resistance between Meter Assembly.>
fuel level sensor terminals.
Terminals
No. 3 — No. 5:
1)Disconnect the connector from fuel sub level Ω? circuit between
sensor. fuel level sensor
2)Measure the resistance between fuel level and fuel sub level
sensor and fuel sub level sensor. sensor.
(R58) No. 3 — (R59) No. 2:
Measure the resistance between fuel sub level Ω? circuit between
sensor and coupling connector. coupling connector
Connector & terminal and fuel sub level
(R57) No. 2 — (R59) No. 1: sensor.
12 CHECK FUEL LEVEL SENSOR. Is the resistance more than 53 Replace the fuel Go to step 13.
1)Remove the fuel pump assembly. <Ref. to Ω? level sensor. <Ref.
FU-62, Fuel Pump.> to FU(TURBO)-62,
2)While moving the fuel level sensor float up Fuel Level Sen-
and down, measure resistance between fuel sor.>
level sensor terminals.
Terminals
No. 3 — No. 5:
13 CHECK FUEL SUB LEVEL SENSOR. Is the resistance more than 45 Replace the fuel Replace the com-
1)Remove the fuel sub level sensor. <Ref. to Ω? sub level sensor. bination meter.
FU-66, Fuel Sub Level Sensor.> <Ref. to <Ref. to IDI-15,
2)While moving the fuel sub level sensor float FU(TURBO)-63, Combination
up and down, measure resistance between Fuel Sub Level Meter Assembly.>
fuel sub level sensor terminals. Sensor.>
Terminals
No. 1 — No. 2:
EN-199
AP:DTC P0464 — FUEL LEVEL SENSOR INTERMITTENT INPUT—

CAUTION:
• WIRING DIAGRAM:

No.13 SBF-4 SBF-1
4 1 1 2
3 4
IGNITION
B36 B72
SWITCH
23
R58
i1
1 2 3
4 5 6
A7
R59
COMBINATION
METER 1 2
A: i10
R15
C: i12 2 : 2.5L MODEL
1 2
A6
C2
3 4 5 6
A: i10
i2
24
1 2 3 4 5 6 7 8 9 10
B37
C: i12
27 B136 ECM
1 2 3 4 5 6
7 8 9 10 11 12 13 14
B99 B36
11
R3 1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
R15
B99 i2
2
R57
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
1
B22
2
B22
16
1
E3
1 2 3 4
2 5 6 7 8
9 10 11 12
13 14 15 16
3
5
R58
1
2
R59
FUEL SUB FUEL
LEVEL LEVEL
SENSOR SENSOR B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
EN1411
EN-200

No.13 SBF-4 SBF-1
4 1 1 2
3 4
MT AT IGNITION
B72
SWITCH R15
B36 B38
1 2
22
4
i1 i3 3 4 5 6
MT AT R58
1 2 3
A7
4 5 6
COMBINATION R59
1 2
A: i10
C: i12 A: i10
A6
C2
1 2 3 4 5 6 7 8 9 10
B22
i2
21
1 2 3 4
B37 5 6 7 8
27 B136 ECM 9 10 11 12
13 14 15 16
B99
i1 C: i12
5
R3
1 2 3 4 5 6
7 8 9 10 11 12 13 14
R15
2
R57 B99 i3
1 1 2 3 4 5 6 7 8 9 10
B22 11 12 13 14 15 16 17 18 19 20 21 22
16
2
E3
1
B136
2
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
3
5
R58
1
2
R59 21 22 23 24 25 26 27 28 29 30
FUEL SUB FUEL
LEVEL LEVEL
SENSOR SENSOR i2
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
EN1412
Step Check Yes No

Trouble Code
(DTC)”. <Ref. to
EN-83, List of
Diagnostic Trou-
ble Code (DTC).>
2 CHECK FUEL LEVEL SENSOR. Does the resistance change 2.5 L: Go to step 3. Replace the fuel
1)Remove the fuel pump assembly. <Ref. to smoothly between approx. 0.5 1.6 L and 2.0 L: level sensor. <Ref.
FU-62, Fuel Pump.> Ω and approx. 52 Ω? Repair the poor to FU-65, Fuel
2)While moving the fuel level sensor float up contact in ECM, Level Sensor.>
and down, make sure that the resistance combination meter
between fuel level sensor terminals changes and coupling con-
smoothly. nectors.
Terminals
No. 3 — No. 5:
EN-201
Step Check Yes No

3 CHECK FUEL SUB LEVEL SENSOR. Does the resistance change Repair the poor Replace the fuel
1)Remove the fuel sub level sensor. smoothly between approx. 0.5 contact in ECM, sub level sensor.
2)<Ref. to FU-66, Fuel Sub Level Sensor.> Ω and approx. 44 Ω? combination meter <Ref. to FU-66,
3)While moving the fuel sub level sensor float and coupling con- Fuel Sub Level
up and down, make sure that the resistance nectors. Sensor.>
between fuel level sensor terminals changes
smoothly.
Terminals
No. 1 — No. 2:
EN-202
AQ:DTC P0480 — COOLING FAN RELAY 1 CIRCUIT LOW INPUT —

• Radiator fan does not operate properly.
• Overheating
CAUTION:
EN-203
• WIRING DIAGRAM:
BATTERY
SBF-1
IGNITION
B72
SWITCH
SBF-4 No.17

1 3
F27 20A F27 20A
2 4
26 18
MAIN SUB
28 20
F66 FAN F29 FAN
RELAY 27 19 RELAY
25 17
MAIN FAN SUB FAN

MOTOR MOTOR
2 F45 2
1
2
1 1
B62
F17 F16
1 LHD :2
RHD :7
2 LHD :12
RHD :17
12
3
B134 ECM
F16
LHD: F45 RHD: F45
F17
1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8
2 1 12 13 14 15 16 17 18 19 20 21 22 23 24 9 10 11 12 13 14 15 16 17 18
B134
F27 F29 F66
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
1 2 5 6 9 13 14 17 21 22 25 29
24 25 26 27 28 29 30 31 32 33 34 35
7 10 15 18 23 26
3 4 8 11 12 16 19 20 24 27 28 30
EN1413
EN-204
Step Check Yes No

1 CHECK OUTPUT SIGNAL FROM ECM. Does voltage change between Repair the poor Go to step 2.
1)Turn the ignition switch to OFF. 0 and 10 V? contact in ECM
2)Connect the test mode connector at the connector.
lower portion of instrument panel (on the
driver's side).
4)While operating the radiator fan relay, mea-
sure the voltage between ECM terminal and
ground.
NOTE:
Radiator fan relay operation can be executed
using the Subaru Select Monitor. For proce-
dure, refer to “Compulsory Valve Operation
Check Mode”.<Ref. to EN-34, Subaru Select
Monitor.>
2 CHECK GROUND SHORT CIRCUIT IN RADI- Is the resistance less than 10 Repair the ground Go to step 3.
ATOR MAIN FAN RELAY CONTROL CIR- Ω? short circuit in radi-
CUIT. ator main fan relay
1)Turn the ignition switch to OFF. control circuit.
2)Disconnect the connectors from ECM.
3 CHECK POWER SUPPLY FOR RELAY. Is the voltage more than 10 V? Go to step 4. Repair the open
1)Remove the main fan relay from A/C relay circuit in harness
holder. between ignition
2)Turn the ignition switch to ON. switch and fuse
3)Measure the voltage between fuse and relay and relay box (F/B)
box (F/B) connector and chassis ground. connector.
4 CHECK MAIN FAN RELAY. Is the resistance between 87 Go to step 5. Replace the main
1)Turn the ignition switch to OFF. and 107 Ω? fan relay.
2)Measure the resistance between main fan
relay terminals.
Terminal
No. 28 — No. 27:
5 CHECK OPEN CIRCUIT IN MAIN FAN RE- Is the resistance less than 1 Go to step 6. Repair the har-
LAY CONTROL CIRCUIT. Ω? ness and connec-
ECM and main fan relay connector. NOTE:
(B134) No. 3 — (F66) No. 27: the following:
• Open circuit in
harness between
ECM and main fan
relay connector
• Poor contact in
coupling connector
(F45)
6 CHECK POOR CONTACT. Is there poor contact in ECM or Repair the poor Contact with your
Check poor contact in ECM or main fan relay main fan relay connector? contact in ECM or Subaru distributor
connector. main fan relay service.
connector.
EN-205
EN-206
AR:DTC P0483 — COOLING FAN FUNCTION PROBLEM —

• Occurrence of noise
• Overheating
CAUTION:
NOTE:
If the vehicle, with the engine idling, is placed very close to a wall or another vehicle, preventing normal cool-
ing function, the OBD system may detect malfunction.
EN-207
• WIRING DIAGRAM:
BATTERY
SBF-1
IGNITION
B72
SWITCH
SBF-4 No.17

1 3
F27 20A F27 20A
2 4
26 18
MAIN SUB
28 20
F66 FAN F29 FAN
RELAY 27 19 RELAY
25 17
MAIN FAN SUB FAN

MOTOR MOTOR
2 F45 2
1
2
1 1
B62
F17 F16
1 LHD :2
RHD :7
2 LHD :12
RHD :17
12
3
B134 ECM
F16
LHD: F45 RHD: F45
F17
1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8
2 1 12 13 14 15 16 17 18 19 20 21 22 23 24 9 10 11 12 13 14 15 16 17 18
B134
F27 F29 F66
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
1 2 5 6 9 13 14 17 21 22 25 29
24 25 26 27 28 29 30 31 32 33 34 35
7 10 15 18 23 26
3 4 8 11 12 16 19 20 24 27 28 30
EN1413
EN-208
Step Check Yes No

Trouble Code
(DTC)”. <Ref. to
EN-83, List of
Diagnostic Trou-
ble Code (DTC).>
2 CHECK ENGINE COOLANT AMOUNT Is the amount of engine cool- Check the radiator Add engine cool-
ant at specified level? fan and fan motor. ant.
<Ref. to CO-10,
Radiator Main Fan
System.> and
<Ref. to CO-18,
Radiator Sub Fan
System.>
EN-209
AS:DTC P0500 — VEHICLE SPEED SENSOR MALFUNCTION —

CAUTION:
• WIRING DIAGRAM:
IGNITION B17
SWITCH BATTERY
1 2 3
SBF-4 SBF-1
1
No.18
4 B72
B72 1 2
3 4
A: i10
1 2 3 4 5 6 7 8 9 10
3
B56 TCM VEHICLE B22

SPEED
SENSOR 1 2 3 4
5 6 7 8
B17 9 10 11 12
17
13 14 15 16
1
2
B56
AT MT
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18
COMBINATION 19 20 21 22 23 24
METER
A: i10
B22 B135
16
A2 1
E3 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
i2 B37
20 21 22 23 24 25 26 27 28
LHD: l2
24
1 LHD :9
RHD :7 1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
B135 ECM
RHD: i2
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
EN1414
Step Check Yes No

1 CHECK TRANSMISSION TYPE. Is the transmission type AT? Go to step 2. Go to step 3.
EN-210
Step Check Yes No

2 CHECK DTC P0720 ON DISPLAY. Does the Subaru Select Moni- Check the front Go to step 3.
tor or OBD-II general scan tool vehicle speed sen-
indicate DTC P0720? sor signal circuit.
<Ref. to AT-57,
DTC 33 FRONT
VEHICLE SPEED
SENSOR, Diag-
nostic Procedure
with Diagnostic
Trouble Code
(DTC).>
3 CHECK SPEEDOMETER OPERATION IN Does the speedometer operate Go to step 4. Check the speed-
COMBINATION METER. normally? ometer and vehi-
cle speed sensor.
<Ref. to IDI-17,
Speedometer.>
and <Ref. to AT-
32, Front Vehicle
Speed Sensor.>
and <Ref. to AT-
36, Rear Vehicle
Speed Sensor.>
and <Ref. to AT-
37, Torque Con-
verter Turbine
Speed Sensor.>
4 CHECK HARNESS BETWEEN ECM AND Is the resistance less than 10 Repair the poor Repair the har-
COMBINATION METER CONNECTOR. Ω? contact in ECM ness and connec-
1)Turn the ignition switch to OFF. connector. tor.
2)Disconnect the connector from combination NOTE:
meter. In this case, repair
3)Measure the resistance between ECM and the following:
(B135) No. 24 — (i10) No. 2: ECM and combi-
nation meter con-
nector
• Poor contact in
ECM connector
• Poor contact in
combination meter
connector
• Poor contact in
coupling connector
(i2)
EN-211
AT:DTC P0506 — IDLE CONTROL SYSTEM RPM LOWER THAN EXPECTED —

• Engine is difficult to start.
• Engine does not start.
• Engine stalls.
CAUTION:
• WIRING DIAGRAM:
MAIN RELAY
B47
6 BATTERY
RHD
RHD
4 1 2
SBF-5 3 4
5 LHD 2 LHD 5 6
3
B61 F44
2
1 E7
B47 1 2 3
B22 4 5 6
1
E3
F44
1 2 3 4
5 6 7 8
5
2
IDLE
AIR CONTROL B22
SOLENOID
VALVE 1 2 3 4
5 6 7 8
E7
9 10 11 12
13 14 15 16
6
3
4
1
E2 B21
3
4
1
2
B21
1 2 3 4
5 6 7 8
A19
A20
A5
A6
9 10 11 12
13 14 15 16
A: B134 17 18 19 20
C: B136 ECM
C22
C21
A: B134
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25 26 27 28 29 30 31 32 33 34 35
B22
16
E3
C: B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
EN1415
EN-212
Step Check Yes No

Trouble Code
(DTC)”. <Ref. to
EN-83, List of
Diagnostic Trou-
ble Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0506.
2 CHECK AIR BY-PASS LINE. Does air flow out? Replace the idle Replace the throt-
1)Turn the ignition switch to OFF. air control solenoid tle body. <Ref. to
2)Remove the idle air control solenoid valve valve. <Ref. to FU- FU-16, INSTALLA-
from throttle body. <Ref. to FU-39, REMOVAL, 39, INSTALLA- TION, Throttle
Idle Air Control Solenoid Valve.> TION, Idle Air Body.>
3)Remove the throttle body from intake mani- Control Solenoid
fold. <Ref. to FU-16, REMOVAL, Throttle Valve.>
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
the throttle body interior.
EN-213
AU:DTC P0507 — IDLE CONTROL SYSTEM RPM HIGHER THAN EXPECTED —

• Engine keeps running at higher revolution than specified idling revolution.
CAUTION:
• WIRING DIAGRAM:
MAIN RELAY
B47
6 BATTERY
RHD
RHD
4 1 2
SBF-5 3 4
5 LHD 2 LHD 5 6
3
B61 F44
2
1 E7
B47 1 2 3
B22 4 5 6
1
E3
F44
1 2 3 4
5 6 7 8
5
2
IDLE
AIR CONTROL B22
SOLENOID
VALVE 1 2 3 4
5 6 7 8
E7
9 10 11 12
13 14 15 16
6
3
4
1
E2 B21
3
4
1
2
B21
1 2 3 4
5 6 7 8
A19
A20
A5
A6
9 10 11 12
13 14 15 16
A: B134 17 18 19 20
C: B136 ECM
C22
C21
A: B134
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25 26 27 28 29 30 31 32 33 34 35
B22
16
E3
C: B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
EN1415
EN-214
Step Check Yes No

Trouble Code
(DTC)”. <Ref. to
EN-83, List of
Diagnostic Trou-
ble Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0507.
2 CHECK AIR INTAKE SYSTEM. Is there a fault in air intake sys- Repair the air suc- Go to step 3.
1)Turn the ignition switch to ON. tem? tion and leaks.
2)Start the engine, and idle it.
3)Check the following items.
•Loose installation of intake manifold, idle air
control solenoid valve and throttle body
•Cracks of intake manifold gasket, idle air con-
trol solenoid valve gasket and throttle body
gasket
•Disconnections of vacuum hoses
3 CHECK THROTTLE CABLE. Does the throttle cable have Go to step 4. Adjust the throttle
play for adjustment? cable. <Ref. to SP-
9, INSTALLA-
TION, Accelerator
Control Cable.>
4 CHECK AIR BY-PASS LINE. Are foreign particles in by-pass Remove the for- Replace the idle
1)Turn the ignition switch to OFF. air line? eign particles from air control solenoid
2)Remove the idle air control solenoid valve by-pass air line. valve. <Ref. to FU-
from throttle body. <Ref. to FU-39, REMOVAL, 39, INSTALLA-
Idle Air Control Solenoid Valve.> TION, Idle Air
3)Confirm that there are no foreign particles in Control Solenoid
by-pass air line. Valve.>
EN-215
AV:DTC P0512 — STARTER SWITCH CIRCUIT HIGH INPUT —

CAUTION:
• WIRING DIAGRAM:
BATTERY
SBF-4 SBF-1
1
IGNITION
SWITCH
B72
3
INHIBITOR SWITCH
P R N D 3 2 1
AT 12 12
11 7
MT
B12 T3 T7
MT
B135 ECM 28 AT
B14
STARTER
MOTOR
B72 B12 T7 B135
1 2 3 4 1 2 3 4 5 6 1 2 3 4 5 6 7
1 2
5 6 7 8 7 8 9 10 11 12 8 9 10 11 12 13 14 15 16 17 18 19
3 4
9 10 11 12 20 21 22 23 24 25 26 27 28
EN0862
EN-216
Step Check Yes No

1 CHECK OPERATION OF STARTER MOTOR. Does the starter motor oper- Repair the battery Check the starter
NOTE: ate when ignition switch is short circuit in motor circuit. <Ref.
Place the inhibitor switch in each position. turned to ON? starter motor cir- to EN-64,
cuit. STARTER
MOTOR CIR-
CUIT, Diagnostics
for Engine Start-
ing Failure.>
EN-217
AW:DTC P0562 — CHARGE SYSTEM CIRCUIT LOW INPUT —

• Power source voltage of the ECM is low.
• Charge warning light comes on.
CAUTION:
• WIRING DIAGRAM:
GENERATOR SBF-1
MAIN RELAY
4 BATTERY
RHD
RHD
6
SBF-5
5 LHD 2 LHD
3
B61 F44
2
1
B47
1
2
B136 ECM
B47 F44 B136
1 2 1 2 3 4 5 6 7
1 2 3 4
3 4 8 9 10 11 12 13 14 15 16 17 18 19 20
5 6 7 8
5 6 21 22 23 24 25 26 27 28 29 30
EN1416
EN-218
Step Check Yes No

1 CHECK GENERATOR. Is the voltage less than 10.8 Go to step 2. Repair the genera-
1)Start the engine. V? tor. <Ref. to CS-
2)Idle after warm-up. 21, General Diag-
3)Measure the voltage between generator B nostic.>
Terminal
Generator B terminal (+) — Chassis
ground (–):
2 CHECK GENERATOR. Is the voltage less than 10.8 Go to step 3. Repair the genera-
1)Run the engine at 5,000 rpm. V? tor. <Ref. to CS-
2)Measure the voltage between generator B 21, General Diag-
terminal and chassis ground. nostic.>
Terminal
ground (−):
3 CHECK BATTERY TERMINAL. Are the positive and ground Go to step 4. Tighten the clamp
Turn the ignition switch to OFF. battery terminals tightly of terminal.
clamped?
4 CHECK INPUT VOLTAGE OF ECM. Is the voltage less than 10.8 Go to step 5. Repair the har-
1)Run the engine at idle. V? ness connector
2)Measure the voltage between ECM connec- between battery,
tor and chassis ground. main relay and
Connector & terminal ECM.
5 CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in con- Repair the con- Go to step 6.
nectors between generator, nector.
battery and ECM?
6 CHECK ECM. Is the same DTC as in the cur- Replace the gen- Go to step 7.
1)Connect all connectors. rent diagnosis still being out- erator.
2)Erase the memory. <Ref. to EN-49, Clear put?
Memory Mode.>
3)Perform inspection mode. <Ref. to EN-42,
Inspection Mode.>
4)Read out the DTC. <Ref. to EN-41, Read
7 CHECK ANY OTHER TROUBLE CODES AP- Are other DTC being output? Proceed with the A temporary poor
PEARANCE. diagnosis corre- contact.
sponding to the
DTC.
EN-219
AX:DTC P0563 — CHARGE SYSTEM CIRCUIT HIGH INPUT —

• Power source voltage of the ECM is high.
CAUTION:
• WIRING DIAGRAM:
GENERATOR SBF-1
MAIN RELAY
4 BATTERY
RHD
RHD
6
SBF-5
5 LHD 2 LHD
3
B61 F44
2
1
B47
1
2
B136 ECM
B47 F44 B136
1 2 1 2 3 4 5 6 7
1 2 3 4
3 4 8 9 10 11 12 13 14 15 16 17 18 19 20
5 6 7 8
5 6 21 22 23 24 25 26 27 28 29 30
EN1416
EN-220
Step Check Yes No

1 CHECK GENERATOR. Is the voltage more than 16.2 Go to step 2. Repair the genera-
1)Start the engine. V? tor. <Ref. to CS-
2)Idle after warm-up. 21, General Diag-
3)Measure the voltage between generator B nostic.>
Terminal
ground (–):
2 CHECK GENERATOR. Is the voltage more than 16.2 Go to step 3. Repair the genera-
1)Run the engine at 5,000 rpm. V? tor. <Ref. to CS-
2)Measure the voltage between generator B 21, General Diag-
terminal and chassis ground. nostic.>
Terminal
ground (−):
clamped?
4 CHECK INPUT VOLTAGE OF ECM. Is the voltage more than 16.2 Go to step 5. Repair the har-
1)Run the engine at idle. V? ness connector
5 CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in con- Repair the con- Go to step 6.
nectors between generator, nector.
battery and ECM?
2)Erase the memory. <Ref. to EN-49, Clear put?
Memory Mode.>
3)Perform the inspection mode. <Ref. to EN-
42, Inspection Mode.>
4)Read out the DTC. <Ref. to EN-41, Read
7 CHECK ANY OTHER TROUBLE CODES AP- Are other DTC being output? Proceed with the A temporary poor
PEARANCE. diagnosis corre- contact.
sponding to the
DTC.
EN-221
AY:DTC P0604 — INTERNAL CONTROL MODULE MEMORY CHECK SUM ER-

ROR —
• Immediately at fault recognition.
• Engine stalls.
CAUTION:
• WIRING DIAGRAM:
MAIN RELAY
RHD
RHD
6
SBF-5
5 LHD 2 LHD
3
B61 F44
2
1 IGNITION
B72 BATTERY
SWITCH
4 1
B19
C1
C2
C9
B7
A: B134
B: B135 ECM
1 AT MODEL: B6
C: B136
MT MODEL: B25
A34
A35
A27
C22
C21
1
A7
A8
B22
13
15
14
16
8
E3
B72 F44 B47 B22 B: B135 C: B136
1 2 3 4 1 2 1 2 3 4 1 2 3 4 5 6 7 1 2 3 4 5 6 7
1 2
5 6 7 8 3 4 5 6 7 8 8 9 10 11 12 13 14 15 16 17 18 19 8 9 10 11 12 13 14 15 16 17 18 19 20
3 4
5 6 9 10 11 12 20 21 22 23 24 25 26 27 28 21 22 23 24 25 26 27 28 29 30
13 14 15 16
A: B134
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25 26 27 28 29 30 31 32 33 34 35
EN1397
Step Check Yes No

1 CHECK ANY OTHER DIAGNOSTIC TROU- Does the Subaru Select Moni- Replace the ECM. It is not necessary
BLE CODE (DTC) ON DISPLAY. tor or OBD-II general scan tool <Ref. to FU-51, to inspect DTC
indicate DTC P0604? Engine Control P0604.
Module.>
EN-222
EN-223
AZ:DTC P0703 — BRAKE SWITCH INPUT MALFUNCTION —

CAUTION:
• WIRING DIAGRAM:
BATTERY
No.16 SBF-2 SBF-1
LHD
RHD
OC WC
2
1
2
WC : WITH CRUISE CONTROL MODEL
BRAKE STOP
LIGHT LIGHT OC : WITHOUT CRUISE CONTROL MODEL
SWITCH SWITCH
B64 B64 : OC
WC OC
1
B65 : WC
3
RHD
LHD TO STOP LIGHTS

12
B55 TCM
B64 B65 B55
1 2 1 2 1 2 3 4 5 6 7 8 9
3 4 10 11 12 13 14 15 16 17 18
19 20 21 22 23 24
EN1417
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-224
Step Check Yes No

2 CHECK HARNESS BETWEEN TCM AND Is the resistance less than 1 Go to step 3. Repair or replace
BRAKE LIGHT SWITCH CONNECTOR. Ω? the harness and
1)Disconnect the connectors from TCM and connector.
brake light switch. NOTE:
TCM and brake light switch connector. the following:
• LHD harness between
(B55) No. 12 — (B64) No.1: TCM and brake
• RHD light switch con-
Without cruise control nector
(B55) No. 12 — (B64) No. 2 • Poor contact in
With cruise control TCM connector
brake light switch
connector
3 CHECK HARNESS BETWEEN TCM AND Is the resistance more than 1 Go to step 4. Repair the ground
BRAKE LIGHT SWITCH CONNECTOR. MΩ? short circuit in har-
TCM and chassis ground. TCM and brake
Connector & terminal light switch con-
(B55) No. 12 — Chassis ground: nector.
4 CHECK INPUT SIGNAL FOR TCM. Is the voltage less than 1 V Go to step 5. Adjust or replace
1)Connect 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 8, STOP LIGHT
chassis ground. SWITCH,
Connector & terminal INSPECTION,
(B55) No. 12 (+) — Chassis ground (−): Stop Light Sys-
tem.>
5 CHECK INPUT SIGNAL FOR TCM. Is the voltage more than 10 V Go 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 8, STOP LIGHT
(B55) No. 12 (+) — Chassis ground (−): SWITCH,
INSPECTION,
Stop Light Sys-
tem.>
6 CHECK POOR CONTACT. Is there poor contact in TCM Repair the poor Replace the TCM.
Check poor contact in TCM connector. connector? contact in TCM <Ref. to AT-46,
connector. Transmission Con-
trol Module
(TCM).>
EN-225
BA:DTC P0731 — GEAR 1 INCORRECT RATIO —

NOTE:
For the diagnostic procedure, refer to DTC P0734. <Ref. to EN-227, DTC P0734 — GEAR 4 INCORRECT
RATIO —, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
BB:DTC P0732 — GEAR 2 INCORRECT RATIO —
NOTE:
BC:DTC P0733 — GEAR 3 INCORRECT RATIO —
NOTE:
EN-226
BD:DTC P0734 — GEAR 4 INCORRECT RATIO —

• Shift point too high or too low; engine brake not effected in “3” range; excessive shift shock; excessive
tight corner “braking”
CAUTION:
• WIRING DIAGRAM:
Step Check Yes No

Trouble Code
(DTC)”. <Ref. to
EN-83, 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 the throttle position sensor circuit. <Ref. tion sensor circuit.
to AT-50, DTC 31 THROTTLE POSITION
SENSOR, Diagnostic Procedure with Diagnos-
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 the front vehicle speed sensor circuit. speed sensor cir-
<Ref. to AT-57, DTC 33 FRONT VEHICLE cuit.
SPEED SENSOR, Diagnostic Procedure with
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 the torque converter turbine speed sen- circuit? verter turbine
sor circuit. <Ref. to AT-62, DTC 36 TORQUE speed sensor cir-
CONVERTER TURBINE SPEED SENSOR, cuit.
Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
5 CHECK POOR CONTACT. Is there poor contact in TCM Repair the poor Go to step 6.
Check poor contact in TCM connector. connector? contact in TCM
connector.
6 CHECK MECHANICAL TROUBLE. Is there any mechanical trou- Repair or replace Replace the TCM.
Check mechanical trouble in automatic trans- ble in automatic transmission? the automatic <Ref. to AT-46,
mission. transmission. Transmission Con-
<Ref. to AT-12, trol Module
INSPECTION, (TCM).>
Road Test.>
EN-227
BE:DTC P0741 — TORQUE CONVERTER CLUTCH SYSTEM MALFUNCTION —

• No lock-up (after engine warm-up)
• No shift or excessive tight corner “braking”
CAUTION:
Step Check Yes No

Trouble Code
(DTC)”. <Ref. to
EN-83, 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 the lock-up duty solenoid circuit. <Ref. solenoid circuit.
to AT-94, DTC 77 LOCK-UP DUTY SOLE-
NOID, Diagnostic Procedure with Diagnostic
Code (DTC).>
5 CHECK ENGINE SPEED INPUT CIRCUIT. Is there any trouble in engine Repair or replace Go to step 6.
Check the engine speed input circuit. <Ref. to speed input circuit? the engine speed
AT-42, DTC 11 ENGINE SPEED SIGNAL, input circuit.
Code (DTC).>
6 CHECK INHIBITOR SWITCH CIRCUIT. Is there any trouble in inhibitor Repair or replace Go to step 7.
Check the inhibitor switch circuit. <Ref. to AT- switch circuit? the inhibitor switch
119, CHECK INHIBITOR SWITCH., Diagnostic circuit.
Procedure for No-diagnostic Trouble Code
(DTC).>
7 CHECK BRAKE LIGHT SWITCH CIRCUIT. Is there any trouble in brake Repair or replace Go to step 8.
Check the brake light switch circuit. <Ref. to light switch circuit? the brake light
AT-110, CHECK BRAKE SWITCH., Diagnostic switch circuit.
(DTC).>
8 CHECK ATF TEMPERATURE SENSOR CIR- Is there any trouble in ATF Repair or replace Go to step 9.
CUIT. temperature sensor circuit? the ATF tempera-
Check the ATF temperature sensor circuit. ture sensor circuit.
<Ref. to AT-46, DTC 27 ATF TEMPERATURE
EN-228
Step Check Yes No

connector.
INSPECTION, (TCM).>
Road Test.>
EN-229
BF:DTC P1110 — ATMOSPHERIC PRESSURE SENSOR CIRCUIT LOW INPUT —

CAUTION:
• WIRING DIAGRAM:
ATMOSPHERIC
PRESSURE
SENSOR
2
3
1
B2
4 LHD RHD 3
1 LHD RHD 1
B122 B83
29
15
16
B136 ECM
B2 B122 B83 B136
1 2 3 1 2 3 4 1 2 3 4 5 6 7
1 2 3
8 9 10 11 12 13 14 15 16 17 18 19 20
4 5 6
21 22 23 24 25 26 27 28 29 30
EN1418
EN-230
Step Check Yes No

1 CHECK CURRENT DATA. Is the value less than 0 kPa Go to step 3. Go to step 2.
1)Start the engine. (0 mmHg, 0 inHg)?
NOTE:
sor connector. atmospheric pres- returned to a nor-
sure sensor con- mal condition at
nector. this time.
and chassis ground.
is required, be-
cause probable
cause is deteriora-
tion of multiple
parts.
Measure the voltage between ECM and chas-
sis ground.
SUBARU SELECT MONITOR.) than 0 kPa (0 mmHg, 0 inHg) contact in ECM
Read the data of atmospheric absolute pres- by shaking harness and con- connector.
sure signal using Subaru Select Monitor. nector of ECM while monitor-
NOTE: ing the value with Subaru
•Subaru Select Monitor select monitor?
EN-231
Step Check Yes No

7 CHECK HARNESS BETWEEN ECM AND AT- Is the voltage more than 4.5 V? Go to step 8. Repair the har-
MOSPHERIC PRESSURE SENSOR CON- ness and connec-
NECTOR. tor.
2)Disconnect the connector from atmospheric In this case, repair
pressure sensor. the following:
4)Measure the voltage between atmospheric harness between
pressure sensor connector and engine ground. ECM and atmo-
Connector & terminal spheric pressure
• Poor contact in
joint connector
(B83) or (B122)
8 CHECK HARNESS BETWEEN ECM AND AT- Is the resistance less than 1 Go to step 9. Repair the har-
MOSPHERIC PRESSURE SENSOR CON- Ω? ness and connec-
NECTOR. tor.
ECM and pressure sensor connector. • Open circuit in
(B136) No. 16 — (B2) No. 1: ECM and pressure
sensor connector
9 CHECK HARNESS BETWEEN ECM AND AT- Is the resistance more than Go to step 10. Repair the ground
MOSPHERIC PRESSURE SENSOR CON- 500 kΩ? short circuit in har-
Measure the resistance of harness between ECM and pressure
pressure sensor connector and engine ground. sensor connector.
10 CHECK POOR CONTACT. Is there poor contact in pres- Repair the poor Replace the atmo-
Check poor contact in pressure sensor con- sure sensor connector? contact in atmospheric pressure
nector. spheric pressure sensor. <Ref. to
sensor connector. FU-38, Atmo-
spheric Pressure
Sensor.>
EN-232
EN-233
BG:DTC P1111 — ATMOSPHERIC PRESSURE SENSOR CIRCUIT HIGH INPUT

—
CAUTION:
• WIRING DIAGRAM:
ATMOSPHERIC
PRESSURE
SENSOR
2
3
1
B2
4 LHD RHD 3
1 LHD RHD 1
B122 B83
29
15
16
B136 ECM
B2 B122 B83 B136
1 2 3 1 2 3 4 1 2 3 4 5 6 7
1 2 3
8 9 10 11 12 13 14 15 16 17 18 19 20
4 5 6
21 22 23 24 25 26 27 28 29 30
EN1418
EN-234
Step Check Yes No

1 CHECK CURRENT DATA. Is the value more than 140 kPa Go to step 10. Go to step 2.
1)Start the engine. (1,050 mmHg, 41.34 inHg)?
NOTE:
and chassis ground.
is required, be-
cause probable
cause is deteriora-
tion of multiple
parts.
and chassis ground.
SUBARU SELECT MONITOR.) than 0 kPa (0 mmHg, 0 inHg) contact in ECM
Read the data of atmospheric absolute pres- by shaking harness and con- connector.
sure signal using Subaru Select Monitor. nector of ECM while monitor-
NOTE: ing the value with Subaru
•Subaru Select Monitor Select Monitor?
PRESSURE SENSOR CONNECTOR. ness and connec-
2)Disconnect the connector from atmospheric NOTE:
pressure sensor. In this case, repair
4)Measure the voltage between atmospheric • Open circuit in
pressure sensor connector and engine ground. harness between
Connector & terminal ECM and pressure
• Poor contact in
joint connector
(B83) or (B122)
EN-235
Step Check Yes No

PRESSURE SENSOR CONNECTOR. Ω? ness and connec-
ECM and pressure sensor connector. the following:
(B136) No. 29 — (B2) No. 2: harness between
ECM and pressure
sensor connector
PRESSURE SENSOR CONNECTOR. Ω? ness and connec-
ECM and pressure sensor connector. NOTE:
• Open circuit in
harness between
ECM and pressure
sensor connector
• Poor contact in
joint connector
(B83), (B122)
9 CHECK POOR CONTACT. Is there poor contact in pres- Repair the poor Replace the atmo-
Check poor contact in pressure sensor con- sure sensor connector? contact in atmospheric pressure
nector. spheric pressure sensor. <Ref. to
sensor connector. FU-38, Atmo-
spheric Pressure
Sensor.>
10 CHECK CURRENT DATA. Is the value more than 140 kPa Repair the battery Replace the atmo-
1)Turn the ignition switch to OFF. (1,050 mmHg, 41.34 inHg)? short circuit in har- spheric pressure
2)Disconnect the connector from atmospheric ness between sensor. <Ref. to
pressure sensor. ECM and atmo- FU-38, Atmo-
3)Turn the ignition switch to ON. spheric pressure spheric Pressure
4)Read the data of intake manifold absolute sensor connector. Sensor.>
NOTE:
EN-236
EN-237
BH:DTC P1112 — ATMOSPHERIC PRESSURE SENSOR CIRCUIT RANGE/PER-

CAUTION:
• WIRING DIAGRAM:
ATMOSPHERIC
PRESSURE
SENSOR
2
3
1
B2
4 LHD RHD 3
1 LHD RHD 1
B122 B83
29
15
16
B136 ECM
B2 B122 B83 B136
1 2 3 1 2 3 4 1 2 3 4 5 6 7
1 2 3
8 9 10 11 12 13 14 15 16 17 18 19 20
4 5 6
21 22 23 24 25 26 27 28 29 30
EN1418
EN-238
Step Check Yes No

Trouble Code
(DTC)”. <Ref. to
EN-83, List of
Diagnostic Trou-
ble Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect P1112.
2 CHECK ATMOSPHERIC PRESSURE SEN- Is the atmospheric pressure Replace the atmo- Go 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- Replace the intake
1)Turn the ignition switch to ON. (550 mmHg, 21.65 inHg) and spheric pressure air temperature
2)Read the data of intake manifold absolute 106.6 kPa (800 mmHg, 31.50 sensor. <Ref. to and pressure sen-
pressure signal using Subaru Select Monitor or inHg)? FU-38, Atmo- sor. <Ref. to FU-
OBD-II general scan tool. spheric Pressure 37, Intake Air
NOTE: Sensor.> Temperature and
•Subaru Select Monitor Pressure Sensor.>
EN-239
BI: DTC P1137 — FRONT OXYGEN (A/F) SENSOR CIRCUIT RANGE/PERFOR-

MANCE PROBLEM —
CAUTION:
• WIRING DIAGRAM:
RHD
RHD
SBF-5
1 2
6 LHD 2 LHD
3 4
4
B61 F44 5 6
5
3
2 B18
1
2
1 2 3
(A/F) SENSOR
B18
5
4
6
3
1
F44
1 2 3 4
5 6 7 8
B22
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
A22
A23
C20
C19
C23
C7
C6
A: B134
A: B134 1 2 3 4 5 6 7 8
ECM 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
C: B136 24 25 26 27 28 29 30 31 32 33 34 35
A34
A35
C: B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
B22 21 22 23 24 25 26 27 28 29 30
8
E3
EN1400
Step Check Yes No

Trouble Code
(DTC)”. <Ref. to
EN-83, List of
Diagnostic Trou-
ble Code (DTC).>
EN-240
Step Check Yes No

2 CHECK FRONT OXYGEN (A/F) SENSOR DA- Is the value equal to or more Go to step 3. Go to step 4.
70°C (160°F).
general scan tool.
NOTE:
3 CHECK FRONT OXYGEN (A/F) SENSOR DA- Is the value more than 1.1 for a Go to step 6. Go to step 4.
TA. moment?
Race the engine at speeds from idling to 5,000
rpm for a total of 5 cycles.
NOTE:
To increase the engine speed to 5,000 rpm,
slowly depress the accelerator pedal, taking
approx. 5 seconds, and quickly release the ac-
celerator pedal to decrease engine speed.
FRONT OXYGEN (A/F) SENSOR. Ω? circuit between
2)Disconnect the connector from ECM and oxygen (A/F) sen-
front oxygen (A/F) sensor connector. sor.
Connector & terminals
(B136) No. 6 — (E24) No. 3:
(B136) No. 7 — (E24) No. 4:
(B136) No. 19 — (E24) No. 1:
(B136) No. 20 — (E24) No. 6:
FRONT OXYGEN (A/F) SENSOR. MΩ? short circuit
Measure the resistance between ECM and between ECM and
chassis ground. front oxygen (A/F)
Connector & terminals sensor.
NOTE: sor. <Ref. to FU-
Check the following items. 47, Front Oxygen
•Loose installation of portions (A/F) Sensor.>
EN-241
BJ:DTC P1142 — THROTTLE POSITION SENSOR CIRCUIT RANGE/PERFOR-

MANCE PROBLEM (LOW INPUT) —
• Engine stalls.
CAUTION:
• WIRING DIAGRAM:
THROTTLE
POSITION
SENSOR E13
1 2 3 4
4
3
2
E13
B122
1 2 3
4 5 6
E2
12
11
9
B21 B83
1 2 3 4
B21
3 LHD RHD 2 1 2 3 4
5 6 7 8
9 10 11 12
1 LHD RHD 1
13 14 15 16
17 18 19 20
B122 B83
B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
15
17
16
21 22 23 24 25 26 27 28 29 30
B136 ECM
EN1405
EN-242
Step Check Yes No

Trouble Code Throttle Position
(DTC)”. <Ref. to Sensor.>
EN-83, List of
Diagnostic Trou-
ble Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect P1142.
EN-243
BK:DTC P1146 — PRESSURE SENSOR CIRCUIT RANGE/PERFORMANCE

PROBLEM (HIGH INPUT) —
CAUTION:
• WIRING DIAGRAM:
INTAKE AIR
TEMPERATURE E20
AND
PRESSURE 1 2 3 4
SENSOR
1
3
2
4
E20
LHD: B83
1 2 3
4 5 6
B122
E2
12
14
15
1 2 3
9
B21 4 5 6
B122 B83 RHD: B83
3 LHD RHD 2 1 2 3 4
1 LHD RHD 1
2 LHD
1 B21
B83 1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
25 LHD
17 18 19 20
16
15
13
B136 ECM
B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
EN1403
EN-244
Step Check Yes No

Trouble Code
(DTC)”. <Ref. to
EN-83, List of
Diagnostic Trou-
ble Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect P1146.
disconnection of hose on the intake system.
air intake system?
2)Place the shift lever in the selector lever in to FU-37, Intake
“N” or “P” position. Air Temperature
3)Turn the A/C switch to OFF. and Pressure Sen-
4)Turn all accessory switches to OFF. sor.>
NOTE:
Specification:
Ignition ON
73.3 — 106.6 kPa (550 — 800 mmHg,
21.65 — 31.50 inHg)
Idling
20.0 — 46.7 kPa (150 — 350 mmHg, 5.91
— 13.78 inHg)
Read the data of throttle position signal using equal to or less than 5 % when the throttle posi-
tool. to FU-35, Throttle
NOTE: Position Sensor.>
EN-245
Step Check Yes No

equal to or more than 85 % air temperature tle position sensor.
when throttle is fully open? and pressure sen- <Ref. to FU-35,
sor. <Ref. to FU- Throttle Position
37, Intake Air Sensor.>
Temperature and
Pressure Sensor.>
EN-246
BL:DTC P1442 — FUEL LEVEL SENSOR CIRCUIT RANGE/PERFORMANCE

PROBLEM 2 —
CAUTION:
• WIRING DIAGRAM:

No.13 SBF-4 SBF-1
4 1 1 2
3 4
IGNITION
B36 B72
SWITCH
23
R58
i1
1 2 3
4 5 6
A7
R59
COMBINATION
METER 1 2
A: i10
R15
C: i12 2 : 2.5L MODEL
1 2
A6
C2
3 4 5 6
A: i10
i2
24
1 2 3 4 5 6 7 8 9 10
B37
C: i12
27 B136 ECM
1 2 3 4 5 6
7 8 9 10 11 12 13 14
B99 B36
11
R3 1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
R15
B99 i2
2
R57
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
1
B22
2
B22
16
1
E3
1 2 3 4
2 5 6 7 8
9 10 11 12
13 14 15 16
3
5
R58
1
2
R59
FUEL SUB FUEL
LEVEL LEVEL
SENSOR SENSOR B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
EN1411
EN-247

No.13 SBF-4 SBF-1
4 1 1 2
3 4
MT AT IGNITION
B72
SWITCH R15
B36 B38
1 2
22
4
i1 i3 3 4 5 6
MT AT R58
1 2 3
A7
4 5 6
COMBINATION R59
1 2
A: i10
C: i12 A: i10
A6
C2
1 2 3 4 5 6 7 8 9 10
B22
i2
21
1 2 3 4
B37 5 6 7 8
27 B136 ECM 9 10 11 12
13 14 15 16
B99
i1 C: i12
5
R3
1 2 3 4 5 6
7 8 9 10 11 12 13 14
R15
2
R57 B99 i3
1 1 2 3 4 5 6 7 8 9 10
B22 11 12 13 14 15 16 17 18 19 20 21 22
16
2
E3
1
B136
2
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
3
5
R58
1
2
R59 21 22 23 24 25 26 27 28 29 30
FUEL SUB FUEL
LEVEL LEVEL
SENSOR SENSOR i2
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
EN1412
Step Check Yes No

BLE CODE (DTC) ON DISPLAY. vant DTC using level sensor. <Ref.
“List of Diagnostic to FU-65, Fuel
Trouble Code Level Sensor.>
(DTC)”. <Ref. to
EN-83, List of
Diagnostic Trou-
ble Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect P1442.
EN-248
BM:DTC P1480 — COOLING FAN RELAY 1 CIRCUIT HIGH INPUT —

• Overheating
CAUTION:
EN-249
• WIRING DIAGRAM:
BATTERY
SBF-1
IGNITION
B72
SWITCH
SBF-4 No.17

1 3
F27 20A F27 20A
2 4
26 18
MAIN SUB
28 20
F66 FAN F29 FAN
RELAY 27 19 RELAY
25 17
MAIN FAN SUB FAN

MOTOR MOTOR
2 F45 2
1
2
1 1
B62
F17 F16
1 LHD :2
RHD :7
2 LHD :12
RHD :17
12
3
B134 ECM
F16
LHD: F45 RHD: F45
F17
1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8
2 1 12 13 14 15 16 17 18 19 20 21 22 23 24 9 10 11 12 13 14 15 16 17 18
B134
F27 F29 F66
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
1 2 5 6 9 13 14 17 21 22 25 29
24 25 26 27 28 29 30 31 32 33 34 35
7 10 15 18 23 26
3 4 8 11 12 16 19 20 24 27 28 30
EN1413
EN-250
Step Check Yes No

1 CHECK OUTPUT SIGNAL FROM ECM. Does voltage change between Even if MIL lights Go to step 2.
1)Turn the ignition switch to OFF. 0 and 10 V? up, the circuit has
4)While operating the radiator fan relay, mea- poor contact in
sure the voltage between ECM and chassis ECM connector.
ground.
NOTE:
Check Mode”.<Ref. to EN-50, Compulsory
Valve Operation Check Mode.>
2 CHECK SHORT CIRCUIT IN RADIATOR FAN Is the voltage more than 10 V? Repair the battery Go to step 3.
RELAY CONTROL CIRCUIT. short circuit in radi-
1)Turn the ignition switch to OFF. ator fan relay con-
2)Remove the main fan relay and sub fan trol circuit.
relay. (with A/C models)
3)Disconnect the test mode connector.
chassis ground.
3 CHECK MAIN FAN RELAY. Is the resistance less than 1 Replace the main Go to step 4.
1)Turn the ignition switch to OFF. Ω? fan relay.
2)Remove the main fan relay.
relay terminals.
Terminal
No. 26 — No. 25:
4 CHECK SUB FAN RELAY. Is the resistance less than 1 Replace the sub Go to step 5.
1)Remove the sub fan relay. Ω? fan relay.
2)Measure the resistance between sub fan
relay terminals.
Terminal
No. 18 — No. 17
Module.>
EN-251
BN:DTC P1507 — IDLE CONTROL SYSTEM MALFUNCTION (FAIL-SAFE) —

CAUTION:
• WIRING DIAGRAM:
MAIN RELAY
B47
6 BATTERY
RHD
RHD
4 1 2
SBF-5 3 4
5 LHD 2 LHD 5 6
3
B61 F44
2
1 E7
B47 1 2 3
B22 4 5 6
1
E3
F44
1 2 3 4
5 6 7 8
5
2
IDLE
AIR CONTROL B22
SOLENOID
VALVE 1 2 3 4
5 6 7 8
E7
9 10 11 12
13 14 15 16
6
3
4
1
E2 B21
3
4
1
2
B21
1 2 3 4
5 6 7 8
A19
A20
A5
A6
9 10 11 12
13 14 15 16
A: B134 17 18 19 20
C: B136 ECM
C22
C21
A: B134
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25 26 27 28 29 30 31 32 33 34 35
B22
16
E3
C: B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
EN1415
EN-252
Step Check Yes No

Trouble Code
(DTC)”. <Ref. to
EN-83, List of
Diagnostic Trou-
ble Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect P1507.
2 CHECK AIR INTAKE SYSTEM. Is there a fault in the air intake Repair the air suc- Go to step 3.
1)Turn the ignition switch to ON. system? tion and leaks.
gasket
9, INSTALLA-
TION, Accelerator
Control Cable.>
2)Remove the idle air control solenoid valve by-pass air line. valve. <Ref. to FU-
from throttle body. <Ref. to FU-39, Idle Air 39, Idle Air Con-
Control Solenoid Valve.> trol Solenoid
3)Confirm that there are no foreign particles in Valve.>
the by-pass air line.
EN-253
BO:DTC P1510 — IDLE AIR CONTROL SOLENOID VALVE SIGNAL 1 CIRCUIT

LOW INPUT —
NOTE:
For the diagnostic procedure, refer to DTC P1516. <Ref. to EN-256, DTC P1516 — IDLE AIR CONTROL
SOLENOID VALVE SIGNAL 4 CIRCUIT LOW INPUT —, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
BP:DTC P1511 — IDLE AIR CONTROL SOLENOID VALVE SIGNAL 1 CIRCUIT
HIGH INPUT —
NOTE:
SOLENOID VALVE SIGNAL 4 CIRCUIT HIGH INPUT —, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
BQ:DTC P1512 — IDLE AIR CONTROL SOLENOID VALVE SIGNAL 2 CIRCUIT
LOW INPUT —
NOTE:
Code (DTC).>
BR:DTC P1513 — IDLE AIR CONTROL SOLENOID VALVE SIGNAL 2 CIRCUIT
HIGH INPUT —
NOTE:
Code (DTC).>
BS:DTC P1514 — IDLE AIR CONTROL SOLENOID VALVE SIGNAL 3 CIRCUIT
LOW INPUT —
NOTE:
Code (DTC).>
BT:DTC P1515 — IDLE AIR CONTROL SOLENOID VALVE SIGNAL 3 CIRCUIT
HIGH INPUT —
NOTE:
Code (DTC).>
EN-254
EN-255
BU:DTC P1516 — IDLE AIR CONTROL SOLENOID VALVE SIGNAL 4 CIRCUIT

LOW INPUT —
• Engine stalls.
• Engine breathing
CAUTION:
• WIRING DIAGRAM:
MAIN RELAY
B47
6 BATTERY
RHD
RHD
4 1 2
SBF-5 3 4
5 LHD 2 LHD 5 6
3
B61 F44
2
1 E7
B47 1 2 3
B22 4 5 6
1
E3
F44
1 2 3 4
5 6 7 8
5
2
IDLE
AIR CONTROL B22
SOLENOID
VALVE 1 2 3 4
5 6 7 8
E7
9 10 11 12
13 14 15 16
6
3
4
1
E2 B21
3
4
1
2
B21
1 2 3 4
5 6 7 8
A19
A20
A5
A6
9 10 11 12
13 14 15 16
A: B134 17 18 19 20
C: B136 ECM
C22
C21
A: B134
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25 26 27 28 29 30 31 32 33 34 35
B22
16
E3
C: B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
EN1415
EN-256
Step Check Yes No

1 CHECK POWER SUPPLY TO IDLE AIR CON- Is the voltage more than 10 V? Go to step 2. Repair the har-
TROL SOLENOID VALVE. ness and connec-
2)Disconnect the connector from idle air con- NOTE:
trol solenoid valve. In this case, repair
4)Measure the voltage between idle air control • Open circuit in
solenoid valve connector and engine ground. harness between
Connector & terminal idle air control
main relay con-
nector
• Poor contact in
coupling connector
(B22)
Measure the voltage between idle air control tor.
solenoid valve connector and engine ground. NOTE:
(E7) No. 5 (+) — Engine ground (−): the following:
• Open circuit in
harness between
idle air control
solenoid valve and
main relay con-
nector
• Poor contact in
coupling connector
(B22)
IDLE AIR CONTROL SOLENOID VALVE Ω? ness and connec-
CONNECTOR. tor.
2)Measure the resistance between ECM and In this case, repair
idle air control solenoid valve connector. the following:
DTC P1510; (B134) No. 5 — (E7) No. 4: harness between
DTC P1512; (B134) No. 6 — (E7) No. 1: ECM and idle air
DTC P1514; (B134) No. 19 — (E7) No. 6: control solenoid
DTC P1516; (B134) No. 20 — (E7) No. 3: valve connector
• Poor contact in
coupling connector
(B21)
IDLE AIR CONTROL SOLENOID VALVE Ω? 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.
DTC P1510; (B134) No. 5 — Chassis
ground:
ground:
ground:
ground:
EN-257
Step Check Yes No

5 CHECK POOR CONTACT. Is there poor contact in ECM Repair the poor Replace the idle
Check poor contact in ECM connector and idle connector or idle air control contact in ECM air control solenoid
air control solenoid valve connector. solenoid valve connector? connector or idle valve. <Ref. to FU-
air control solenoid 39, Idle Air Con-
valve connector. trol Solenoid
Valve.>
EN-258
EN-259
BV:DTC P1517 — IDLE AIR CONTROL SOLENOID VALVE SIGNAL 4 CIRCUIT

HIGH INPUT —
• Engine stalls.
CAUTION:
• WIRING DIAGRAM:
MAIN RELAY
B47
6 BATTERY
RHD
RHD
4 1 2
SBF-5 3 4
5 LHD 2 LHD 5 6
3
B61 F44
2
1 E7
B47 1 2 3
B22 4 5 6
1
E3
F44
1 2 3 4
5 6 7 8
5
2
IDLE
AIR CONTROL B22
SOLENOID
VALVE 1 2 3 4
5 6 7 8
E7
9 10 11 12
13 14 15 16
6
3
4
1
E2 B21
3
4
1
2
B21
1 2 3 4
5 6 7 8
A19
A20
A5
A6
9 10 11 12
13 14 15 16
A: B134 17 18 19 20
C: B136 ECM
C22
C21
A: B134
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25 26 27 28 29 30 31 32 33 34 35
B22
16
E3
C: B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
EN1415
EN-260
Step Check Yes No

indicate DTC P1511, P1513,
P1515 and P1517 at same
time?
2 CHECK GROUND CIRCUIT FOR ECM. Is the resistance less than 5 Go to step 3. Repair the har-
2)Measure the resistance between ECM con- tor.
nector and chassis ground. NOTE:
harness between
ECM connector
and engine ground
terminal
• Poor contact in
ECM connector
• Poor contact in
coupling connector
(B22)
3 CHECK HARNESS BETWEEN ECM AND Is the voltage more than 10 V? Repair the battery Replace the ECM.
IDLE AIR CONTROL SOLENOID VALVE short circuit in har- <Ref. to FU-51,
CONNECTOR. ness between Engine Control
1)Turn the ignition switch to OFF. ECM and idle air Module.>
2)Disconnect the connector from idle air con- control solenoid
trol solenoid valve. valve connector.
4)Measure the voltage between ECM connec- replace the ECM.
tor and chassis ground. <Ref. to FU-51,
DTC P1511; (B134) No. 5 (+) — Chassis Module.>
ground (–):
DTC P1513; (B134) No. 6 (+) — Chassis
ground (–):
DTC P1515; (B134) No. 19 (+) — Chassis
ground (–):
DTC P1517; (B134) No. 20 (+) — Chassis
ground (–):
EN-261
BW:DTC P1518 — STARTER SWITCH CIRCUIT LOW INPUT —

CAUTION:
• WIRING DIAGRAM:
BATTERY
B72
SBF-4 SBF-1
1 2
3 4
1
IGNITION
SWITCH
B72
T7
3
1 2 3 4 5 6
7 8 9 10 11 12
INHIBITOR SWITCH
P R N D 3 2 1
B135 ECM 26 12 12
11 7 B12
B12 T3 T7 1 2 3 4
5 6 7 8
9 10 11 12
B135
STARTER SWITCH
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 28
B14
EN1419
EN-262
Step Check Yes No

1 CHECK OPERATION OF STARTER MOTOR. Does the starter motor operate Repair the har- Check the starter
NOTE: when ignition switch is turned ness and connec- motor circuit. <Ref.
Place the inhibitor switch in the “P” or “N” posi- to START? tor. to EN-64,
tion. NOTE: STARTER
In this case, repair MOTOR CIR-
the following: CUIT, Diagnostics
• Open or ground for Engine Start-
short circuit in har- ing Failure.>
ness between
ECM and starter
motor connector
• Poor contact in
ECM connector
EN-263
BX:DTC P1540 — VEHICLE SPEED SENSOR MALFUNCTION 2 —

CAUTION:
• WIRING DIAGRAM:
IGNITION B17
SWITCH BATTERY
1 2 3
SBF-4 SBF-1
1
No.18
4 B72
B72 1 2
3 4
A: i10
1 2 3 4 5 6 7 8 9 10
3
B56 TCM VEHICLE B22

SPEED
SENSOR 1 2 3 4
5 6 7 8
B17 9 10 11 12
17
13 14 15 16
1
2
B56
AT MT
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18
COMBINATION 19 20 21 22 23 24
METER
A: i10
B22 B135
16
A2 1
E3 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
i2 B37
20 21 22 23 24 25 26 27 28
LHD: l2
24
1 LHD :9
RHD :7 1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
B135 ECM
RHD: i2
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
EN1414
EN-264
Step Check Yes No

<Ref. to AT-57,
DTC 33 FRONT
VEHICLE SPEED
SENSOR, Diag-
nostic Procedure
with Diagnostic
Trouble Code
(DTC).>
cle speed sensor.
<Ref. to IDI-17,
Speedometer.>
nation meter con-
nector
• Poor contact in
ECM connector
• Poor contact in
combination meter
connector
• Poor contact in
coupling connector
(i2)
EN-265
BY:DTC P1560 — BACK-UP VOLTAGE CIRCUIT MALFUNCTION —

CAUTION:
• WIRING DIAGRAM:
RHD
RHD
BATTERY
SBF-5
LHD 2 LHD
B61 F44
C9
A: B134
1 AT MODEL : B6
B: B135 ECM
MT MODEL : B25
C: B136
A27
C22
C21
A34
A35
1
A7
A8
B22
13
15
14
16
E3
F44 B22 B: B135 C: B136
1 2 3 4 1 2 3 4 5 6 7 1 2 3 4 5 6 7
1 2 3 4
5 6 7 8 8 9 10 11 12 13 14 15 16 17 18 19 8 9 10 11 12 13 14 15 16 17 18 19 20
5 6 7 8
9 10 11 12 20 21 22 23 24 25 26 27 28 21 22 23 24 25 26 27 28 29 30
13 14 15 16
A: B134
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25 26 27 28 29 30 31 32 33 34 35
EN1420
Step Check Yes No

1 CHECK INPUT SIGNAL FOR ECM. Is the voltage more than 10 V? Repair the poor Go to step 2.
1)Turn the ignition switch to OFF. contact in ECM
chassis ground.
EN-266
Step Check Yes No

MAIN FUSE BOX CONNECTOR. Ω? 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.
3 CHECK FUSE SBF-5. Is the fuse blown? Replace the fuse. Repair the har-
ness and connec-
tor.
NOTE:
the following:
• Open circuit in
harness between
ECM and battery
• Poor contact in
ECM connector
• Poor contact in
battery terminal
EN-267
BZ:DTC P1590 — NEUTRAL POSITION SWITCH CIRCUIT HIGH INPUT (AT

MODEL) —
CAUTION:
• WIRING DIAGRAM:
BATTERY
B72
SBF-4 SBF-1
1 2
3 4
1
IGNITION
SWITCH
B72
T7
3
1 2 3 4 5 6
7 8 9 10 11 12
INHIBITOR SWITCH
P R N D 3 2 1
B135 ECM 26 12 12
11 7 B12
B12 T3 T7 1 2 3 4
5 6 7 8
9 10 11 12
B135
STARTER SWITCH
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 28
B14
EN1419
EN-268
Step Check Yes No

1 CHECK DTC P0705 ON DISPLAY. Does the Subaru Select Moni- Inspect DTC Go to step 2.
tor or OBD-II general scan tool P0705 using “List
Trouble Code
(DTC)”. <Ref. to
EN-83, List of
Diagnostic Trou-
ble Code (DTC).>
2 CHECK INPUT SIGNAL FOR ECM. Is the voltage less than 1 V? Go to step 3. Go to step 5.
chassis ground in selector lever “N” and “P”
positions.
3 CHECK INPUT SIGNAL FOR ECM. 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.
4 CHECK POOR CONTACT. Is there poor contact in ECM Repair the poor Contact with your
Check poor contact in ECM connector. connector? contact in ECM Subaru distributor
connector. service.
NOTE:
Inspection by DTM
is required, be-
cause probable
cause is deteriora-
tion of multiple
parts.
5 CHECK INPUT SIGNAL FOR ECM. Is the voltage more than 10 V? Repair the 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
(B135) No. 26 (+) — Chassis ground (−): switch connector.
6 CHECK HARNESS BETWEEN ECM AND IN- Is the resistance less than 1 Go to step 7. Repair the har-
HIBITOR SWITCH CONNECTOR. Ω? ness and connec-
2)Disconnect the connectors from ECM and NOTE:
inhibitor switch. In this case, repair
ECM and inhibitor switch connector. • Open circuit in
(B135) No. 26 — (T7) No. 12: ECM and inhibitor
switch connector
• Poor contact in
coupling connector
(B12)
• Poor contact in
inhibitor switch
connector
• Poor contact in
ECM connector
EN-269
Step Check Yes No

7 CHECK INHIBITOR SWITCH GROUND LINE. Is the resistance less than 5 Go to step 8. Repair the open
Measure the resistance of harness between Ω? circuit 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:
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
8 CHECK INHIBITOR SWITCH. Is the resistance less than 1 Go to step 9. Replace the inhibi-
Measure the resistance between inhibitor Ω? tor switch. <Ref. to
switch connector receptacle's terminals in AT-28, Inhibitor
selector lever “N” and “P” positions. Switch.>
Terminals
No. 7 — No. 12:
9 CHECK SELECTOR CABLE CONNECTION. Is there any fault in selector Repair the selector Contact with your
cable connection to inhibitor cable connection. Subaru distributor
switch? <Ref. to CS-10, service.
INSPECTION, NOTE:
Select Cable.> Inspection by DTM
is required, be-
cause probable
cause is deteriora-
tion of multiple
parts.
EN-270
EN-271
CA:DTC P1591 — NEUTRAL POSITION SWITCH CIRCUIT LOW INPUT (AT MOD-
EL) —
CAUTION:
• WIRING DIAGRAM:
BATTERY
B72
SBF-4 SBF-1
1 2
3 4
1
IGNITION
SWITCH
B72
T7
3
1 2 3 4 5 6
7 8 9 10 11 12
INHIBITOR SWITCH
P R N D 3 2 1
B135 ECM 26 12 12
11 7 B12
B12 T3 T7 1 2 3 4
5 6 7 8
9 10 11 12
B135
STARTER SWITCH
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 28
B14
EN1419
EN-272
Step Check Yes No

1 CHECK DTC P0705 ON DISPLAY. Does the Subaru Select Moni- Inspect the DTC Go to step 2.
Trouble Code
(DTC)”. <Ref. to
EN-83, List of
Diagnostic Trou-
ble Code (DTC).>
2 CHECK INPUT SIGNAL FOR ECM. Is the voltage between 4.5 and Even if MIL lights Go 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-
Connector & terminal this time.
TRANSMISSION HARNESS CONNECTOR. Ω? short circuit in har-
2)Disconnect the connectors from ECM and ECM and trans-
transmission harness connector (T3). mission harness
3)Measure the resistance of harness between connector.
4 CHECK TRANSMISSION HARNESS CON- Is the resistance less than 10 Repair the ground Go to step 5.
NECTOR. Ω? 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.
(T3) No. 12 — Engine ground:
5 CHECK INHIBITOR SWITCH. Is the resistance more than 1 Go to step 6. Replace the inhibi-
Measure the resistance between inhibitor MΩ at except “N” and “P” posi- tor switch. <Ref. to
switch connector receptacle's terminals in tions? AT-28, Inhibitor
selector lever except for “N” position. Switch.>
Terminals
No. 7 — No. 12:
INSPECTION, NOTE:
is required, be-
cause probable
cause is deteriora-
tion of multiple
parts.
EN-273
CB:DTC P1592 — NEUTRAL POSITION SWITCH CIRCUIT LOW INPUT (MT

MODEL) —
CAUTION:
• WIRING DIAGRAM:
B135 ECM
B25
1 2
26
B25
1
T2 B22
1 2 3 4
NEUTRAL 5 6 7 8
POSITION 9 10 11 12
SWITCH 13 14 15 16
T2
1 LHD : 16
2
B25 RHD : 15
B22 B135
1
1 2 3 4 5 6 7
E3 8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 28
EN1421
Step Check Yes No

1 CHECK INPUT SIGNAL FOR ECM. Is the voltage more than 10V in Go to step 2. Go to step 4.
1)Turn the ignition switch to ON. neutral position?
chassis ground.
EN-274
Step Check Yes No

2 CHECK INPUT SIGNAL FOR ECM. Is the voltage less than 1V in Go to step 3. Go to step 4.
Measure the voltage between ECM and chas- other position?
sis ground.
3 CHECK POOR CONTACT. Is the poor contact in ECM Repair the poor Contact with your
connector. service.
4 CHECK NEUTRAL POSITION SWITCH. Is the resistance more than Go to step 5. Repair the short
1)Turn the ignition switch to OFF. 1MΩ in neutral position? circuit in transmis-
2)Disconnect the connector from transmission sion harness or
harness. replace neutral
3)Measure the resistance between transmis- position switch.
sion harness and connector terminals.
(T2) No. 1 — No. 2:
5 CHECK NEUTRAL POSITION SWITCH. Is the resistance less than 1Ω Go to step 6. Repair the short
Measure the resistance between transmission in other positions? circuit in transmis-
harness connector terminals. sion harness or
replace neutral
position switch.
NEUTRAL POSITION SWITCH CONNEC- Ω? short circuit in har-
TOR. ness between
Measure the resistance between ECM and ECM and trans-
chassis ground. mission harness
Connector & terminal connector.
NEUTRAL POSITION SWITCH CONNEC- Ω? circuit in harness
TOR. between ECM and
1)Disconnect the connector from ECM. transmission har-
2)Measure the resistance of harness between ness connector.
ECM and transmission harness connector.
(B135) No. 26 — (B25) No. 1:
NEUTRAL POSITION SWITCH CONNEC- Ω? circuit between
TOR. transmission har-
Measure the resistance of harness between ness connector
transmission harness connector and engine and engine ground
ground. terminal.
9 CHECK POOR CONTACT. Is there poor contact in trans- Repair the poor Contact with your
Check poor contact in transmission harness mission harness connector? contact in trans- Subaru distributor
connector. mission harness service.
connector.
EN-275
CC:DTC P1594 — AUTOMATIC TRANSMISSION DIAGNOSIS INPUT SIGNAL

CIRCUIT MALFUNCTION —
CAUTION:
• WIRING DIAGRAM:
B56
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18
B56 TCM 19 20 21 22 23 24
21
B135
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 28
4
B135 ECM
EN0889
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-46,
tor fan makes one complete rotation. Transmission Con-
2)Drive the vehicle. trol Module
(TCM).>
EN-276
Step Check Yes No

2 CHECK ACCESSORY. Are the car phone and/or CB Repair the ground- Replace the TCM.
installed on vehicle? ing line of car <Ref. to AT-46,
phone or CB sys- Transmission Con-
tem. trol Module
(TCM).>
EN-277
CD:DTC P1595 — AUTOMATIC TRANSMISSION DIAGNOSIS INPUT SIGNAL

CIRCUIT LOW INPUT —
CAUTION:
• WIRING DIAGRAM:
B56
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18
B56 TCM 19 20 21 22 23 24
21
B135
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 28
4
B135 ECM
EN0889
EN-278
Step Check Yes No

1 CHECK HARNESS BETWEEN ECM AND Is the voltage less than 1 V? Go 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.
(B135) No. 4 (+) — Chassis ground (−): In this case, repair
the following:
• Poor contact in
ECM connector
• Poor contact in
TCM connector
TCM CONNECTOR. Ω? short circuit in har-
2)Disconnect the connector from ECM and ECM and TCM
TCM. connector.
3 CHECK OUTPUT SIGNAL FOR ECM. Is the voltage more than 5 V? Go to step 4. Repair the poor
1)Connect the connector to ECM. contact in ECM
chassis ground.
4 CHECK TROUBLE CODE FOR AUTOMATIC Does the DTC appear for auto- Inspect the DTC Replace the TCM.
TRANSMISSION. matic transmission? for automatic <Ref. to AT-46,
Read the DTC for automatic transmission. transmission. Transmission Con-
<Ref. to AT-22, Read Diagnostic Trouble Code <Ref. to AT-42, trol Module
(DTC).> Diagnostic Proce- (TCM).>
dure with Diagnos-
tic Trouble Code
(DTC).>
EN-279
CE:DTC P1596 — AUTOMATIC TRANSMISSION DIAGNOSIS INPUT SIGNAL

CIRCUIT HIGH INPUT —
CAUTION:
• WIRING DIAGRAM:
B56
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18
B56 TCM 19 20 21 22 23 24
21
B135
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 28
4
B135 ECM
EN0889
Step Check Yes No

1 CHECK HARNESS BETWEEN ECM AND Is 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. ness between
2)Measure the voltage between ECM and ECM and TCM
chassis ground. connector.
EN-280
Step Check Yes No

2 CHECK HARNESS BETWEEN ECM AND Is the voltage more than 4 V? Go to step 5. Go to step 3.
TCM CONNECTOR.
and chassis ground.
3 CHECK HARNESS BETWEEN ECM AND Is the voltage less than 1 V? Repair the poor Go to step 4.
TCM CONNECTOR. contact in ECM
Measure the voltage between ECM connector connector.
and chassis ground.
4 CHECK OUTPUT SIGNAL FROM ECM. Does the voltage change from Even if MIL lights Contact with your
Measure the voltage between ECM and chas- 1 V to 4 V while monitoring the up, the circuit has Subaru distributor
sis ground. value with voltage meter? returned to a nor- service.
Connector & terminal mal condition at NOTE:
(B135) No. 4 (+) — Chassis ground (−): this time. Inspection by DTM
NOTE: is required, be-
In this case, repair cause probable
the following: cause is deteriora-
• Poor contact in tion of multiple
ECM connector parts.
• Poor contact in
TCM connector
5 CHECK HARNESS BETWEEN ECM AND Is the voltage more than 4 V? Go to step 6. Repair the open
TCM CONNECTOR. circuit in harness
Measure the voltage between TCM and chas- between ECM and
sis ground. TCM connector.
6 CHECK POOR CONTACT. Is there poor contact in TCM Repair the poor Check the TCM
Check poor contact in TCM connector. connector? contact in TCM power supply line
connector. and grounding
line.
EN-281
CF:DTC P1698 — ENGINE TORQUE CONTROL CUT SIGNAL CIRCUIT LOW IN-
PUT —
CAUTION:
• WIRING DIAGRAM:
B55
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18
B55 TCM 19 20 21 22 23 24
10
B135
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 28
31
B134 ECM
EN0890
Step Check Yes No

1)Start the engine and warm-up engine. contact in ECM
2)Turn the ignition switch to OFF. connector.
chassis ground.
EN-282
Step Check Yes No

2)Disconnect the connectors from ECM and ECM and TCM
TCM. connector.
3 CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Repair the poor Repair the open
TCM CONNECTOR. Ω? contact in ECM or circuit in harness
Measure the resistance of harness between TCM connector. between ECM and
ECM and TCM connector. TCM connector.
(B134) No. 31 — (B55) No. 10:
EN-283
CG:DTC P1699 — ENGINE TORQUE CONTROL CUT SIGNAL CIRCUIT HIGH IN-
PUT —
CAUTION:
• WIRING DIAGRAM:
B55
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18
B55 TCM 19 20 21 22 23 24
10
B135
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 28
31
B134 ECM
EN0890
EN-284
Step Check Yes No

1 CHECK OUTPUT SIGNAL FROM ECM. Is the voltage less than 3 V? Go to step 2. Repair the battery
1)Start the engine and warm-up engine. short circuit in har-
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 FU-
Connector & terminal 51, Engine Con-
(B134) No. 31 (+) — Chassis ground (−): trol Module.>
2 CHECK HARNESS BETWEEN ECM AND Does the voltage change more Repair the battery Contact with your
TCM CONNECTOR. than 10 V by shaking harness short circuit in har- Subaru distributor
1)Turn the ignition switch to OFF. and connector of ECM while ness between service.
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-
(B134) No. 31 (+) — Chassis ground (−): ECM. <Ref. to FU- cause probable
51, Engine Con- cause is deteriora-
trol Module.> tion of multiple
parts.
EN-285
CH:DTC P1701 — CRUISE CONTROL SET SIGNAL CIRCUIT MALFUNCTION

FOR AUTOMATIC TRANSMISSION —
CAUTION:
• WIRING DIAGRAM:
B94
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
B94 CCM
3
B55
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18
19 20 21 22 23 24
22
B55 TCM
EN1422
EN-286
Step Check Yes No

1 CHECK HARNESS BETWEEN TCM AND Is the resistance less than 1 Go to step 2. Repair the open
CCM CONNECTOR. Ω? circuit in harness
1)Turn the ignition switch to OFF. between TCM and
2)Disconnect the connectors from TCM and CCM connector.
CCM.
TCM and CCM connector.
(B55) No. 22 — (B94) No. 3:
2 CHECK HARNESS BETWEEN TCM AND Is the resistance less than 10 Repair the short Go to step 3.
Measure the resistance of harness between between TCM and
TCM and chassis ground. CCM connector.
3 CHECK INPUT SIGNAL FOR TCM. Is the resistance less than 1 V? Go to step 4. Check the cruise
1)Connect the connector to TCM and CCM. control command
2)Lift-up the vehicle or set the vehicle on free switch circuit.
rollers. <Ref. to CC-6,
CAUTION: INSPECTION,
On AWD models, raise all wheels off Cruise Control
ground. Command
3)Start the engine. Switch.>
4)Cruise control main switch to ON.
5)Move the selector lever to “D” range and
slowly increase vehicle speed to 50 km/h (31
MPH).
6)Cruise control command switch to ON.
7)Measure the voltage between TCM and
chassis ground.
trol Module
(TCM).>
EN-287
CI: DTC P1711 — ENGINE TORQUE CONTROL SIGNAL 1 CIRCUIT MALFUNC-

TION —
• Excessive shift shock
CAUTION:
• WIRING DIAGRAM:
B56
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18
B56 TCM 19 20 21 22 23 24
5
B135
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 28
16
B135 ECM
EN0892
Step Check Yes No

chassis ground.
EN-288
Step Check Yes No

Connector & terminal ECM and TCM
(B135) No. 16 (+) — Chassis ground (−): connector.
Module.>
TCM CONNECTOR. Ω? circuit in harness
2)Disconnect the connectors from ECM and TCM connector.
TCM.
ECM and TCM connector.
(B135) No. 16 — (B56) No. 5:
ECM and chassis ground. ECM and TCM
trol Module
(TCM).>
EN-289
CJ:DTC P1712 — ENGINE TORQUE CONTROL SIGNAL 2 CIRCUIT MALFUNC-

TION —
CAUTION:
• WIRING DIAGRAM:
B56
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18
B56 TCM 19 20 21 22 23 24
14
B135
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 28
17
B135 ECM
EN0893
Step Check Yes No

chassis ground.
EN-290
Step Check Yes No

Module.>
TCM.
(B135) No. 17 — (B56) No. 14:
trol Module
(TCM).>
EN-291
GENERAL DIAGNOSTIC TABLE
20.General Diagnostic Table

A: INSPECTION
1. ENGINE
NOTE:
Malfunction of parts other than those listed is also possible. <Ref. to ME-95, Engine Trouble in General.>
Symptom Problem parts
1) Idle air control solenoid valve
2) Intake air temperature and pressure sensor
3) Ignition parts (*1)
1. Engine stalls during idling. 4) Engine coolant temperature sensor (*2)
5) Crankshaft position sensor (*3)
6) Camshaft position sensor (*3)
7) Fuel injection parts (*4)
3) Engine coolant temperature sensor (*2)
5) Air intake system (*5)
2. Rough idling 6) Fuel injection parts (*4)
7) Throttle position sensor
10) Oxygen sensor
11) Fuel pump and fuel pump relay
2) Engine coolant temperature sensor
3. Engine does not return to idle. 3) Accelerator cable (*6)
4. Poor acceleration
8) A/C switch and A/C cut relay
9) Engine torque control signal circuit
5. Engine stalls or engine sags or hesitates at 4) Camshaft position sensor (*3)
acceleration. 5) Purge control solenoid valve
1) Intake manifold pressure sensor
2) Intake air temperature sensor
6. Surge 5) Crankshaft position sensor (*3)
EN-292

7. Spark knock 4) Engine coolant temperature sensor
5) Knock sensor
8. After burning in exhaust system
*1: Check ignition coil & ignitor assembly and spark plug.
*2: Indicate the symptom occurring only in cold temperatures.
*3: Ensure the secure installation.
*4: Check fuel injector, fuel pressure regulator and fuel filter.
*5: Inspect air leak in air intake system.
*6: Adjust accelerator cable.
2. AUTOMATIC TRANSMISSION
NOTE:
Check general diagnostics table with non-conformity symptom for automatic transmission. <Ref. to AT-2, Ba-
sic Diagnostic Procedure.>
EN-293
EN-294
ENGINE 2 SECTION
FUEL INJECTION (FUEL SYSTEMS) FU(w/oOBD)
EMISSION CONTROL EC(w/oOBD)

EXHAUST EX(w/oOBD)
IGNITION IG(w/oOBD)
ENGINE(DIAGNOSTICS) EN(w/oOBD)
of SUBARU vehicles. FUEL INJECTION (FUEL SYSTEMS) FU(TURBO)
sembling, inspection and adjustment of EMISSION CONTROL EC(TURBO)
components and diagnostics for guid- (AUX. EMISSION CONTROL DEVICES)
Please peruse and utilize this manual INTAKE (INDUCTION) IN(TURBO)
their vehicle in optimum condition. MECHANICAL ME(TURBO)
SUBARU genuine parts. EXHAUST EX(TURBO)
IGNITION IG(TURBO)
ENGINE (DIAGNOSTICS) EN(TURBO)

approval.

FU(w/oOBD)
Page
2. Throttle Body.............................................................................................16
3. Intake Manifold..........................................................................................17
7. Knock Sensor............................................................................................33
9. Intake Air Temperature and Pressure Sensor...........................................38
11. Fuel Injector ..............................................................................................40
12. Oxygen Sensor .........................................................................................46
14. Main Relay ................................................................................................49
15. Fuel Pump Relay.......................................................................................50
16. Fuel ...........................................................................................................51
17. Fuel Tank ..................................................................................................52
18. Fuel Filler Pipe ..........................................................................................55
19. Fuel Pump.................................................................................................59
22. Fuel Filter ..................................................................................................65
23. Fuel Cut Valve...........................................................................................66
GENERAL DESCRIPTION
A: SPECIFICATIONS
Model 1600 cc and 2000 cc 2500 cc
Capacity 50 2 (13.2 US gal, 11.0 Imp gal) 60 2 (15.9 US gal, 13.2 Imp gal)
Fuel tank
Type Impeller
Shutoff discharge pressure 370 — 677 kPa (3.77 — 6.9 kg/cm2, 53.6 — 98 psi)
Fuel pump
Discharge flow
[12 V at 300 kPa (3.06 kg/cm2, 43.5 psi)]
FU(w/oOBD)-2
GENERAL DESCRIPTION
FU(w/oOBD)-3
GENERAL DESCRIPTION
B: COMPONENT
1. INTAKE MANIFOLD
T5 (2)
(20)
T3
(4) T5
(3)
(7) (23) T5
(5) (8)
T3
T6
(2)
T4 (6)
T3
(22) T2
(13) (9)
T5 T5
T4 (20)
(4)
T6
(14) (3)
(5)
T6
(16)
(1) T6
(10)
(21)
T5
T6
T5
(15)
(19) T1
(18)
(11) (21)
T1 (18) T1
T1 (12)
(19) (17)
T1
(19) T5
T1
T3
(18)
EN1385
FU(w/oOBD)-4
GENERAL DESCRIPTION
(1) Intake manifold gasket RH (12) Fuel pipe protector LH (22) Plug cord holder RH
(2) Fuel injector pipe (13) Intake air temperature and pres- (23) Accelerator cable bracket
(3) Fuel injector sure sensor
(4) O-ring (14) O-ring Tightening torque: N·m (kgf-m, ft-lb)
(5) O-ring (15) Plug cord holder LH T1: 1.5 (0.15, 1.1)
(6) Plug (16) Fuel pipe protector RH T2: 3.4 (0.35, 2.5)
(7) PCV valve (17) Fuel pipe ASSY T3: 5.0 (0.51, 3.7)
(8) Purge control solenoid valve (18) Fuel hose T4: 17 (1.7, 12.5)
(9) Nipple (19) Clip T5: 19 (1.9, 14.0)
(10) Intake manifold (20) Clip T6: 25 (2.5, 18.4)
(11) Intake manifold gasket LH (21) Guide pin
FU(w/oOBD)-5
GENERAL DESCRIPTION
B2M3455C
(1) Gasket (4) Throttle body Tightening torque: N·m (kgf-m, ft-lb)
(2) Throttle position sensor T1: 1.6 (0.16, 1.2)
(3) Idle air control solenoid valve T2: 22 (2.2, 16.2)
FU(w/oOBD)-6
GENERAL DESCRIPTION
B2M2282B
(2) Knock sensor (4) Camshaft position sensor support T1: 6.4 (0.65, 4.7)
T2: 24 (2.4, 17.4)
FU(w/oOBD)-7
GENERAL DESCRIPTION
4. FUEL TANK
• 1600 CC and 2000 CC MODEL
T1
T1
(25)
(16)
(9) D
(8) (10) (11)

(6) D (11)
C
B (11)
A (14)
(13)
(7) (24)
T1 (12) (24)
(11)
C
(9) (11)
(8)
(5) (15)
B
(11)
(17)
(19) (18) (20)
A
(4) (11)
(21)
(11)
(22)
(2)
T3 (18)
T3
(19)
(11)
(23)
(3)
(2)
T2
T2
(1)
T2
EN0439
FU(w/oOBD)-8
GENERAL DESCRIPTION
(1) Heat shield cover (11) Clip (21) Fuel pipe ASSY
(2) Fuel tank band (12) Evaporation hose B (22) Evaporation hose F
(3) Protector RH (13) Joint pipe (23) Fuel return hose B
(4) Fuel tank (14) Evaporation hose C (24) Evaporation hose G
(5) Fuel pump gasket (15) Evaporation pipe ASSY (25) Evaporation hose H
(6) Fuel pump ASSY (16) Evaporation pipe
(7) Fuel meter unit (17) Evaporation hose D Tightening torque: N·m (kgf-m, ft-lb)
(8) Fuel cut valve gasket (18) Retainer T1: 4.4 (0.45, 3.3)
(9) Fuel cut valve (19) Quick connector T2: 7.4 (0.75, 5.4)
(10) Evaporation hose A (20) Evaporation hose E T3: 33 (3.4, 24.3)
FU(w/oOBD)-9
GENERAL DESCRIPTION
• 2500 CC MODEL
T1
T1
(30)
(17)
(10) E
(9) (11) (12)

(7) D (12)
C
B (12)
A (15)
T1 (14)
(8) (29)
(13) (29)
(12)
T1
D
(9) (12)
(8)
(28)
(6) (16)
E
B (12)
(12)
(18)
(21) (20) (22)
(19) A
(5) (27)
(12)
(12)
(26)
(23) F
(12)
(24)
(2)
T3 (20)
T3
(12)
(25)
(4)
(2)
T2
T2
(1)
(3) T2
T2
EN1503
FU(w/oOBD)-10
GENERAL DESCRIPTION
FU(w/oOBD)-11
GENERAL DESCRIPTION
5. FUEL LINE
(19)
(18)
B
(24) (20) (17)
A (16)
(25) (15)
(24)
(22)
(21) (13)
T
(23) (14)
B
(1) (1)
C
A C
(12)
(8)
(1) (1) (10)

(9) (1)
(1)
(1)
(1)
(10) (11)
(7)
(1)
(6) (2)
(1)
(5)
(4)
(3)
EN0440
FU(w/oOBD)-12
GENERAL DESCRIPTION
FU(w/oOBD)-13
GENERAL DESCRIPTION
6. FUEL FILLER PIPE
(9)
(8)
(10)
(11)
(1)
(3)
T
(5) (2)
T
(3)
(6)
T
(4)
(3)
(7)
EN0441
(1) Fuel filler pipe ASSY (7) Air vent pipe holder Tightening torque: N·m (kgf-m, ft-lb)
(2) Evaporation hose holder (8) Filler pipe packing T: 7.5 (0.76, 5.5)
(3) Clip (9) Filler ring
(4) Clamp (10) Filler cap
(5) Air vent hose (11) Filler pipe protector
(6) Air vent pipe
FU(w/oOBD)-14
GENERAL DESCRIPTION

D: PREPARATION TOOL
(Newly adopted
tool)
B2M3876
B2M3877
FU(w/oOBD)-15
THROTTLE BODY
2. Throttle Body 6) Disconnect the air by-pass hose from purge con-
trol solenoid valve.
A: REMOVAL
H2M2949
G6M0095 (A) Throttle position sensor

(B) Idle air control solenoid valve
(C) Air by-pass hose from purge control solenoid
valve
7) Disconnect the engine coolant hoses from throt-

tle body.
H2M2947

B2M4255
8) Remove the bolts which install throttle body to

intake manifold.
B: INSTALLATION
NOTE:
Always use a new gasket.
Tightening torque:
B2M4254A Throttle body;
22 N·m (2.2 kgf-m, 16.2 ft-lb)
5) Disconnect the connectors from idle air control Air cleaner case;
solenoid valve and throttle position sensor. 6.5 N·m (0.66 kgf-m, 4.8 ft-lb)
FU(w/oOBD)-16
INTAKE MANIFOLD
3. Intake Manifold 7) Remove the power steering pump and tank from
brackets.
A: REMOVAL (1) Remove the resonator chamber. <Ref. to
1) Release the fuel pressure. <Ref. to FU(w/ IN-8, REMOVAL, Resonator Chamber.>
oOBD)-51, RELEASING OF FUEL PRESSURE, (2) Remove the front side V-belt. <Ref. to ME-
OPERATION, Fuel.> 44, REMOVAL, V-belt.>
2) Open the fuel flap lid and remove fuel filler cap. (3) Remove the bolts which hold power steering
3) Disconnect the ground cable from battery. pipes onto intake manifold protector.
NOTE:
Do not disconnect the power steering hose.
G6M0095

sembly. <Ref. to IN-7, REMOVAL, Air Intake B2M4126
Duct.> and <Ref. to IN-6, REMOVAL, Air Cleaner
Case.> (4) Remove the bolts which install power steer-
ing pump bracket.
B2M3151

B2M4254A ing pump switch.
EN0360
FU(w/oOBD)-17
INTAKE MANIFOLD
(6) Remove the power steering tank from the 11) Disconnect the brake booster hose.
B2M4259
EN0361
12) Remove the air cleaner case stay RH and en-
(7) Place the power steering pump and tank on gine harness bracket, and then disconnect the en-
right side wheel apron. gine harness connectors from bulkhead harness
connectors.
EN0208
B2M4260
8) Disconnect the spark plug cords from spark
plugs. 13) Disconnect the connectors from engine coolant
9) Disconnect the PCV hose from intake manifold. temperature sensor.
B2M4258 B2M4261
10) Disconnect the engine coolant hose from throt- 14) Disconnect the knock sensor connector.
tle body.
B2M4262
B2M4255
FU(w/oOBD)-18
INTAKE MANIFOLD
15) Disconnect the connector from crankshaft posi- 18) Disconnect the fuel hoses from fuel pipes.
tion sensor. WARNING:
• Do not spill fuel.
cloth.
B2M1252
16) Disconnect the connector from oil pressure

switch.
S2M0500F

(B) Return hose
19) Remove the bolts which hold intake manifold

B2M1253
17) Disconnect the connector from camshaft posi-

tion sensor.
B2M4128
20) Remove the intake manifold.
B2M4263
B2M0160
FU(w/oOBD)-19
INTAKE MANIFOLD
B: INSTALLATION 4) Connect the connector to oil pressure switch.

1) Install the intake manifold onto cylinder heads.
NOTE:
Tightening torque:
25 N·m (2.5 kgf-m, 18.4 ft-lb)
B2M1253
5) Connect the connector to crankshaft position

sensor.
B2M4128
2) Connect the fuel hoses.
B2M1252
S2M0500F

(B) Return hose

sor. B2M4262
7) Connect the connectors to engine coolant tem-

perature sensor.
B2M4263
B2M4261
FU(w/oOBD)-20
INTAKE MANIFOLD
8) Install the air cleaner case stay RH and engine 13) Install the power steering pump and tank on
harness bracket, and then connect the engine har- brackets.
ness connectors to bulkhead connectors. (1) Install the power steering tank on bracket.
B2M4260 EN0361
9) Connect the brake booster hose. (2) Connect the connector to power steering
pump switch.
B2M4259
EN0360
10) Connect the engine coolant hose to throttle
body. (3) Tighten the bolts which install power steer-
ing pump on bracket.
Tightening torque:
22 N·m (2.2 kgf-m, 16.2 ft-lb)
B2M4255
11) Connect the PCV hose to intake manifold.
B2M3151
(4) Install the power steering pipes onto right

side intake manifold protector.
B2M4258
12) Connect the spark plug cords to spark plugs.
B2M4126
FU(w/oOBD)-21
INTAKE MANIFOLD
(5) Install the front side V-belt. <Ref. to ME-44, 18) Connect the battery ground cable to battery.
(6) Install the resonator chamber.
Tightening torque:
33 N·m (3.4 kgf-m, 24.3 ft-lb)
G6M0095
C: DISASSEMBLY
1) Disconnect the engine ground cable from intake
manifold.
B6M1237
14) Connect the accelerator cable (A).

15) Connect the cruise control cable (B). (With
cruise control models)
B2M4265

ignitor assembly.
B2M4254A
16) Install the air intake duct and air cleaner as-
sembly. <Ref. to IN-7, INSTALLATION, Air Intake
Duct.> and <Ref. to IN-6, INSTALLATION, Air
Cleaner Case.>
H2M2957
3) Remove the ignition coil and ignitor assembly.
EN0344
H2M2958
FU(w/oOBD)-22
INTAKE MANIFOLD
4) Disconnect the connector from intake air tem- 9) Remove the fuel pipe protector LH.
B2M4129
H2M2959
10) Remove the fuel pipe protector RH.
sensor from intake manifold.
B2M4130
11) Disconnect the connectors from fuel injectors.

H2M2960
6) Disconnect the connectors from throttle position

sensor and idle air control solenoid valve.
7) Remove the throttle body.
B2M3371
12) Disconnect the connector from purge control

solenoid valve.
H2M2951
8) Disconnect the pressure regulator vacuum hose

from intake manifold.
B2M3485
H2M2961
FU(w/oOBD)-23
INTAKE MANIFOLD
13) Disconnect the air by-pass hose (A) from purge 18) Remove the bolt which installs injector pipe on
control solenoid valve. intake manifold.
(A)
EN1003 H2M2966
14) Remove the harness bands (A) and harness 19) Remove the two bolts which hold fuel pipes on
bracket (B) which hold engine harness onto intake the left side of intake manifold.
manifold.
B2M4272
B2M4271A
20) Remove the fuel injectors.
15) Remove the engine harness from intake mani- (1) Remove the fuel injector securing clip.
fold.
16) Remove the purge control solenoid valve.
H2M2969
B2M3487
fuel injector pipe.
17) Remove the bolt which installs injector pipe on
intake manifold as shown in the figure.
H2M2970
H2M2965
FU(w/oOBD)-24
INTAKE MANIFOLD
21) Loosen the clamp which holds front left side 25) Remove the fuel pipe assembly (B) and pres-
fuel hose to injector pipe, and then remove the pipe sure regulator (A) from intake manifold.
from fuel hose.
H2M2976A
B2M4289
22) Loosen the clamp which holds front right side

fuel hose to injector pipe, and remove the pipe from
fuel hose.
B2M4274
23) Remove the fuel injector pipe.
H2M2975
24) Remove the bolt which installs fuel pipes on in-

take manifold.
H2M2974
FU(w/oOBD)-25
INTAKE MANIFOLD
D: ASSEMBLY 5) Connect the left side fuel hose to injector pipe,

1) Install the fuel pipe assembly (B) and pressure and then tighten the clamp screw.
regulator (A), etc. to intake manifold.
B2M4289
H2M2976A 6) Install the fuel injectors.

2) Tighten the bolt which installs fuel pipes on in- NOTE:
take manifold. Always use new O-rings.
Tightening torque:
5.0 N·m (0.51 kgf-m, 3.7 ft-lb)
B2M3372A
(A) O-ring
H2M2974
(B) Fuel injector
3) Connect the right side fuel hose to injector pipe, (C) Intake manifold protector
NOTE:
Do not forget to install the fuel injector securing clip.
B2M4274
4) Install the fuel injector pipe.

H2M2969
H2M2975
FU(w/oOBD)-26
INTAKE MANIFOLD
7) Tighten the bolt which installs injector pipe on in- 10) Install the purge control solenoid valve.
take manifold.
Tightening torque:
5.0 N·m (0.51 kgf-m, 3.7 ft-lb)
B2M3487
11) Connect the hoses to purge control solenoid

valve.
H2M2965 CAUTION:
8) Tighten the two bolts which install fuel pipes on Carefully connect the evaporation hoses.
the left side of intake manifold.
Tightening torque:
5.0 N·m (0.51 kgf-m, 3.7 ft-lb)
B2M1893E
A: To fuel pipe
B: To throttle body
B2M4272
12) Install the engine harness onto intake manifold.
9) Tighten the bolt which installs injector pipe on in-
take manifold. Tightening torque:
16 N·m (1.6 kgf-m, 11.8 ft-lb)
Tightening torque:
5.0 N·m (0.51 kgf-m, 3.7 ft-lb) 13) Connect the connectors to fuel injectors and
purge control solenoid valve.
14) Hold the engine harness by harness band (A)
and harness bracket (B).
H2M2966
B2M4271A
NOTE:
Do not use the harness band on harnesses where
they are supposed to be protected by the fuel pipe
protector.
FU(w/oOBD)-27
INTAKE MANIFOLD
15) Install the fuel pipe protector RH. 18) Install the throttle body to intake manifold.
Tightening torque: NOTE:
19 N·m (1.9 kgf-m, 14.0 ft-lb) Replace the gasket with a new one.
Tightening torque:
22 N·m (2.2 kgf-m, 16.2 ft-lb)
B2M4130
16) Install the fuel pipe protector LH.

H2M2951
Tightening torque:
19 N·m (1.9 kgf-m, 14.0 ft-lb) 19) Connect the air by-pass hose (A) from purge
control solenoid valve to intake manifold.
B2M4129 (A)
EN1003
17) Connect the pressure regulator vacuum hose
to intake manifold.
H2M2961
FU(w/oOBD)-28
INTAKE MANIFOLD
20) Install the intake air temperature and pressure 25) Install the engine ground cable to intake mani-
sensor. fold.
3.4 N·m (0.35 kgf-m, 2.5 ft-lb) 19 N·m (1.9 kgf-m, 14.0 ft-lb)
H2M2960 B2M4265
NOTE: E: INSPECTION
Replace the O-ring with a new one. Make sure the fuel pipe and fuel hoses are not
H2M2999
21) Connect the connector to intake air tempera-

ture and pressure sensor.
22) Connect the connectors to throttle position sen-
sor and idle air control solenoid valve.
23) Install the ignition coil and ignitor assembly.
H2M2958
24) Connect the connector to ignition coil and igni-

tor assembly.
FU(w/oOBD)-29

Tightening torque:
B2M4275
G6M0095

sembly. <Ref. to IN-7, REMOVAL, Air Intake
Duct.> and <Ref. to IN-6, REMOVAL, Air Cleaner
Case.>
temperature sensor.
B2M4261
FU(w/oOBD)-30

A: REMOVAL
T: 6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
G6M0095
B2M1252B
G2M0408
3) Remove the crankshaft position sensor, and

then disconnect the connector from it.
G2M0409
FU(w/oOBD)-31
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.
B2M2322
G6M0095
B: INSTALLATION
2) Disconnect the connector from camshaft posi- Install in the reverse order of removal.
tion sensor.
Tightening torque:
Camshaft position sensor support;
6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
Camshaft position sensor;
6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
B2M4263

sensor to camshaft position sensor support.
B2M2375

sensor support to camshaft cap LH.
B2M2321
FU(w/oOBD)-32
KNOCK SENSOR

A: REMOVAL
24 N·m (2.4 kgf-m, 17.4 ft-lb)
NOTE:
G6M0095
H2M3511C
(A) Front side
H2M2947
B2M4262
3) Install the air cleaner case.
B2M4262
H2M2947
S2M1673
FU(w/oOBD)-33
KNOCK SENSOR
G6M0095
FU(w/oOBD)-34

A: REMOVAL
1.6 N·m (0.16 kgf-m, 1.2 ft-lb)
CAUTION:
When installing the throttle position sensor, ad-
just to the specified data.
G6M0095

sensor.
H2M2979
B2M3493

H2M2979
FU(w/oOBD)-35
C: ADJUSTMENT 4) When using the 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.
B2M3765 B2M3765
3) When using the 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 proper (3) Insert the cartridge to Subaru Select Moni-
position to allow the voltage signal to ECM to be tor.
in specification.
Connector & terminal/Specified voltage
(B136) No. 15 — (B136) No. 17/0.45 — 0.55 V
[Fully closed.]
S2M0286A
(4) Connect the Subaru Select Monitor to data

link connector.
B2M4131A
(4) Tighten the throttle position sensor holding

screws.
Tightening torque:
1.6 N·m (0.16 kgf-m, 1.2 ft-lb)
B2M3148
5) Turn the ignition switch to ON, and Subaru Se-

lect Monitor switch to ON.
Menu.
7) Select the {Engine Control System} in Selection
Menu.
B2M3765 8) Select the {1. Current Data Display & Save} in
Menu.
FU(w/oOBD)-36
10) Adjust the throttle position sensor to the proper

position to match with the following specifications.
Condition: Throttle fully closed
Throttle opening angle 0.00 %
Throttle sensor voltage 0.50 V
11) Tighten the throttle position sensor holding
screws.
Tightening torque:
1.6 N·m (0.16 kgf-m, 1.2 ft-lb)
B2M3765
FU(w/oOBD)-37
INTAKE AIR TEMPERATURE AND PRESSURE SENSOR
9. Intake Air Temperature and B: INSTALLATION

Pressure Sensor Install in the reverse order of removal.
Tightening torque:
H2M2982
G6M0095
2) Disconnect the spark plug cord from ignition coil NOTE:

and ignitor assembly. Replace the O-ring with a new one.
B2M3373 H2M2999

H2M2981

sensor.
H2M2982
FU(w/oOBD)-38

NOTE:
Tightening torque:
1.6 N·m (0.16 kgf-m, 1.2 ft-lb)
G6M0095
2) Disconnect the connector from idle air control H2M2984

solenoid valve.
H2M2983

throttle body.
H2M2984
FU(w/oOBD)-39
FUEL INJECTOR
11.Fuel Injector (3) Remove the bolts which install power steer-
ing pump to bracket.
A: REMOVAL
1. RH SIDE
<Ref. to FU(w/oOBD)-51, RELEASING OF FUEL
PRESSURE, OPERATION, Fuel.>
cap.
B2M3151

ing pump switch.
G6M0095
4) Remove the resonator chamber. <Ref. to IN-8,

REMOVAL, Resonator Chamber.>
(#1 and #3 cylinders). EN0360
(5) Remove the power steering tank from the

bracket by pulling it upwards.
B2M4127

brackets. EN0361
(1) Remove the front side V-belt. <Ref. to ME- (6) Place the power steering pump and tank on
44, REMOVAL, V-belt.> the right side wheel apron.
(2) Remove the bolts which hold power steering
EN0208
B2M4126
FU(w/oOBD)-40
FUEL INJECTOR
7) Remove the fuel pipe protector RH. 10) Remove the fuel injector from intake manifold.
B2M4130
H2M2991
fuel injector pipe.
B2M4280
9) Remove the bolts which hold injector pipe to in-

H2M2992
take manifold.
B2M4281
B2M4282
FU(w/oOBD)-41
FUEL INJECTOR
2. LH SIDE 8) Move the washer tank, and secure it away from

working area.
1) Release the fuel pressure. <Ref. to FU(w/
oOBD)-51, RELEASING OF FUEL PRESSURE,
OPERATION, Fuel.>
cap.
B2M3140

G6M0095
4) Remove the two bolts which install washer tank

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

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

suitable cap. B2M3379
FU(w/oOBD)-42
FUEL INJECTOR
12) Remove the bolt which installs injector pipe to (2) Remove the fuel injector while lifting up the
intake manifold. fuel injector pipe.
B2M4133 H2M3241
B: INSTALLATION
1. RH SIDE
NOTE:
H2M2994
13) Remove the bolt which holds fuel pipe on the

left side intake manifold.
B2M3372A
(A) O-ring
(B) Fuel injector
(C) Intake manifold protector
Tightening torque:
H2M2995
5.0 N·m (0.51 kgf-m, 3.7 ft-lb)
14) Remove the fuel injector from intake manifold.
B2M4293
H2M2997
FU(w/oOBD)-43
FUEL INJECTOR
Tightening torque: 2. LH SIDE

19 N·m (1.9 kgf-m, 14.0 ft-lb)
NOTE:
B2M4132
Tightening torque:
19 N·m (1.9 kgf-m, 14.0 ft-lb) B2M3372A
(A) O-ring
(B) Fuel injector
(C) Intake manifold protector
Tightening torque:
5.0 N·m (0.51 kgf-m, 3.7 ft-lb)
B2M4130
Tightening torque:
33 N·m (3.4 kgf-m, 24.3 ft-lb)
H2M2994
Tightening torque:
5.0 N·m (0.51 kgf-m, 3.7 ft-lb)
B6M1237
H2M2995
FU(w/oOBD)-44
FUEL INJECTOR
Tightening torque:
19 N·m (1.9 kgf-m, 14.0 ft-lb)
B2M4133
Tightening torque:
19 N·m (1.9 kgf-m, 14.0 ft-lb)
B2M4129
FU(w/oOBD)-45
OXYGEN SENSOR
12.Oxygen Sensor B: INSTALLATION

1) Before installing the oxygen sensor, apply anti-
A: REMOVAL seize compound only to the threaded portion of ox-
1) Disconnect the ground cable from battery. ygen sensor to make the next removal easier.
SS-30 by JET LUBE
CAUTION:
tor of oxygen sensor.
G6M0095
2) Disconnect the connector from oxygen sensor.
G2M0412
2) Install the oxygen sensor.

Tightening torque:
21 N·m (2.1 kgf-m, 15.2 ft-lb)
B2M3108

threaded portion of oxygen sensor, and leave it for
1 minute or more.
5) Remove the oxygen sensor.
CAUTION: G2M0411
When removing the oxygen sensor, wait until
the exhaust pipe cools, otherwise it will dam- 3) Lower the vehicle.
age exhaust pipe. 4) Connect the connector of oxygen sensor.
G2M0411 B2M3108
FU(w/oOBD)-46
OXYGEN SENSOR
G6M0095
FU(w/oOBD)-47

A: REMOVAL
G6M0095

EN0532

(A)
(A)
(B)
EN0533

the ECM.
FU(w/oOBD)-48
MAIN RELAY

A: REMOVAL
G6M0095

er.
on body.
EN0534
FU(w/oOBD)-49
FUEL PUMP RELAY

A: REMOVAL
G6M0095

er.
bracket on body.
EN0535

bracket.
FU(w/oOBD)-50
FUEL

WARNING:
EN0999
• 2500 cc MODEL
EN0344

onds.
2. DRAINING FUEL
EN0839
WARNING:
• Place “NO FIRE” signs near the working area. 6) Tighten the fuel drain plug.
• Be careful not to spill fuel on the floor. Tightening torque:
1) Set the vehicle on a lift. 26 N·m (2.7 kgf-m, 19.2 ft-lb)
2) Disconnect the ground cable from battery. • 1600 cc and 2000 cc MODEL
G6M0095 EN0999
3) Open the fuel filler flap lid and remove fuel filler • 2500 cc MODEL
cap.
EN0839
FU(w/oOBD)-51
FUEL TANK
A: REMOVAL
WARNING:
OPERATION, Fuel.>
3) Drain fuel from the fuel tank. <Ref. to FU(w/
oOBD)-51, DRAINING FUEL, OPERATION, Fuel.> EN0539
5) Disconnect the connector (A) of fuel tank cord to 10) Move the clips, and then disconnect quick con-
rear harness. nector. <Ref. to FU(w/oOBD)-68, REMOVAL, Fuel
6) Push the grommet (B) which holds fuel tank cord Delivery, Return and Evaporation Lines.>
(B)
(A) EN0540
EN0537
(A) (B)
EN0840
EN0541
FU(w/oOBD)-52
FUEL TANK
B: INSTALLATION 5) Connect the fuel hoses, and then secure them

1) Support the fuel tank with transmission jack and with clips and quick connector. <Ref. to FU(w/
push the fuel tank harness into access hole with oOBD)-69, INSTALLATION, Fuel Delivery, Return
grommet. and Evaporation Lines.>
2) Set the fuel tank and temporarily tighten the
WARNING:
EN0540
6) Tighten the band mounting bolts.

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

valve and connect the canister hose (B) to canister.
(A) (B)
EN0541

INSTALLATION, Rear Crossmember.>
EN0840
8) Connect the connectors (A) to fuel tank cord and
4) Connect the fuel filler hose and air vent hose. plug the service hole with grommet (B).
(B)
(A)
EN0539 EN0537
FU(w/oOBD)-53
FUEL TANK
EN0344
C: INSPECTION
1) Make sure there are no cracks, holes, or other
FU(w/oOBD)-54
FUEL FILLER PIPE
A: REMOVAL tank.
WARNING: • 1600 cc and 2000 cc MODEL
OPERATION, Fuel.>
cap.
EN0999
• 2500 cc MODEL
G6M0095

EN0839
Tightening torque:
26 N·m (2.7 kgf-m, 19.2 ft-lb)
EN0542
6) Remove the rear right side wheel nuts.

EN0999
• 2500 cc MODEL
B2M1748
EN0839
FU(w/oOBD)-55
FUEL FILLER PIPE
11) Remove the fuel filler pipe protector. 16) Move the clip and separate air vent hose (B).
(A)
(B)
EN0544 EN0548
12) Separate the evaporation hoses from clip of 17) Remove the fuel filler pipe to under side of the
fuel filler pipe. vehicle.
from body.
EN0545
13) Disconnect the air vent hose from fuel filler EN0549
pipe.
EN0546
14) Remove the bolt which holds fuel filler pipe

bracket on body.
EN0547

FU(w/oOBD)-56
FUEL FILLER PIPE
B: INSTALLATION 6) Insert the fuel filler hose (A) approx. 35 to 40 mm

1) Hold the fuel filler flap open. (1.38 to 1.57 in) over the lower end of fuel filler pipe
2) Set the fuel saucer (A) with rubber packing (C) and tighten the clamp.
and insert the fuel filler pipe into hole from the inner CAUTION:
side of apron. Do not allow clips to touch the air vent hose (B)
3) Align the holes in fuel filler pipe neck and set cup and rear suspension crossmember.
NOTE: (A)
side, straighten it with a screwdriver. (B)
EN0548
7) Insert the air vent hose approx. 25 to 30 mm

and hold clip.
B2M1196A
L = 27.5±2.5 mm (1.083±0.098 in)
4) Install the air vent pipe.
B2M1195A
EN0549
5) Connect the air vent hose to fuel filler pipe. (1) Hose
(2) Clip
(3) Pipe
8) Tighten the bolt which holds fuel filler pipe brack-

et on body.
Tightening torque:
7.5 N·m (0.75 kgf-m, 5.4 ft-lb)
EN0546
EN0547
FU(w/oOBD)-57
FUEL FILLER PIPE
9) Tighten the bolts which hold evaporation hoses 15) Connect the battery ground cable to battery.
onto clip of fuel filler pipe.
G6M0095
EN0545
EN0544
B2M1748

13) Tighten the wheel nuts.
EN0344
FU(w/oOBD)-58
FUEL PUMP

26 N·m (2.7 kgf-m, 19.2 ft-lb)
WARNING:
NOTE:
level sensor.
OPERATION, Fuel.>
EN0999
cap. 7) Raise the rear seat and turn floor mat up.
3) Disconnect the ground cable from battery. 8) Remove the access hole lid.
G6M0095 EN0553
4) Lift-up the vehicle. 9) Disconnect the connector from fuel pump.

tank.
EN0554
10) Disconnect the quick connector and then dis-

EN0999 connect fuel delivery hose (A). <Ref. to FU(w/
oOBD)-68, REMOVAL, Fuel Delivery, Return and
Evaporation Lines.>
FU(w/oOBD)-59
FUEL PUMP
11) Move the clip and then disconnect the fuel re- 5) Drain fuel from the fuel tank. Set a container un-
turn hose (B). der the vehicle and remove the drain plug from fuel
tank.
(A)
(B)
EN0555
EN0839
sembly onto fuel tank. 6) Tighten the fuel drain plug.
Tightening torque:
26 N·m (2.7 kgf-m, 19.2 ft-lb)
EN0556
oOBD)-51, RELEASING OF FUEL PRESSURE, 7) Raise the rear seat and turn floor mat up.
OPERATION, Fuel.> 8) Remove the access hole lid.
cap.
EN0553
9) Disconnect the connector from fuel pump.
G6M0095
S2M0172
FU(w/oOBD)-60
FUEL PUMP
10) Disconnect the quick connector, and then dis- • 2500 cc MODEL
connect fuel delivery hose (A). <Ref. to FU(w/
oOBD)-68, REMOVAL, Fuel Delivery, Return and
Evaporation Lines.>
11) Move the clips, and then disconnect the fuel re-
turn hose (B) and jet pump hose (C).
S2M0063A
C: INSPECTION
S2M0060A whether the pump operates.
12) Remove the nuts which install fuel pump as- WARNING:
sembly onto fuel tank. • Wipe off the fuel completely.
as possible.
S2M0061
3 2 1
6 5 4
B: INSTALLATION
Install in the reverse order of removal. Do the fol-
lowing:
EN1502
Tightening torque:
4.4 N·m (0.45 kgf-m, 3.3 ft-lb)
(C) (A) (E)
(H)
(G)
(F) (B) (D)

EN0557
FU(w/oOBD)-61
FUEL LEVEL SENSOR
20.Fuel Level Sensor • 2500 cc MODEL
A: REMOVAL
WARNING:
NOTE:
Fuel level sensor is built in the fuel pump assembly.
1) Remove the fuel pump assembly. <Ref. to FU(w/
oOBD)-59, REMOVAL, Fuel Pump.>
2) Disconnect the connector from fuel pump brack- EN0846
et.
• 1600 cc and 2000 cc MODEL B: INSTALLATION
EN0559
• 2500 cc MODEL
S2M0145
3) Remove the bolt which installs fuel level sensor

;;;;;
;
EN0560
FU(w/oOBD)-62
A: REMOVAL
NOTE:
Fuel sub level sensor is equipped to only 2500 cc
model.
WARNING:
G2M0863

G6M0095

der the vehicle and remove the drain plug from fuel S2M0151
tank.
9) Remove the bolts which install the fuel sub
meter unit on fuel tank.
EN0839
4) Tighten the fuel drain plug. S2M0152
Tightening torque: 10) Remove the fuel sub meter unit.

26 N·m (2.7 kgf-m, 19.2 ft-lb)
S2M0153
EN0839
FU(w/oOBD)-63
B: INSTALLATION
Tightening torque:
4.4 N·m (0.45 kgf-m, 3.3 ft-lb)
B2M3178
FU(w/oOBD)-64
FUEL FILTER
22.Fuel Filter C: INSPECTION

A: REMOVAL sediment.
WARNING: 2) If it is clogged, or if replacement interval has
• Place “NO FIRE” signs near the working area. been reached, replace it.
• Be careful not to spill fuel on the floor. 3) If water is found in it, shake and expel the water
1) Release the fuel pressure. <Ref. to FU(w/ from inlet port.
OPERATION, Fuel.>
ter.
S2M0195

B: INSTALLATION
CAUTION:
new ones.
Tightening torque:
1.25 N·m (0.13 kgf-m, 0.94 ft-lb)
S2M0195
FU(w/oOBD)-65
FUEL CUT VALVE

A: REMOVAL
Tightening torque:
1) Remove the fuel tank. <Ref. to FU(w/oOBD)-52,
REMOVAL, Fuel Tank.>
S2M0177
S2M0176
FU(w/oOBD)-66
FUEL DAMPER VALVE

A: REMOVAL
OPERATION, Fuel.>
line.
EN0852
FU(w/oOBD)-67
cap.
2) Release the fuel pressure. <Ref. to FU(w/ return pipes and hoses, evaporation pipes and hos-
oOBD)-51, RELEASING OF FUEL PRESSURE, es.
OPERATION, Fuel.>
EN0564
6) In the engine compartment, detach the fuel de- 8) Disconnect the two-way valve hose (A) from
livery hoses, return hoses and evaporation hose. two-way valve and disconnect the canister hose (B)
from canister.
(A) (B)
S2M0500F
EN0840
(B) Return hose
FU(w/oOBD)-68
9) Separate the quick connector on fuel delivery (1) Set the new retainer (B) to connector (A).
and return line. (2) Push the pipe into connector completely.
(1) Clean the pipe and connector, if they are NOTE:
covered with dust. At this time, two clicking sounds are heard.
down.
NOTE:
S2M0230A
(A) Connector
(B) Retainer
(C) Pipe
S2M0228A
CAUTION:
(A) Connector • Pull the connector to ensure it is connected
(B) Retainer securely.
(C) Pipe • Ensure the two retainer pawls are engaged in
B: INSTALLATION • Be sure to inspect the hoses and their con-
1) Connect the quick connector on fuel delivery nections for any leakage of fuel.
line.
NOTE:
• Make sure that the connected portion is not dam-
aged or has dust. If necessary, clean the seal sur-
face of pipe.
S2M0231A
(A) Connector
(B) Retainer
(C) Pipe
S2M0229A
FU(w/oOBD)-69
2) Connect the fuel delivery hose to pipe with an C: INSPECTION

overlap of 20 to 25 mm (0.79 to 0.98 in). 1) Make sure that there are no cracks on the fuel
Type A: When the fitting length is specified. pipes and fuel hoses.
Type B: When the fitting length is not specified. 2) Make sure that the fuel pipe and fuel hose con-
2: 2.5±1.5 mm (0.098±0.059 in) nections are tight.
L: 22.5±2.5 mm (0.886±0.098 in)
B2M1194B
(1) Fitting
(2) Clamp
(3) Hose

L = 17.5±2.5 mm (0.689±0.098 in)
CAUTION:
B2M1195A
(1) Hose
(2) Clip
(3) Pipe
FU(w/oOBD)-70

A: INSPECTION
securely.
tube.
1) Retightening.
filler pipe.
1) Defective operation of fuel meter unit. Replace.
5. Noise
NOTE: season, drain water which may have accumulat-
• When the vehicle is left unattended for an ex- ed in the fuel filter and fuel tank in the manner
tended period of time, water may accumulate in the same as that described under “Affected areas”
fuel tank. below.
To prevent water condensation. (4) Affected areas
(1) Top off the fuel tank or drain the fuel com- When water condensation is notched in the fuel
pletely. filter, drain water from both the fuel filter and fuel
(2) Drain water condensation from the fuel filter. tank or use a water removing agent (or anti-
• Refilling the fuel tank. freeze solution) in the fuel tank.
water condensation.
(3) Cold areas
level drops to about one-half. After the winter
FU(w/oOBD)-71
FU(w/oOBD)-72
EMISSION CONTROL
EC(w/oOBD)
Page
4. Canister.......................................................................................................7
6. Two-way Valve............................................................................................9
GENERAL DESCRIPTION
A: CAUTION
tion.
points.
cable from battery.
EC(w/oOBD)-2
2. Front Catalytic Converter 7) Remove the nuts which hold front exhaust pipe
A: REMOVAL
B2M3200
8) Remove the front and center exhaust pipe from

hanger bracket.
G6M0095
CAUTION:
3) Disconnect the front oxygen sensor connector. Be careful not to pull down the front exhaust
pipe and center exhaust pipe.
B2M3108
4) Lift-up the vehicle. B2M3111

5) Remove the under cover. 9) Separate the front catalytic converter from front
6) Separate the center exhaust pipe from rear ex- exhaust pipe.
haust pipe.
CAUTION:
S2M0923
B2M3109
EC(w/oOBD)-3
B: INSTALLATION 4) Tighten the bolts which install front and center

exhaust pipe assembly to rear exhaust pipe.
NOTE:
Replace gaskets with new ones. Tightening torque:
1) Install the front catalytic converter to front ex- 18 N·m (1.8 kgf-m, 13.0 ft-lb)
haust pipe.
Tightening torque:
30 N·m (3.1 kgf-m, 22.4 ft-lb)
B2M3109

S2M0923 Tightening torque:
2) Install the front and center exhaust pipe assem- 35 N·m (3.6 kgf-m, 26.0 ft-lb)
bly to the vehicle. And temporarily tighten the bolt
which installs center exhaust pipe to hanger brack-
et.
B2M3111

B2M3111
8) Connect the front oxygen sensor connector.
Tightening torque:
30 N·m (3.1 kgf-m, 22.4 ft-lb)
B2M3108
B2M3200
EC(w/oOBD)-4
G6M0095
C: INSPECTION
nections and welds.
EC(w/oOBD)-5

A: REMOVAL
the same as the those for the front catalytic con-
verter. <Ref. to EC(w/oOBD)-3, REMOVAL, Front
Catalytic Converter.>
B2M3112A

B: INSTALLATION
the same as the ones described under front catalyt-
ic converter. <Ref. to EC(w/oOBD)-4, INSTALLA-
TION, Front Catalytic Converter.>
B2M3112A

C: INSPECTION
nections and welds.
EC(w/oOBD)-6
CANISTER
4. Canister
A: REMOVAL
from canister.
EN0898
B2M4166
B: INSTALLATION
Tightening torque:
23 N·m (2.3 kgf-m, 17 ft-lb)
B2M4166
C: INSPECTION
cracked or loose.
EC(w/oOBD)-7

A: REMOVAL
16 N·m (1.6 kgf-m, 11.6 ft-lb)
G6M0095
H2M2985
2) Remove the bolt which installs purge control so-
lenoid valve onto intake manifold. CAUTION:
H2M2985
3) Take out the purge control solenoid valve B2M1893E

through the bottom of intake manifold.
4) Disconnect the connector and hoses from purge A: To fuel pipe
control solenoid valve. B: To throttle body
C: INSPECTION
Make sure hoses are not cracked or loose.
H2M2986
EC(w/oOBD)-8
TWO-WAY VALVE
6. Two-way Valve
A: REMOVAL
2) Remove the canister from body. <Ref. to EC(w/
oOBD)-7, REMOVAL, Canister.>
gle unit from body.
EN0901

B: INSTALLATION
C: INSPECTION
Make sure that the hoses are not cracked or loose.
EC(w/oOBD)-9
TWO-WAY VALVE
EC(w/oOBD)-10
EXHAUST
EX(w/oOBD)
Page
3. Center Exhaust Pipe .................................................................................12
5. Muffler .......................................................................................................14
GENERAL DESCRIPTION
EXHAUST
A: COMPONENT
1. WITH CATALYTIC CONVERTER (1600 CC MODEL)
(16)
(15)
(13)
(14)
T7 (16)
(11)
(10)
(12)
(9)
(16)
T1
T6
T2
(26) T2
(17) (27)
(22) (18)
T4
(25)
T2 (24)
(23)
(8) T2
(3)
T3
(30)
(1) (29)
(2) T6
(3)
(19)
T1
(21) (28)
(4)
(7) T5
T2 (20)
T5 (30)
(6)
(5)
T5
EN1374
EX(w/oOBD)-2
GENERAL DESCRIPTION
EXHAUST
(1) Upper front exhaust pipe cover (14) Self-locking nut (27) Upper rear catalytic converter
CTR (15) Muffler cover
(2) Lower front exhaust pipe cover (16) Cushion rubber (28) Lower rear catalytic converter
CTR (17) Lower clamp cover
(3) Clamp (18) Upper center exhaust pipe cover (29) Rear catalytic converter
(4) Upper front exhaust pipe cover LH (19) Lower center exhaust pipe cover (30) Gasket
(5) Lower front exhaust pipe cover LH (20) Protector
(6) Front exhaust pipe (21) Gasket Tightening torque: N·m (kgf-m, ft-lb)
(7) Lower front exhaust pipe cover RH (22) Oxygen sensor T1: 8 (0.8, 5.8)
(8) Upper front exhaust pipe cover RH (23) Front catalytic converter T2: 13 (1.3, 9.4)
(9) Gasket (24) Center exhaust pipe T3: 18 (1.8, 13.0)
(10) Spring (25) Lower front catalytic converter T4: 21 (2.1, 15.2)
(11) Chamber cover T5: 30 (3.1, 22.4)
(12) Rear exhaust pipe (26) Upper front catalytic converter T6: 35 (3.6, 26.0)
(13) Gasket cover T7: 48 (4.9, 35.4)
EX(w/oOBD)-3
GENERAL DESCRIPTION
EXHAUST
2. WITH CATALYTIC CONVERTER (2000 CC AND 2500 CC MODEL)
(16)
(15)
(13)
(14)
T2
T7 (16)
(11)
(10)
(17)
(9)
(16)
(12)
T1
T6
T2
(27) T2
(18) (28)
(23) (19)
T4
(26)
T2 (25)
(24)
(8) T2
(3) T3
(31)
(1) (30)
(2) T6
(3)
(20)
T1
(22) (29)
(4)
(7) (21) T5
T2
T5
(31)
(6)
(5)
T5
EN1375
EX(w/oOBD)-4
GENERAL DESCRIPTION
EXHAUST
(1) Upper front exhaust pipe cover (15) Muffler (28) Upper rear catalytic converter
CTR (16) Cushion rubber cover
(2) Lower front exhaust pipe cover (17) Rear exhaust pipe (29) Lower rear catalytic converter
CTR (18) Lower clamp cover
(3) Clamp (19) Upper center exhaust pipe cover (30) Rear catalytic converter
(4) Upper front exhaust pipe cover LH (20) Lower center exhaust pipe cover (31) Gasket
(5) Lower front exhaust pipe cover LH (21) Protector
(6) Front exhaust pipe (22) Gasket Tightening torque: N·m (kgf-m, ft-lb)
(7) Lower front exhaust pipe cover RH (23) Oxygen sensor T1: 8 (0.8, 5.8)
(8) Upper front exhaust pipe cover RH (24) Front catalytic converter T2: 13 (1.3, 9.4)
(9) Gasket (25) Center exhaust pipe T3: 18 (1.8, 13.0)
(10) Spring (26) Lower front catalytic converter T4: 21 (2.1, 15.2)
(11) Chamber cover T5: 30 (3.1, 22.4)
(12) Rear exhaust pipe cover (27) Upper front catalytic converter T6: 35 (3.6, 26.0)
(13) Gasket cover T7: 48 (4.9, 35.4)
(14) Self-locking nut
EX(w/oOBD)-5
GENERAL DESCRIPTION
EXHAUST
3. WITHOUT CATALYTIC CONVERTER
(16)
(15)
(13)
(14)
T1
T5 (16)
(11)
(10)
(24)
(9)
(16)
(12)
T4
(23) (17)
(18)
(22)
T1 (21)
(8) T1
(3)
(25)
(1) T2
T4
(2)
(3)
T1
(20)
(4)
(7) (19) T3
T3
(25)
(6)
(5)
T3
T1 Muffler cutter (Except 1600cc Model)

EN1376
EX(w/oOBD)-6
GENERAL DESCRIPTION
EXHAUST
(1) Upper front exhaust pipe cover (11) Chamber (23) Upper center exhaust pipe cover
CTR (12) Rear exhaust pipe cover (24) Rear exhaust pipe
(2) Lower front exhaust pipe cover (13) Gasket (25) Gasket
CTR (14) Self-locking nut
(3) Clamp (15) Muffler Tightening torque: N·m (kgf-m, ft-lb)
(4) Upper front exhaust pipe cover LH (16) Cushion rubber T1: 13 (1.3, 9.4)
(5) Lower front exhaust pipe cover LH (17) Upper clamp T2: 18 (1.8, 13.0)
(6) Front exhaust pipe (18) Lower clamp T3: 30 (3.1, 22.4)
(7) Lower front exhaust pipe cover RH (19) Protector T4: 35 (3.6, 26.0)
(8) Upper front exhaust pipe cover RH (20) Gasket T5: 48 (4.9, 35.4)
(9) Gasket (21) Center exhaust pipe
(10) Spring (22) Lower center exhaust pipe cover
EX(w/oOBD)-7
GENERAL DESCRIPTION
EXHAUST
B: CAUTION
tion.
points.
cable from battery.
EX(w/oOBD)-8
FRONT EXHAUST PIPE
EXHAUST
2. Front Exhaust Pipe 6) Remove the nuts which hold front exhaust pipe
A: REMOVAL CAUTION:
1) Disconnect the ground cable from battery. Be careful not to pull down the front and center
exhaust pipe assembly.
G6M0095
2) Disconnect the oxygen sensor connector. (With B2M3200

7) Remove the bolt which installs front and center
exhaust pipe assembly to hanger bracket.
B2M3108
3) Lift-up the vehicle. B2M3111

4) Separate the front and center exhaust pipe as-
8) Remove the front and center exhaust pipe as-
sembly from rear exhaust pipe.
sembly from vehicle.
WARNING:
CAUTION:
• Be careful not to let the front and center ex-
haust pipe assembly fall off when removing as
it is quite heavy.
• After removing the front and center exhaust
pipe assembly, do not apply excessive pulling
force on the rear exhaust pipe.
9) Separate the front exhaust pipe from center ex-
haust pipe.
B2M3109
S2M0923
10) Remove the oxygen sensor. (With catalytic

converter) <Ref. to FU(w/oOBD)-46, REMOVAL,
Oxygen Sensor.>
EX(w/oOBD)-9
FRONT EXHAUST PIPE
EXHAUST
B: INSTALLATION 7) Tighten the bolts which install front and center

1) Install the oxygen sensor. (With catalytic con- exhaust pipe assembly to rear exhaust pipe.
verter) <Ref. to FU(w/oOBD)-46, INSTALLATION, Tightening torque:
Oxygen Sensor.> 18 N·m (1.8 kgf-m, 13.0 ft-lb)
2) Install the front exhaust pipe to center exhaust
pipe.
NOTE:
Tightening torque:
30 N·m (3.1 kgf-m, 22.4 ft-lb)
B2M3109

Tightening torque:
35 N·m (3.6 kgf-m, 26.0 ft-lb)
S2M0923

bly to vehicle.
4) Temporarily tighten the bolt which installs front
and center exhaust pipe assembly to hanger brack-
et.
B2M3111

10) Connect the oxygen sensor connector. (With
B2M3111

Tightening torque:
30 N·m (3.1 kgf-m, 22.4 ft-lb)
B2M3108
B2M3200
EX(w/oOBD)-10
FRONT EXHAUST PIPE
EXHAUST
G6M0095
C: INSPECTION
nections and welds.
EX(w/oOBD)-11
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(w/
oOBD)-9, REMOVAL, Front Exhaust Pipe.>
B: INSTALLATION
Install the center exhaust pipe and front exhaust
pipe as one unit. Refer to the procedure for install-
ing the front exhaust pipe. <Ref. to EX(w/oOBD)-
10, INSTALLATION, Front Exhaust Pipe.>
C: INSPECTION
nections and welds.
EX(w/oOBD)-12
REAR EXHAUST PIPE
EXHAUST
4. Rear Exhaust Pipe 2) Install the rear exhaust pipe bracket to cushion
rubber.
A: REMOVAL
haust pipe.
CAUTION:
S2M0560
NOTE:
B2M3109 Tightening torque:
48 N·m (4.9 kgf-m, 35.4 ft-lb)
CAUTION:
Be careful not to pull down the rear exhaust
pipe.
G2M0382
4) Install the rear exhaust pipe to center exhaust

pipe.
G2M0382 Tightening torque:
18 N·m (1.8 kgf-m, 13.0 ft-lb)
4) Remove the rear exhaust pipe bracket from the
cushion rubber.
B2M3109
C: INSPECTION
nections and welds.
S2M0560 2) Make sure there are no holes or rusting.
B: INSTALLATION cracked.
EX(w/oOBD)-13
MUFFLER
EXHAUST
A: REMOVAL
1) Separate the muffler from rear exhaust pipe. NOTE:
CAUTION:
48 N·m (4.9 kgf-m, 35.4 ft-lb)
G2M0382
G2M0382
the cushion rubbers in advance. C: INSPECTION
SUBARU CRC (Part No. 004301003) 1) Make sure there are no exhaust leaks from con-
nections and welds.
cracked.
G2N0385
3) Remove the front, right and left cushion rubber,

and detach the muffler assembly.
EX(w/oOBD)-14
IGNITION
IG(w/oOBD)
Page
2. Spark Plug...................................................................................................5
4. Spark Plug Cord........................................................................................10
GENERAL DESCRIPTION
IGNITION
A: SPECIFICATIONS
Item Designation
1600 cc CM12—100C
Model 2000 cc
and FH0137
2500 cc
1600 cc HITACHI
2000 cc
Manufacturer
and DIAMOND
2500 cc
Ignition coil and ignitor 1600 cc 0.7 Ω±10%
assembly 2000 cc
Primary coil resistance
and 0.73 Ω±10%
2500 cc
1600 cc 13.0 kΩ±20%
Secondary coil resistance 2000 cc
and 12.8 kΩ±15%
2500 cc
Insulation resistance between primary terminal
More than 100 MΩ
and case
NGK: BKR6E*
1600 cc CHAMPION: RC8YC4**
NGK: BKR6E-11** (Alternate)
Type and manufacturer
2000 cc NGK: BKR6E*
Spark plug and CHAMPION: RC10YC4**
2500 cc NGK: BKR5E-11** (Alternate)
Thread size mm 14, P = 1.25
0.7 — 0.8 (0.028 — 0.031)*
Spark gap mm (in)
1.0 — 1.1 (0.039 — 0.043)**
*: Without catalytic converter
**: With catalytic converter
IG(w/oOBD)-2
GENERAL DESCRIPTION
IGNITION
B: COMPONENT
1. 1600 CC MODEL
T1
(3)
(2)
(2)
(1)
T2
(4)
(4)
T2
EN1039
(2) Spark plug cord (#1, #3) T1: 6.4 (0.65, 4.7)
IG(w/oOBD)-3
GENERAL DESCRIPTION
IGNITION
2. 2000 CC AND 2500 CC MODEL
S6M0329B
(2) Spark plug cord (#1, #3) T1: 21 (2.1, 15.2)
(3) Ignition coil and ignitor ASSY T2: 6.4 (0.65, 4.7)

tion. points.
• Remove contamination including dirt and corro- • Before disconnecting electrical connectors of
sion before removal, installation or disassembly. sensors or units, be sure to disconnect the ground
• Keep the disassembled parts in order and pro- cable from battery.
IG(w/oOBD)-4
SPARK PLUG
IGNITION
2. Spark Plug 4) Remove the spark plugs with the spark plug
sockets.
A: REMOVAL
CAUTION:
Spark plug
NGK: BKR6E*
1600 cc CHAMPION: RC8YC4**
NGK: BKR6E-11** (Alternate)
2000 cc NGK: BKR6E*
and CHAMPION: RC10YC4** B2M4286
2500 cc NGK: BKR5E-11** (Alternate)
2. LH SIDE
*: Without catalytic converter
**: With catalytic converter 1) Disconnect the ground cable from battery.
1. RH SIDE
G6M0095
2) Disconnect the washer motor connector.
G6M0095
2) Remove the resonator chamber. <Ref. to IN-8,

REMOVAL, Resonator Chamber.>
3) Remove the spark plug cords by pulling boot, not
the cord itself.
B6M0562

from washer motor, then plug the connection with a
suitable cap.
4) Remove the two bolts which hold washer tank,
then take the tank away from working area.
B2M4127
B2M2023
IG(w/oOBD)-5
SPARK PLUG
IGNITION
5) Remove the spark plug cords by pulling boot, not 2. LH SIDE

the cord itself.
21 N·m (2.1 kgf-m, 15.2 ft-lb)
CAUTION:
should be reduced by approx. 1/3 of the speci-
B2M4287 C: INSPECTION
Check the electrodes and inner and outer porcelain
6) Remove the spark plugs with spark plug sock-
of plugs, noting the type of deposits and the degree
ets.
of electrode erosion.
B2M4288
S6M0420A
B: INSTALLATION
(A) Electrode gap
1. RH SIDE (B) Carbon accumulation or wear
1) Install in the reverse order of removal. (C) Cracks
(D) Damage
(E) Damaged gasket
21 N·m (2.1 kgf-m, 15.2 ft-lb)
CAUTION: 1) Normal:
The above torque should be only applied to Brown to grayish-tan deposits and slight electrode
new spark plugs without oil on their threads. wear indicates correct spark plug heat range.
G6M0087
IG(w/oOBD)-6
SPARK PLUG
IGNITION
2) Carbon fouled: D: CLEANING

Dry fluffy carbon deposits on insulator and elec- Clean the spark plugs in a sand blast type cleaner.
trode are mostly caused by slow speed driving in Avoid excessive blasting. Clean and remove the
city, weak ignition, too rich fuel mixture, dirty air carbon or oxide deposits, but do not wear away
cleaner, etc. porcelain.
It is advisable to replace with plugs having hotter If deposits are too stubborn, replace the plugs.
heat range.
E: ADJUSTMENT
Correct it if the spark plug gap is measured with a
gap gauge, and it is necessary.
Spark plug gap: L
With catalyst:
1.0 — 1.1 mm (0.039 — 0.043 in)
Without catalyst:
0.7 — 0.8 mm (0.028 — 0.031 in)
G6M0088
3) Oil fouled:
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.
S6M0412B
NOTE:
Replace with a new spark plug if this area (A) is
worn to “ball” shape.
G6M0089
4) Overheating:
White or light gray insulator with black or gray
brown spots and bluish burnt electrodes indicates
engine overheating. Moreover, the appearance re-
plugs, wrong selection of fuel, hotter range plug,
etc. It is advisable to replace with plugs having
colder heat range.
G6M0090
IG(w/oOBD)-7
IGNITION
3. Ignition Coil and Ignitor As- 4) Remove the ignition coil and ignitor assembly.
• 1600 cc MODEL
sembly
A: REMOVAL
EN1044
G6M0095
2) Disconnect the spark plug cords from ignition

coil and ignitor assembly.
• 1600 cc MODEL
B6M0930
B: INSTALLATION
Tightening torque:
EN1040 6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
• 2000 cc and 2500 cc MODEL CAUTION:
Be sure to connect the wires to their proper po-
sitions. Failure to do so will damage the unit.
• 1600 cc MODEL
S6M0373

ignitor assembly. EN1044
IG(w/oOBD)-8
IGNITION
• 2000 cc and 2500 cc MODEL Specified resistance:(2000 cc and 2500 cc)

[Primary side]
0.73 Ω±10%
0.73 Ω±10%
B6M0930
4 3 2 1
C: INSPECTION
Using the accurate tester, inspect the following
items, and replace if defective.
1) Primary resistance
2) Secondary coil resistance EN1041
CAUTION: [Secondary side]

If the resistance is extremely low, this indicates Between (A) and (B)
the presence of a short-circuit. 12.8 kΩ±15%
Specified resistance:(1600 cc) Between (C) and (D)
12.8 kΩ±15%
[Primary side]
Between terminal No. 1 and No. 4 (C)
0.7 Ω±10% (A)
0.7 Ω±10%
(D)
(B)
4 3 2 1 EN1043
3) Insulation between primary terminal and case:

100 MΩ or more.
EN1041
[Secondary side]
Between (A) and (B)
13.0 kΩ±20%
Between (C) and (D)
13.0 kΩ±20%
(C) (D)
(A) (B)
EN1042
IG(w/oOBD)-9
SPARK PLUG CORD
IGNITION
4. Spark Plug Cord

A: INSPECTION
Check for:
1) Damage to cords, deformation, burning or rust
formation of terminals
2) Resistance values of cords
Resistance value:
#1 cord: 5.6 — 10.6
#2 cord: 7.3 — 13.7
#3 cord: 5.9 — 11.1
#4 cord: 7.3 — 13.7
S6M0337
IG(w/oOBD)-10
EN(w/oOBD)
Page
4. Electrical Components Location................................................................10
8. Inspection Mode........................................................................................28

A: PROCEDURE
1. WITH SUBARU SELECT MONITOR
Step Check Yes No

1)Ask the customer when and how trouble “Diagnostics for
occurred using the interview check list. <Ref. Engine Starting
to EN(w/oOBD)-4, CHECK, Check List for Failure”. <Ref. to
Interview.> EN(w/oOBD)-42,
2)Start the engine. Diagnostics for
Engine Starting
Failure.>
2 CHECK ILLUMINATION OF CHECK ENGINE Does the MIL illuminate? Go to step 3. Inspection using
MALFUNCTION INDICATOR LAMP (MIL). “General Diagnos-
<Ref. to EN(w/oOBD)-32, ACTIVATION OF tic Table”. <Ref. to
CHECK ENGINE MALFUNCTION INDICA- EN(w/oOBD)-110,
TOR LAMP (MIL), Engine Malfunction Indica- INSPECTION,
tor Lamp (MIL).> General Diagnos-
tic Table.>
3 CHECK INDICATION OF DIAGNOSTIC Does the Subaru Select Moni- Record the DTC. Repair the related
TROUBLE CODE (DTC) ON DISPLAY. tor indicate DTC? <Ref. to Repair the trouble parts.
1)Turn the ignition switch to OFF. EN(w/oOBD)-63, LIST, List of cause. <Ref. to NOTE:
2)Connect the Subaru Select Monitor to data Diagnostic Trouble Code EN(w/oOBD)-66, If a DTC is not
link connector. (DTC).> Diagnostic Proce- shown on display
3)Turn the ignition switch to ON and the Sub- dure with Diagnos- although MIL illu-
aru Select Monitor switch to ON. tic Trouble Code minates, perform
4)Read any DTC on Subaru Select Monitor. (DTC).> Go to diagnostics of MIL
<Ref. to EN(w/oOBD)-26, WITH SUBARU step 4. (CHECK ENGINE
SELECT MONITOR, OPERATION, Read malfunction indica-
Diagnostic Trouble Code (DTC).> tor lamp) circuit or
combination
meter. <Ref. to
EN(w/oOBD)-32,
Engine Malfunc-
tion Indicator Lamp
(MIL).>
4 PERFORM THE DIAGNOSIS. Does the Subaru Select Moni- Record the DTC. Complete the
1)Perform the clear memory mode. <Ref. to tor indicate DTC? <Ref. to Repair the trouble diagnosis.
EN(w/oOBD)-30, OPERATION, Clear Memory EN(w/oOBD)-63, LIST, List of cause. <Ref. to
Mode.> Diagnostic Trouble Code EN(w/oOBD)-66,
2)Perform the inspection mode. <Ref. to EN(w/ (DTC).> Diagnostic Proce-
oOBD)-28, OPERATION, Inspection Mode.> dure with Diagnos-
tic Trouble Code
(DTC).> Go to
step 4.
EN(w/oOBD)-2
2. WITHOUT SUBARU SELECT MONITOR

CAUTION:
• Check the connector while it is connected unless specified otherwise.
• Be sure to check again from the beginning in order to prevent secondary trouble caused by repair
work.
Step Check Yes No

occurred using interview check list. <Ref. to Engine Starting
EN(w/oOBD)-4, CHECK, Check List for Inter- Failure”. <Ref. to
view.> EN(w/oOBD)-42,
Engine Starting
Failure.>
2 CHECK ILLUMINATION OF CHECK ENGINE Does the MIL illuminate? Go to step 3. Inspection using
MALFUNCTION INDICATOR LAMP (MIL). “General Diagnos-
<Ref. to EN(w/oOBD)-32, ACTIVATION OF tic Table”. <Ref. to
CHECK ENGINE MALFUNCTION INDICA- EN(w/oOBD)-110,
TOR LAMP (MIL), Engine Malfunction Indica- INSPECTION,
tor Lamp (MIL).> General Diagnos-
tic Table.>
3 CHECK INDICATION OF DIAGNOSTIC Does the MIL indicate DTC? Repair the trouble Repair the related
TROUBLE CODE (DTC) ON MIL. <Ref. to EN(w/oOBD)-63, cause. Go to step parts.
1)Perform the read DTC (read memory LIST, List of Diagnostic Trou- 4. NOTE:
mode).<Ref. to EN(w/oOBD)-26, WITHOUT ble Code (DTC).> If the DTC is not
SUBARU SELECT MONITOR, OPERATION, shown on MIL al-
Read Diagnostic Trouble Code (DTC).> though MIL illumi-
2)Read any DTC on MIL. nates, perform
diagnostics of MIL
(CHECK ENGINE
malfunction indica-
tor lamp) circuit or
combination
meter.<Ref. to
EN(w/oOBD)-32,
Engine Malfunc-
tion Indicator Lamp
(MIL).>
4 PERFORM THE DIAGNOSIS. Does the MIL indicate DTC? Repair the trouble Complete the
1)Perform the clear memory mode. <Ref. to <Ref. to EN(w/oOBD)-63, cause. Go to step diagnosis.
EN(w/oOBD)-30, OPERATION, Clear Memory LIST, List of Diagnostic Trou- 4.
Mode.> ble Code (DTC).>
2)Perform the inspection mode. <Ref. to EN(w/
oOBD)-28, OPERATION, Inspection Mode.>
EN(w/oOBD)-3

A: CHECK
1. CHECK LIST NO. 1
NOTE:
Vin No. miles
Weather ❏ Fine
❏ Cloudy
❏ Rainy
❏ Snowy
❏ Various/Others:
Outdoor temperature °F (°C)
❏ Hot
❏ Warm
❏ Cool
❏ Cold
Place ❏ Highway
❏ Suburbs
❏ Inner city
❏ Uphill
❏ Downhill
❏ Rough road
❏ Others:
❏ Warming-up
❏ Any temperature
❏ Others:
Engine speed rpm
Vehicle speed MPH
❏ At starting
❏ While idling
❏ At racing
❏ While cruising
EN(w/oOBD)-4
2. CHECK LIST NO. 2

NOTE:
b) Fuel level
• What:
• What:
• What:
• Where:
• From where:
• What kind:
• From where:
• What kind:
❏ Rough idling
❏ Back fire
❏ After fire
❏ No shift
EN(w/oOBD)-5
GENERAL DESCRIPTION
1) Airbag system wiring harness is routed near en-
gine control module (ECM), main relay and fuel
pump relay.
CAUTION:
EN1393
2) Never connect the battery in reverse polarity. (A) Stud bolt
• The ECM will be destroyed instantly.
• The fuel injector and other part will be damaged 9) Use the engine grounding terminal or engine
in just a few minutes more. proper as the grounding point to the body, when
3) Do not disconnect the battery cables while the measuring voltage and resistance in the engine
engine is running. compartment.
switch to OFF.
control modules at the harness side connector, use
a tapered pin with a diameter of less than 0.64 mm B2M2779
(0.025 in). Do not insert the pin more than 5 mm 10) Use the TCM mounting stud bolts at the body
(0.20 in) into the part. head grounding point, when measuring voltage and
6) Before removing the ECM from located position, resistance inside the passenger compartment.
CAUTION:
waterproof. However, it is still necessary to take
care not to allow water to get into the connectors EN1394

vehicle on a rainy day. (A) Stud bolt
11) Every MFI-related part is a precision part. Do

not drop them.
EN(w/oOBD)-6
GENERAL DESCRIPTION
12) Observe the following cautions when installing 2) Check the condition of the main and other fuses,
a radio in MFI equipped models. and harnesses and connectors. Also check for
CAUTION: proper grounding.
• The antenna must be kept as far apart as pos- 2. ENGINE GROUNDING
(The ECM is located under the steering column, Make sure the engine grounding cable is properly
inside of the instrument panel lower trim panel.) connected to the engine.
• The antenna feeder must be placed as far
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.
B2M2779
the fuel pump connector and crank the engine for C: NOTE
more than 5 seconds to release pressure in the fuel
system. If the engine starts during this operation, 1. ENGINE AND EMISSION CONTROL SYS-
run it until it stops. TEM
14) Problems in the electronic-controlled automatic • The Multipoint Fuel Injection (MFI) system is a
transmission may be caused by failure of the en- system that supplies the optimum air-fuel mixture
gine, the electronic control system, the transmis- to the engine for all the various operating condi-
sion proper, or by a combination of these. These tions through the use of the latest electronic tech-
three causes must be distinguished clearly when nology.
performing diagnostics. With this system fuel, which is pressurized at a con-
15) Diagnostics should be conducted by rotating stant pressure, is injected into the intake air pas-
with simple, easy operations and proceeding to sage of the cylinder head. The injection quantity of
complicated, difficult operations. The most impor- fuel is controlled by an intermittent injection system
tant thing in diagnostics is to understand custom- where the electro-magnetic injection valve (fuel in-
er's complaint, and distinguish between the three jector) opens only for a short period of time, de-
causes. pending on the quantity of air required for one cycle
16) In AT vehicles, do not continue the stall for of operation. In actual operation, the injection quan-
more than 5 seconds at a time (from closed throttle, tity is determined by the duration of an electric
fully open throttle to stall engine speed). pulse applied to the fuel injector and this permits
17) On ABS vehicle, when performing driving test simple, yet highly precise metering of the fuel.
in jacked-up or lifted-up position, sometimes the • Further, all the operating conditions of the engine
warning light may be lit, but this is not a malfunction are converted into electric signals, and this results
of the system. The reason for this is the speed dif- in additional features of the system, such as large
ference between the front and rear wheels. After di- improved adaptability, easier addition of compen-
agnosis of engine control system, perform the ABS sating element, etc.
memory clearance procedure of self-diagnosis sys- The MFI system also has the following features:
tem. • Reduced emission of harmful exhaust gases.
B: INSPECTION • Reduced in fuel consumption.
Before performing diagnostics, check the following • Increased engine output.
items which might affect engine problems: • Superior acceleration and deceleration.
• Superior startability and warm-up perfor-
1. BATTERY mance in cold weather since compensation is
1) Measure the battery voltage and specific gravity made for coolant and intake air temperature.
of electrolyte.
Standard voltage: 12 V
Specific gravity: Above 1.260
EN(w/oOBD)-7
GENERAL DESCRIPTION
D: PREPARATION TOOL
(Newly adopted tool) systems.
B2M3876
systems.
out printer)
(Without printer)
(Without printer)
(Without printer)
B2M3877
EN(w/oOBD)-8
GENERAL DESCRIPTION
EN(w/oOBD)-9

A: LOCATION
1. MODULE
LHD model (1)
(3) (4) (2) (5)

EN0713
RHD model (3) (4) (2) (5)
(1)
EN0714
(1) Engine control module (ECM) (3) Read memory connector

(2) CHECK ENGINE malfunction indi- (4) Test mode connector
cator lamp (MIL) (5) Data link connector
EN(w/oOBD)-10
(2)
S2M0256A EN0718
(5)
EN1034 EN0717
EN(w/oOBD)-11
2. SENSOR
(1) (7) (3) (2) (4)
(5) (6)
EN0928
(1) Engine coolant temperature sen- (3) Throttle position sensor (7) Vehicle speed sensor
sor (4) Knock sensor
(2) Intake air temperature and pres- (5) Crankshaft position sensor
sure sensor (6) Camshaft position sensor
EN(w/oOBD)-12
S2M1248A H2M3255A
H2M3256A S2M1406B
B2M0213M B2M0212F
S2M0907C
EN(w/oOBD)-13
(8)
EN0929
(8) Oxygen sensor (With catalyst

model)
S2M0264B
EN(w/oOBD)-14
EN(w/oOBD)-15
3. SOLENOID VALVE, EMISSION CONTROL SYSTEM PARTS AND IGNITION SYSTEM

PARTS
(4) (1) (3) (2)
EN0930
(1) Purge control solenoid valve (3) Ignition coil and ignitor ASSY (4) CO resistor (Without catalyst
(2) Idle air control solenoid valve model)
EN(w/oOBD)-16
H2M3258A H2M3259A
H2M3261A S2M1764B
EN(w/oOBD)-17
LHD model (2) (3) (1)
EN1031
RHD model (1)
(2) (3)
EN1032
(1) Fuel pump (2) Main relay (3) Fuel pump relay
EN(w/oOBD)-18
LHD model
(2) (3)
EN0744
EN0744
EN1501
RHD model (2)

(3)
EN0748
EN(w/oOBD)-19

H2M3262A
Signal (V)
Connec- Terminal
Content Ignition SW Engine ON Note
tor No. No.
ON (Engine OFF) (Idling)
Crankshaft Signal (+) B135 *2 1 0 ±6 Sensor output waveform
position Signal (−) B135 8 0 0 —
Camshaft Signal (+) B135 *1 2 0 ±6 Sensor output waveform
Intake air
tempera- Signal B136 13 2.3 — 2.5 1.4 — 1.6 Ambient temperature: 25°C (77°F)
ture sensor
Fully closed: 0.5±0.3
Signal B136 17 —
Throttle Fully opened: 4.3±0.3
position Power
B136 15 5 5 —
sensor supply
GND B136 16 0 0 —
Rich mixture: 0.7
Oxygen Signal B136 7 0
Lean mixture: 0
sensor
Shield B136 23 0 0 —
Engine cool- Signal B136 14 0.6 — 1.0 0.6 — 1.0 After warm-up
ant temper-
ature sensor GND B136 16 0 0 —
“5” and “0” are repeatedly displayed
Vehicle speed sensor B135 24 0 or 5 0 or 5
when vehicle is driven.
Starter switch B135 28 0 0 Cranking: 10 to 14
ON: 10 — 13 ON: 13 — 14
OFF: 0 OFF: 0
Neutral position switch ON: 5 Switch is ON when gear is in neutral
B135 26
(MT) OFF: 0 position.
Park/Neutral position ON: 0 Switch is ON when shift lever is in
B135 26
switch (AT) OFF: 5 “P” or “N” position.
EN(w/oOBD)-20
Signal (V)
Connec- Terminal
Content Ignition SW Engine ON Note
tor No. No.
ON (Engine OFF) (Idling)
Read memory connector B135 15 5 5 When connected: 0
Back-up power supply B136 9 10 — 13 13 — 14 —
Control unit power sup- 1
B136 10 — 13 13 — 14 —
ply 2
Ignition con- # 1, # 2 B134 25 0 3.4, max. —
trol # 3, # 4 B134 26 0 3.4, max. —
#1 B134 4 10 — 13 13 — 14 Waveform
#2 B134 13 10 — 13 13 — 14 Waveform
Fuel injector
#3 B134 14 10 — 13 13 — 14 Waveform
#4 B134 15 10 — 13 13 — 14 Waveform
*: With immobilizer
EN(w/oOBD)-21
Signal (V)
Connec- Terminal
Content Ignition SW Note
tor No. No. Engine ON (Idling)
ON (Engine OFF)
Idle air con- Signal 2 B134 6 — 1 — 13 Waveform
trol sole-
noid valve Signal 3 B134 19 — 1 — 13 Waveform
Torque control signal 1 B135 16 5 5 —
Torque control signal 2 B135 17 5 5 —
ON: 0
Fuel pump relay control B134 29* 16 0 —
OFF: 10 — 13
ON: 0 ON: 0
OFF: 10 — 13 OFF: 13 — 14
Radiator fan relay 1 con- ON: 0 ON: 0
B134 3 —
trol OFF: 10 — 13 OFF: 13 — 14
Radiator fan relay 2 con- ON: 0 ON: 0
B134 12 —
trol OFF: 10 — 13 OFF: 13 — 14
Self-shutoff control B135 19 10 — 13 13 — 14 —
Malfunction indicator Light “ON”: 1, max.
B134 11 — —
Engine speed output B134 30 — 0 — 13, min. Waveform
Knock sen- Signal B136 4 2.8 2.8 —
sor Shield B136 25 0 0 —
Signal 5 3.4 — 3.6 1.2 — 1.8 —
Pressure Power
B136 15 5 5 —
sensor supply
GND 16 0 0 —
Purge control solenoid ON: 0 ON: 0
B134 2 —
valve OFF: 10 — 13 OFF: 13 — 14
GND (power supply) B134 8 0 0 —
B136 21 0 0 —
B136 22 0 0 —
11 — — —
Select monitor signal B135
12 — — —
ON: 0 ON: 0
Power steering switch B135 13 —
OFF: 10 — 13 OFF: 10 — 13
Torque control cut signal B134 31 8 8 —
AT load signal B136 11 0 — 0.3 0.8 — 1.2 —
MT: 0 MT: 0
MT/AT identification B135 25 —
AT: 5 AT: 5
*: With immobilizer
EN(w/oOBD)-22
6. Subaru Select Monitor 5) Turn the ignition switch to ON (engine OFF) and
A: OPERATION
1. HOW TO USE SUBARU SELECT MONI-
TOR
1) Prepare the Subaru Select Monitor kit.
S2M0288E
(A) Power switch
6) Using the Subaru Select Monitor, call up any

S2M0285
DTCs and various data, then record them.
2) Connect the diagnosis cable to Subaru Select 2. READ DIAGNOSTIC TROUBLE CODE
Monitor. (DTC) FOR ENGINE.
3) Insert the cartridge into Subaru Select Monitor. Refer to Read Diagnostic Trouble Code for infor-
mation about how to indicate the DTC. <Ref. to
EN(w/oOBD)-26, Read Diagnostic Trouble Code
(DTC).>
S2M0286A

connector.
(1) The data link connector is located in lower
portion of instrument panel (on driver's side).
EN0768

connector.
CAUTION:
Do not connect the scan tools except for Suba-
ru Select Monitor.
EN(w/oOBD)-23
3. READ CURRENT DATA SHOWN ON DISPLAY.

1) On the «Main Menu» display screen, select the {2. Each System Check} and press [YES] key.
key.
3) Press the [YES] key after displayed information of engine type.
4) On the «Engine Diagnosis» display screen, select the {1. Current Data Display & Save} and press [YES]
key.
5) On the «Data Display Menu» display screen, select the {1. 12 Data Display} and press [YES] key.
Contents Unit of measure
Battery voltage V
Vehicle speed signal km/h or MPH
Engine speed signal rpm
Engine coolant temperature signal °C or °F
Ignition timing signal deg
Pressure sensor signal mmHg or kPa or inHg or psi
Intake air temperature signal °C or °F
Throttle position signal V
Injection pulse width ms
ISC valve step STEP
Oxygen sensor output signal*1 V
Knock correction deg
CO resistor*2 g/h
A/F correction #1 %
A/F learning #1 %
Ignition switch signal ON or OFF
Automatic transmission vehicle identification signal ON or OFF
Test mode connector signal ON or OFF
Neutral position switch signal ON or OFF
Air conditioning switch signal ON or OFF
Air conditioning compressor signal ON or OFF
Radiator fan relay signal #1 ON or OFF
Fuel pump relay signal ON or OFF
Knocking signal ON or OFF
Radiator fan relay signal #2 ON or OFF
Torque control signal #1 ON or OFF
Torque control signal #2 ON or OFF
Torque permission signal ON or OFF
TCS AET signal ON or OFF
Canister purge control solenoid valve ON or OFF
Oxygen sensor rich signal ON or OFF
Read memory connector signal ON or OFF
P/S switch ON or OFF
Starter switch ON or OFF
Crankshaft position sensor signal ON or OFF
Camshaft position sensor signal ON or OFF
Rear defogger switch ON or OFF
Blower fan switch ON or OFF
Light switch ON or OFF
Idle switch signal ON or OFF
*1: With catalyst model only
*2: Without catalyst model only
EN(w/oOBD)-24
NOTE:
Contents Message LED “ON” requirements
Ignition switch signal ON or OFF When ignition switch is turned ON.
Automatic transmission vehicle identification
ON or OFF When AT identification signal is entered.
signal
Test mode connector signal ON or OFF When test mode connector is connected.
Neutral position switch signal*1 ON or OFF When neutral position switch signal is entered.
Air conditioning switch signal ON or OFF When air conditioning switch is turned ON.
Air conditioning compressor signal ON or OFF When air conditioning compressor is in function.
Radiator fan relay signal #1 ON or OFF When radiator fan relay #1 is in function.
Fuel pump relay signal ON or OFF When fuel pump relay is in function.
Knocking signal ON or OFF When knocking signal is entered.
Radiator fan relay signal #2 ON or OFF When radiator fan relay #2 is in function.
Engine torque control signal #1 ON or OFF When torque control signal #1 is entered.
Torque control signal #2 ON or OFF When torque control signal #2 is entered.
Torque permission signal ON or OFF When torque permission signal is entered.
TCS AET signal ON or OFF When TCS AET signal is entered.
Canister purge control solenoid valve ON or OFF When canister purge control solenoid valve is in function.
Oxygen sensor rich signal*2 ON or OFF When oxygen sensor mixture ratio is rich.
Read memory connector signal ON or OFF When read memory connector is connected.
P/S switch ON or OFF When steering wheel is turned.
Starter switch ON or OFF When starter switch signal is entered.
Crankshaft position sensor signal ON or OFF When crankshaft position sensor signal is entered.
Camshaft position sensor signal ON or OFF When camshaft position sensor signal is entered.
Rear defogger switch ON or OFF When rear defogger switch signal is entered.
Blower fan switch ON or OFF When blower fan switch signal is entered.
Light switch ON or OFF When light switch signal is entered.
When throttle sensor sends signal that throttle opening angle
Idle switch signal ON or OFF
is in idle position.
*1: On MT model, switch is turned ON when gear position is in neutral position.

On AT model, switch is turned ON when shift position is in “P” or “N” position.
*2: With catalyst model only
NOTE:
EN(w/oOBD)-25
7. Read Diagnostic Trouble Code (DTC)

A: OPERATION
key.
4) On the «Engine Diagnosis» display screen, select the {Diagnostic Code(s) Display} and press [YES] key.
5) On the «Diagnostic Code(s) Display» display screen, select the {Current Diagnostic Code(s)} or {History
Diagnostic Code(s)} and press [YES] key.
NOTE:
• For detailed concerning diagnostic trouble codes, refer to the List of Diagnostic Trouble Code (DTC). <Ref.
to EN(w/oOBD)-63, LIST, List of Diagnostic Trouble Code (DTC).>
Step Check Yes No

1 CHECK STATUS OF CHECK ENGINE MAL- Does the MIL come on? Go to step 2. Check the follow-
FUNCTION INDICATOR LAMP (MIL). ing and repair if
1)Turn the ignition switch to OFF. necessary.
2)Connect the read memory connector. <Ref. NOTE:
to EN(w/oOBD)-10, LOCATION, Electrical • Open or short
Components Location.> circuit in engine
3)Turn the ignition switch to ON. control module
power supply or
ground line
• Open or short
circuit in CHECK
ENGINE malfunc-
tion indicator lamp
2 CHECK DIAGNOSTIC TROUBLE CODE Does the MIL indicate DTC? Record the DTC. Complete the read
(DTC). Then turn the igni- DTC. Turn the
tion switch to OFF, ignition switch to
disconnect read OFF and discon-
memory connec- nect read memory
tor. connector.
EN(w/oOBD)-26
The CHECK ENGINE malfunction indicator lamp (MIL) flashes code corresponding to faulty parts. The long
segment (1.3 seconds ON) indicates a “ten”, and the short segment (0.2 seconds ON) signifies “one”. And
middle segment (0.5 seconds ON) means OK code.
NOTE:
• For detailed concerning diagnostic trouble codes, refer to the List of Diagnostic Trouble Code (DTC). <Ref.
to EN(w/oOBD)-63, LIST, List of Diagnostic Trouble Code (DTC).>
S2M1768A
EN(w/oOBD)-27
INSPECTION MODE
8. Inspection Mode 2. WITH SUBARU SELECT MONITOR

A: OPERATION After performing diagnostics and clearing memory,
check for any remaining unresolved trouble data.
1. PREPARATIONS FOR THE INSPECTION 1) Connect the test mode connector (green) at the
MODE lower portion of instrument panel (on the driver’s
side).
Raise the vehicle using a garage jack and place on
safety stands or drive the vehicle onto free rollers.
WARNING:
• Before raising the vehicle, ensure parking
brake is applied.
safety stand.
• Do not abruptly depress/release the clutch EN1450
pedal or accelerator pedal during works even
when engine is operating at low speeds since (A) Test mode connector
this may cause vehicle to jump off free rollers.
• In order to prevent the vehicle from slipping 2) Connect the Subaru Select Monitor to data link
due to vibration, do not place any wooden connector. <Ref. to EN(w/oOBD)-10, LOCATION,
blocks or similar items between the safety Electrical Components Location.>
stands and the vehicle. 3) Turn the ignition switch to ON (engine OFF) and
• Since the rear wheels will also rotate, do not Subaru Select Monitor switch to ON.
S2M0288E
(A) Power switch

press [YES] key.
lect the {6. Dealer Check Mode Procedure} and
press [YES] key.
B2M2969C 8) When the “Perform Inspection (Dealer Check)
Mode?” is shown on the display screen, press
(A) Safety stand [YES] key.
(B) Free rollers
EN(w/oOBD)-28
INSPECTION MODE
9) Perform subsequent procedures as instructed • For detailed concerning diagnostic trouble codes
on the display screen. (DTCs), refer to the DIAGNOSTIC TROUBLE
• If trouble still remains in the memory, the corre- CODE (DTC) LIST. <Ref. to EN(w/oOBD)-63,
sponding diagnostic trouble code (DTC) appears LIST, List of Diagnostic Trouble Code (DTC).>
on the display screen. • On AWD vehicles, release the parking brake.
NOTE: • The speed difference between front and rear
• For detailed operation procedure, refer to the wheels may light either ABS warning light, but this
SUBARU SELECT MONITOR OPERATION MAN- indicates no malfunctions. When the engine control
UAL. diagnosis is finished, perform the ABS memory.
Step Check Yes No

1)Start and warm-up the engine. necessary.
3)Set the shift lever to neutral position (MT • Open or short
vehicles), or set selector lever to “P” position circuit in engine
(AT vehicles). control module
4)Connect the test mode connector (green) at power supply or
lower portion of instrument panel (on driver’s ground line
side). • Open or short
5)Turn the ignition switch to ON. circuit in CHECK
ENGINE malfunc-
tion indicator lamp
2 CHECK DIAGNOSTIC TROUBLE CODE Does the MIL indicate DTC? Record the DTC Go to step 3.
(DTC). and inspect using
1)Set the selector lever to “N” position, and DTC. <Ref. to
then set selector lever to “P” position again (AT EN(w/oOBD)-66,
vehicles only). Diagnostic Proce-
2)Start the engine. dure with Diagnos-
tic Trouble Code
(DTC).>
3 CHECK DIAGNOSTIC TROUBLE CODE Does the MIL indicate DTC? Record the DTC Turn the ignition
(DTC). and inspect using switch to OFF.
1)Drive the vehicle at speed greater than 11 DTC. <Ref. to Disconnect the
km/h (7 MPH) for at least 1 minute. EN(w/oOBD)-66, test mode connec-
2)Warm-up the engine above 2,000 rpm. Diagnostic Proce- tor. Complete the
dure with Diagnos- inspection mode.
tic Trouble Code NOTE:
(DTC).> When the on-
board diagnosis
system indicates
no trouble, trouble
is in a different
symptom.
EN(w/oOBD)-29
CLEAR MEMORY MODE
9. Clear Memory Mode

A: OPERATION
1) On the «Main Menu» display screen, select the {2. Each System Check} and press [YES] key.
key.
4) On the «Engine Diagnosis» display screen, select the {Clear Memory} and press [YES] key.
5) When the “Done” and “Turn Ignition Switch OFF” are shown on the display screen, turn the Subaru Select
Monitor and ignition switch to OFF.
NOTE:
• After the memory has been cleared, the ISC must be initialized. To do this, turn the ignition switch to the
ON position. Wait 3 seconds before starting the engine.
Step Check Yes No

1)Turn the ignition switch to OFF. necessary.
2)Set the shift lever to neutral position (MT NOTE:
vehicles), or set selector lever to “P” position • Open or short
(AT vehicles). circuit in engine
3)Connect the test mode connector and read control module
memory connectorat at lower portion of instru- power supply or
ment panel (on driver’s side). ground line
4)Turn the ignition switch to ON. • Open or short
circuit in CHECK
ENGINE malfunc-
tion indicator lamp
2 CHECK DIAGNOSTIC TROUBLE CODE Does the MIL indicate DTC? Record the DTC. Turn the ignition
(DTC). <Ref. to EN(w/oOBD)-63, Repair the trouble switch to OFF.
1)Set the selector lever to “N” position, and LIST, List of Diagnostic Trou- cause. <Ref. to Disconnect the
then set selector lever to “P” position again (AT ble Code (DTC).> EN(w/oOBD)-66, read memory con-
vehicles only). Diagnostic Proce- nector and test
2)Start the engine. dure with Diagnos- mode connector.
3)Drive the vehicle at speed greater than 11 tic Trouble Code Complete the clear
km/h (7 MPH) for at least 1 minute. (DTC).> memory mode.
4)Warm-up engine above 2,000 rpm.
EN(w/oOBD)-30
10.Compulsory Valve Operation

Check Mode
A: OPERATION
1) Connect the test mode connector at the lower
portion of instrument panel (on the driver's side).
EN1450
(A) Test mode connector
2) Each valve functions when the ignition switch is

turned to ON (engine OFF).
• A list of the support portion is shown in the follow-
ing table.
Contents
Compulsory fuel pump relay operation check
Compulsory purge control solenoid valve operation check
Compulsory radiator fan relay operation check
Compulsory air conditioning relay operation check
EN(w/oOBD)-31

A: PROCEDURE
1. Activation of check engine malfunction indicator lamp (MIL). <Ref. to EN(w/oOBD)-32, ACTIVATION OF CHECK ENGINE
MALFUNCTION INDICATOR LAMP (MIL), Engine Malfunction Indicator Lamp (MIL).>
↓
2. Check that engine malfunction indicator lamp (MIL) does not come on. <Ref. to EN(w/oOBD)-34, CHECK ENGINE MAL-
FUNCTION INDICATOR LAMP (MIL) DOES NOT COME ON., Engine Malfunction Indicator Lamp (MIL).>
↓
3. Check that engine malfunction indicator lamp (MIL) does not go off. <Ref. to EN(w/oOBD)-36, CHECK ENGINE MALFUNC-
TION INDICATOR LAMP (MIL) DOES NOT GO OFF., Engine Malfunction Indicator Lamp (MIL).>
↓
4. Check that engine malfunction indicator lamp (MIL) does not blink at a cycle of 3 Hz. <Ref. to EN(w/oOBD)-38, CHECK
ENGINE MALFUNCTION INDICATOR LAMP (MIL) DOES NOT BLINK AT A CYCLE OF 3 HZ., Engine Malfunction Indicator
Lamp (MIL).>
↓
5. Check that engine malfunction indicator lamp (MIL) remains blinking at a cycle of 3 Hz. <Ref. to EN(w/oOBD)-40, CHECK
ENGINE MALFUNCTION INDICATOR LAMP (MIL) REMAINS BLINKING AT A CYCLE OF 3 HZ., Engine Malfunction Indicator
Lamp (MIL).>
B: ACTIVATION OF CHECK ENGINE 2) After starting the engine, the MIL goes out. If it
MALFUNCTION INDICATOR does not, either the engine or the emission control
system is malfunctioning. <Ref. to EN(w/oOBD)-2,
LAMP (MIL) PROCEDURE, Basic Diagnostic Procedure.>
off), the CHECK ENGINE malfunction indicator
NOTE:
tion meter circuit. <Ref. to IDI-15, Combination
Meter Assembly.>
OBD0053A

off) or to START with the test mode connector con-
nected, the MIL blinks at a cycle of 3 Hz.
EN0774
OBD0055A
EN(w/oOBD)-32
EN(w/oOBD)-33

ON.
• DIAGNOSIS:
• When the ignition switch is turned ON (engine OFF), MIL does not come on.
• WIRING DIAGRAM:
IGNITION
B72 BATTERY
SWITCH
No.13 SBF-4 SBF-1
4 1
LHD RHD
AT MT
B36 B38 B36

23
22
i1 i3 i1
AT MT
LHD RHD
A7
C6
i2
1 LHD :16
1
COMBINATION
RHD :13
METER B37
A: i10
11
C: i12
B134 ECM
B72 B36 B134 i1 A: i10
1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10
1 2 1 2 3 4 5 6
12 13 14 15 16 17 18 19 20 21 22 23 24 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
3 4 7 8 9 10 11 12 13 14
24 25 26 27 28 29 30 31 32 33 34 35
1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10
12 13 14 15 16 17 18 19 20 21 22 23 24 10 11 12 13 14 15 16 17 18 19 20 21
7 8 9 10 11 12 13 14 11 12 13 14 15 16 17 18 19 20 21 22
22 23 24 25 26 27 28 29 30 31 32
EN1395
Step Check Yes No

2 CHECK POOR CONTACT. Does the MIL come on when Repair poor con- Go to step 3.
shaking or pulling ECM contact in the ECM
EN(w/oOBD)-34
Step Check Yes No

connected? nection of ECM
connector.
(B134) No. 11 — (i12) No. 6: nector
• Poor contact in
coupling connector
nector. <Ref. to IDI-15, Combination Meter nation meter con-
Assembly.> nector.
NECTOR. necessary.
(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
connector
7 CHECK POOR CONTACT. Is there poor contact in combi- Repair the poor Replace the bulb
Check poor contact in combination meter con- nation meter connector? contact in combi- or combination
nector. <Ref. to IDI-15, Combination Meter nation meter con- meter.
Assembly.> nector.
EN(w/oOBD)-35

OFF.
• DIAGNOSIS:
• WIRING DIAGRAM:
IGNITION
B72 BATTERY
SWITCH
No.13 SBF-4 SBF-1
4 1
LHD RHD
AT MT
B36 B38 B36

23
22
i1 i3 i1
AT MT
LHD RHD
A7
C6
i2
1 LHD :16
1
COMBINATION
RHD :13
METER B37
A: i10
11
C: i12
B134 ECM
B72 B36 B134 i1 A: i10
1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10
1 2 1 2 3 4 5 6
12 13 14 15 16 17 18 19 20 21 22 23 24 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
3 4 7 8 9 10 11 12 13 14
24 25 26 27 28 29 30 31 32 33 34 35
1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10
12 13 14 15 16 17 18 19 20 21 22 23 24 10 11 12 13 14 15 16 17 18 19 20 21
7 8 9 10 11 12 13 14 11 12 13 14 15 16 17 18 19 20 21 22
22 23 24 25 26 27 28 29 30 31 32
EN1395
Step Check Yes No

TION METER AND ECM CONNECTOR. circuit in harness <Ref. to FU(w/
1)Turn the ignition switch to OFF. between combina- oOBD)-48, Engine
2)Disconnect the connector from ECM. tion meter and Control Module.>
3)Turn the ignition switch to ON. ECM connector.
EN(w/oOBD)-36
EN(w/oOBD)-37

AT A CYCLE OF 3 HZ.
• DIAGNOSIS:
• Test mode connector circuit is in open.
• WIRING DIAGRAM:
IGNITION
B72 BATTERY
SWITCH
No.13 SBF-4 SBF-1
4 1
LHD RHD
AT MT
B36 B38 B36
23
22
i1 i3 i1
AT MT 1 LHD :16
RHD :13
LHD RHD
A7
C6 1 1 16
i2 B75 B76 B22 E3

1
COMBINATION B37
METER
A: i10
A11
B14
C: i12
A: B134
ECM
B: B135
B75 B72 A: i10 C: i12 B22 B36
1 1 2 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11
2 3 4 7 8 9 10 11 12 13 14 5 6 7 8 12 13 14 15 16 17 18 19 20 21 22 23 24
9 10 11 12
13 14 15 16
B135 i1 RHD: i2 B134
1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8
1 2 3 4 5 6
8 9 10 11 12 13 14 15 16 17 18 19 10 11 12 13 14 15 16 17 18 19 20 21 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
7 8 9 10 11 12 13 14
20 21 22 23 24 25 26 27 28 22 23 24 25 26 27 28 29 30 31 32 24 25 26 27 28 29 30 31 32 33 34 35
LHD: i2 i3
1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9 10
12 13 14 15 16 17 18 19 20 21 22 23 24 11 12 13 14 15 16 17 18 19 20 21 22
EN1451
EN(w/oOBD)-38
Step Check Yes No

FUNCTION INDICATOR LAMP (MIL). cuit. <Ref. to
1)Turn the ignition switch to OFF. EN(w/oOBD)-34,
2)Disconnect the test mode connector at lower CHECK ENGINE
portion of instrument panel (on driver’s side). MALFUNCTION
3)Turn the ignition switch to ON. INDICATOR
LAMP (MIL)
DOES NOT
COME ON.,
Engine Malfunc-
tion Indicator
Lamp (MIL).>
Measure the voltage between test mode con-
nector and chassis ground.
TEST MODE CONNECTOR. Ω? ness and connec-
ECM and test mode connector. the following:
ECM and test
mode connector
Check poor contact in ECM connector. connector? contact in ECM <Ref. to FU(w/
connector. oOBD)-48, Engine
Control Module.>
test mode connec-
tor and chassis
ground
Control Module.>
EN(w/oOBD)-39

• DIAGNOSIS:
• Even though test mode connector is disconnected, MIL blinks at a cycle of 3 Hz when ignition switch is
turned to ON.
• WIRING DIAGRAM:
IGNITION
B72 BATTERY
SWITCH
No.13 SBF-4 SBF-1
4 1
LHD RHD
AT MT
B36 B38 B36
23
22
i1 i3 i1
AT MT 1 LHD :16
RHD :13
LHD RHD
A7
C6 1 1 16
i2 B75 B76 B22 E3

1
COMBINATION B37
METER
A: i10
A11
B14
C: i12
A: B134
ECM
B: B135
B75 B72 A: i10 C: i12 B22 B36
1 1 2 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11
2 3 4 7 8 9 10 11 12 13 14 5 6 7 8 12 13 14 15 16 17 18 19 20 21 22 23 24
9 10 11 12
13 14 15 16
B135 i1 RHD: i2 B134
1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8
1 2 3 4 5 6
8 9 10 11 12 13 14 15 16 17 18 19 10 11 12 13 14 15 16 17 18 19 20 21 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
7 8 9 10 11 12 13 14
20 21 22 23 24 25 26 27 28 22 23 24 25 26 27 28 29 30 31 32 24 25 26 27 28 29 30 31 32 33 34 35
LHD: i2 i3
1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9 10
12 13 14 15 16 17 18 19 20 21 22 23 24 11 12 13 14 15 16 17 18 19 20 21 22
EN1451
EN(w/oOBD)-40
Step Check Yes No

NECTOR AND ENGINE GROUNDING TER- Ω? circuit in harness <Ref. to FU(w/
MINAL. between ECM and oOBD)-48, Engine
1)Turn the ignition switch to OFF. test mode connec- Control Module.>
ECM connector and engine ground.
EN(w/oOBD)-41

A: PROCEDURE
1. Inspection of starter motor circuit. <Ref. to EN(w/oOBD)-44, STARTER MOTOR CIRCUIT, Diagnostics for Engine Starting
Failure.>
↓
2. Inspection of ECM power supply and ground line. <Ref. to EN(w/oOBD)-48, CONTROL MODULE POWER SUPPLY AND
GROUND LINE, Diagnostics for Engine Starting Failure.>
↓
3. Inspection of ignition control system. <Ref. to EN(w/oOBD)-52, IGNITION CONTROL SYSTEM, Diagnostics for Engine Start-
ing Failure.>
↓
4. Inspection of fuel pump circuit. <Ref. to EN(w/oOBD)-56, FUEL PUMP CIRCUIT, Diagnostics for Engine Starting Failure.>
↓
5. Inspection of fuel injector circuit. <Ref. to EN(w/oOBD)-60, FUEL INJECTOR CIRCUIT, Diagnostics for Engine Starting Fail-
ure.>
EN(w/oOBD)-42
EN(w/oOBD)-43

CAUTION:
After repair or replacement of faulty parts, conduct CLEAR MEMORY and INSPECTION MODES. <Ref.
to EN(w/oOBD)-30, OPERATION, Clear Memory Mode.> and <Ref. to EN(w/oOBD)-28, OPERATION,
Inspection Mode.>
• WIRING DIAGRAM:
BATTERY
SBF-4 SBF-1
1
IGNITION
SWITCH
B72
3
INHIBITOR SWITCH
P R N D 3 2 1
AT 12 12
11 7
MT
B12 T3 T7
MT
B135 ECM 28 AT
B14
STARTER
MOTOR
B72 B12 T7 B135
1 2 3 4 1 2 3 4 5 6 1 2 3 4 5 6 7
1 2
5 6 7 8 7 8 9 10 11 12 8 9 10 11 12 13 14 15 16 17 18 19
3 4
9 10 11 12 20 21 22 23 24 25 26 27 28
EN0862
Step Check Yes No

(DTC). <Ref. to EN(w/oOBD)-63, Repair the trouble
<Ref. to EN(w/oOBD)-26, OPERATION, Read LIST, List of Diagnostic Trou- cause. <Ref. to
Diagnostic Trouble Code (DTC).> ble Code (DTC).> EN(w/oOBD)-66,
Diagnostic Proce-
dure with Diagnos-
tic Trouble Code
(DTC).>
EN(w/oOBD)-44
Step Check Yes No

TOR.
ground.
NOTE:
On AT vehicles, place the selector lever in the
“P” or “N” position.
1)Turn the ignition switch to OFF. SC-10, INSPEC- cable.
2)Disconnect the terminal from starter motor. TION, Starter.>
ground.
motor and ECM.
1)Ignition the switch to OFF. between ignition
switch.
8 CHECK HARNESS BETWEEN BATTERY Is the voltage more than 10 V? Go to step 9. Replace the igni-
AND IGNITION SWITCH CONNECTOR. tion switch.
1)Connect the connector to ignition switch.
3)Measure the voltage between ignition switch
and chassis ground.
9 CHECK TRANSMISSION TYPE. Is the vehicle AT? Go to step 10. Repair the open
circuit between
ignition switch and
starter motor cir-
cuit.
EN(w/oOBD)-45
Step Check Yes No

10 CHECK INHIBITOR SWITCH CIRCUIT. Is the resistance less than 1 Repair the open Go to step 11.
2)Place the selector lever in the “P” or “N” posi- between starter
tion. motor and ignition
3)Separate the transmission harness connec- switch connector.
tor.
sion harness connector receptacle's terminals.
(T3) No. 11 — No. 12:
11 CHECK TRANSMISSION HARNESS. Is the resistance less than 1 Go to step 12. Repair the open
1)Disconnect the connector from inhibitor Ω? circuit in harness
switch. between transmis-
2)Measure the resistance of harness between sion harness and
transmission harness and inhibitor switch con- inhibitor switch
nector. connector.
(T3) No. 11 — (T7) No. 7:
(T3) No. 12 — (T7) No. 12:
12 CHECK POOR CONTACT. Is there poor contact in inhibi- Repair the poor Replace the inhibi-
Check poor contact in inhibitor switch connector switch connector? contact in inhibitor tor switch.
EN(w/oOBD)-46
EN(w/oOBD)-47

CAUTION:
Inspection Mode.>
• WIRING DIAGRAM:
MAIN RELAY
RHD
RHD
4 B61 F44
SBF-5
5 LHD 2 LHD
3
2
1 IGNITION
B72 BATTERY
SWITCH
4 1
B19
C1
C2
C9
B7
1 AT MODEL (RHD ONLY) : B6

ECM MT MODEL : B25
A: B134
B: B135
C: B136
C22
C21
A27
1
A7
A8
B22
13
15
14
16
E3
B72 B47 F44 B22 B: B135 C: B136

1 2 1 2 3 4 1 2 3 4 1 2 3 4 5 6 7 1 2 3 4 5 6 7
1 2
3 4 5 6 7 8 5 6 7 8 8 9 10 11 12 13 14 15 16 17 18 19 8 9 10 11 12 13 14 15 16 17 18 19 20
3 4
5 6 9 10 11 12 20 21 22 23 24 25 26 27 28 21 22 23 24 25 26 27 28 29 30
13 14 15 16
A: B134
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25 26 27 28 29 30 31 32 33 34 35
EN1452
Step Check Yes No

No. 1 and No. 2.
terminals.
Terminals
No. 3 — No. 5:
No. 4 — No. 6:
EN(w/oOBD)-48
Step Check Yes No

(B135) No. 25 — Chassis ground: (MT
vehicle)
(B135) No. 6 — Chassis ground: (AT
vehicle (RHD ONLY))
1)Turn the ignition switch to ON. ground short cir-
2)Measure the voltage between ECM connec- cuit of power sup-
tor and chassis ground. ply circuit.
Connector & terminal connector, and
(B135) No. 19 — Chassis ground: then replace the
ECM.
nector.
EN(w/oOBD)-49
Step Check Yes No

2)Turn the ignition switch to ON. <Ref. to EN(w/ cuit in harness
3)Measure the voltage between ECM connec- oOBD)-52, IGNI- between ECM
tor and chassis ground. TION CONTROL connector and
Connector & terminal SYSTEM, Diag- main relay con-
(B136) No. 1 (+) — Chassis ground (–): nostics for Engine nector.
(B136) No. 2 (+) — Chassis ground (–): Starting Failure.>
EN(w/oOBD)-50
EN(w/oOBD)-51

CAUTION:
After repair or replacement of the faulty parts, conduct the CLEAR MEMORY and INSPECTION
MODES. <Ref. to EN(w/oOBD)-30, OPERATION, Clear Memory Mode.> and <Ref. to EN(w/oOBD)-28,
OPERATION, Inspection Mode.>
• WIRING DIAGRAM:
B134 ECM
27
26
25
IGNITION
B72
SWITCH BATTERY
NO.11 SBF-4 SBF-1
4 1
B22
14
6
4
5
E3
1 2.0L AND 2.5L: 4
1.6L: 2
2 2.0L AND 2.5L: 1
1.6L: 4
3 2.0L AND 2.5L: 2

1.6L: 1
E12
1
2
3
3
3 4
1 2
IGNITOR
&
IGNITION COIL ASSY
E12 B72 B22 B134
1 2 3 4 1 2 3 4 1 2 3 4 5 6 7 8
1 2 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
3 4 5 6 7 8
9 10 11 12 24 25 26 27 28 29 30 31 32 33 34 35
13 14 15 16
EN1398
EN(w/oOBD)-52
Step Check Yes No

1)Remove the plug cord cap from each spark inder? pump system.
plug. <Ref. to EN(w/
2)Install new spark plug on the plug cord cap. oOBD)-56, FUEL
CAUTION: PUMP CIRCUIT,
Do not remove the spark plug from engine. Diagnostics for
3)Contact the spark plug's thread portion on Engine Starting
engine. Failure.>
4)While opening the throttle valve fully, crank
inder.
4)Measure the power supply voltage between • Open circuit or
ignition coil & ignitor assembly connector and ground short in
engine ground. harness between
Connector & terminal ignition coil & igni-
•1.6 L tor assembly, and
(E12) No. 1 (+) — Engine ground (−): ignition switch
•2.0 L and 2.5 L connector
(E12) No. 2 (+) — Engine ground (−): • Poor contact in
coupling connector
(B22)
ignition coil & igni-
tor assembly con-
nector and engine
grounding terminal
BLY. and 15 Ω? tion coil & ignitor
1)Remove the spark plug cords. assembly.
2)Measure the resistance between spark plug
cord contact portions to check secondary coil.
Terminals
•1.6 L
No. 4 — No. 1:
•2.0 L and 2.5 L
No. 1 — No. 2:
BLY. and 15 Ω? tion coil & ignitor
Measure the resistance between spark plug assembly.
cord contact portions to check secondary coil.
Terminals
•1.6 L
No. 3 — No. 2:
•2.0 L and 2.5 L
No. 3 — No. 4:
EN(w/oOBD)-53
Step Check Yes No

Check if the voltage varies synchronously with assembly.
engine speed when cranking, while monitoring
voltage between ignition coil & ignitor assem-
bly connector and engine ground.
•1.6 L
•2.0 L and 2.5 L
Check if the voltage varies synchronously with assembly.
engine speed when cranking, while monitoring
voltage between ignition coil & ignitor assem-
bly connector and engine ground.
•1.6 L
•2.0 L and 2.5 L
NECTOR. tor.
ECM and ignition coil & ignitor assembly con- the following:
nector. • Open circuit in
•1.6 L ECM and ignition
(B134) No. 26 — (E12) No. 2: coil & ignitor
•2.0 L and 2.5 L assembly connec-
(B134) No. 26 — (E12) No. 4: tor
• Poor contact in
a coupling connec-
tor (B22)
NECTOR. tor.
•1.6 L harness between
(B134) No. 25 — (E12) No. 4: ECM and ignition
•2.0 L and 2.5 L coil & ignitor
(B134) No. 25 — (E12) No. 1: assembly connec-
tor
• Poor contact in
a coupling connec-
tor (B22)
EN(w/oOBD)-54
Step Check Yes No

NECTOR. tor.
Connector & terminal: • Open circuit in
(B134) No. 27 — (E12) No. 3: harness between
ECM and ignition
coil & ignitor
assembly connec-
tor
• Poor contact in
a coupling connec-
tor (B22)
ECM and chassis ground. coil & ignitor
(B134) No. 26 — Chassis ground: tor.
ECM and chassis ground. coil & ignitor
(B134) No. 25 — Chassis ground: tor.
13 CHECK POOR CONTACT. Is there poor contact in ECM Repair the poor Check the spark
Check poor contact in ECM connector. connector? contact in ECM plug and spark
connector. plug cord. <Ref. to
IG(w/oOBD)-6,
INSPECTION,
Spark Plug.>
<Ref. to IG(w/
oOBD)-10,
INSPECTION,
Spark Plug Cord.>
EN(w/oOBD)-55

CAUTION:
Inspection Mode.>
• WIRING DIAGRAM:
RHD
RHD
SBF-5
LHD 2 LHD
IGNITION
B61 F44 B72 BATTERY
SWITCH
No.11 SBF-4 SBF-1
FUEL PUMP 4 1
RELAY
2
1
3 2 B134 ECM
4
B46
B97
1
1 LHD :7
R1 RHD :5
2 WITH
IMMOBILIZER :29
WITHOUT
IMMOBILIZER :16
FUEL PUMP
1 1
4 3
R58 R57 R15
B46 B72 R58 F44 B97 R15 B134
1 2 1 2 3 1 2 1 2 3 4 5 6 7 8
1 2 1 2 3 4 1 2 3 4
3 4 4 5 6 3 4 5 6 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
3 4 5 6 7 8 5 6 7 8
24 25 26 27 28 29 30 31 32 33 34 35
EN1399
Step Check Yes No

1 CHECK OPERATING SOUND OF FUEL Does the fuel pump produce Check the fuel Go to step 2.
PUMP. operating sound? injector circuit.
Make sure that the fuel pump is in operation for <Ref. to EN(w/
2 seconds when turning ignition switch to ON. oOBD)-60, FUEL
NOTE: INJECTOR CIR-
Fuel pump operation check can also be execut- CUIT, Diagnostics
ed using the Subaru Select Monitor. For the for Engine Start-
procedure, refer to “COMPULSORY VALVE ing Failure.>
OPERATION CHECK MODE”.<Ref. to EN(w/
oOBD)-31, OPERATION, Compulsory Valve
Operation Check Mode.>
EN(w/oOBD)-56
Step Check Yes No

2 CHECK GROUND CIRCUIT OF FUEL PUMP. Is the resistance less than 5 Go to step 3. Repair the har-
2)Raise the rear seat, and turn floor mat up. tor.
3)Remove the service hole cover. NOTE:
4)Disconnect the connector from fuel pump. In this case, repair
5)Measure the resistance of harness connec- the following:
tor between fuel pump and chassis ground. • Open circuit in
(R58) No. 4 — Chassis ground: fuel pump connec-
tor and chassis
grounding terminal
• Poor contact in
coupling connector
(R15) and (B97)
3 CHECK POWER SUPPLY TO FUEL PUMP. Is the voltage more than 10 V? Replace the fuel Go to step 4.
1)Turn the ignition switch to ON. pump.
2)Measure the voltage of power supply circuit
between fuel pump connector and chassis
ground.
(R58) No. 1 (+) — Chassis ground (−):
AND FUEL PUMP RELAY CONNECTOR. Ω? ness and connec-
fuel pump and fuel pump relay connector. In this case, repair
(R58) No. 1 — (B46) No. 4: • Open circuit in
harness between
fuel pump and fuel
pump relay con-
nector
• Poor contact in
coupling connec-
tors (R15) and
(B97)
5 CHECK HARNESS BETWEEN FUEL PUMP Is the resistance more than 1 Go to step 6. Repair the ground
AND FUEL PUMP RELAY CONNECTOR. MΩ? short circuit in har-
Measure the resistance of harness between ness between fuel
fuel pump and fuel pump relay connector. pump and fuel
Connector & terminal pump relay con-
(R58) No. 1 — Chassis ground: nector.
6 CHECK FUEL PUMP RELAY. Is the resistance less than 10 Go to step 7. Replace the fuel
1)Disconnect the connector from fuel pump Ω? pump relay.
relay.
2)Remove the fuel pump relay from 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:
EN(w/oOBD)-57
Step Check Yes No

FUEL PUMP RELAY CONNECTOR. Ω? circuit 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.
•With Immobilizer
(B134) No. 29 — (B46) No. 3:
•Without Immobilizer
(B134) No. 16 — (B46) No. 3:
Check poor contact in ECM connector. connector? contact in ECM injector circuit.
connector. <Ref. to EN(w/
oOBD)-60, FUEL
INJECTOR CIR-
CUIT, Diagnostics
for Engine Start-
ing Failure.>
EN(w/oOBD)-58
EN(w/oOBD)-59

CAUTION:
• Check or repair only the faulty parts.
• After repair or replacement of the faulty parts, conduct the CLEAR MEMORY and INSPECTION
MODES. <Ref. to EN(w/oOBD)-30, OPERATION, Clear Memory Mode.> and <Ref. to EN(w/oOBD)-28,
OPERATION, Inspection Mode.>
• WIRING DIAGRAM:
MAIN RELAY
4 BATTERY
RHD
RHD
6
SBF-5
5 LHD 2 LHD
3
B61 F44
2
1
B47
C2
C1
A: B134 C: B136 ECM

A13
A14
A15
A4
B22
10
11
12
1
E3
E5 E16 E6 E17
2

No.1 No.2 No.3 No.4
E5 E16 B47 F44 B22
E6 E17 1 2 1 2 3 4 1 2 3 4
3 4 5 6 7 8 5 6 7 8
1 2 5 6 9 10 11 12
13 14 15 16
C: B136 A: B134
1 2 3 4 5 6 7 1 2 3 4 5 6 7 8
8 9 10 11 12 13 14 15 16 17 18 19 20 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
21 22 23 24 25 26 27 28 29 30 24 25 26 27 28 29 30 31 32 33 34 35
EN0866
Step Check Yes No

While cranking the engine, check that each ME-29, INSPEC-
fuel injector emits “operating” sound. Use a TION, Fuel Pres-
sound scope or attach a screwdriver to injector sure.>
for this check.
EN(w/oOBD)-60
Step Check Yes No

• Poor contact in
coupling connector
(B22)
• Poor contact in
fuel injector con-
nector
(B134) No. 4 — (B136) No. 2: • Open circuit in
harness between
ECM and fuel
injector connector
• Poor contact in
coupling connector
(B22)
• Open circuit in
harness between
ECM and fuel
injector connector
• Poor contact in
coupling connector
(B22)
EN(w/oOBD)-61
Step Check Yes No

• Open circuit in
harness between
ECM and fuel
injector connector
• Poor contact in
coupling connector
(B22)
• Open circuit in
harness between
ECM and fuel
injector connector
• Poor contact in
coupling connector
(B22)
injector terminals.
Terminals
No. 1 — No. 2:
EN-292, INSPEC-
TION, General
Diagnostic Table.>
EN(w/oOBD)-62

A: LIST
Trouble
Item Contents of diagnosis Index
code
11 Crankshaft position sen- • No signal entered from crankshaft <Ref. to EN(w/oOBD)-66, DTC 11 CRANKSHAFT
sor position sensor when starter switch is POSITION SENSOR, Diagnostic Procedure with
ON. Diagnostic Trouble Code (DTC).>
• Harness connector between ECM
and crankshaft position sensor is in
short or open.
12 Starter switch • Starter switch signal is abnormal. <Ref. to EN(w/oOBD)-68, DTC 12 STARTER
• Harness connector between ECM SWITCH, Diagnostic Procedure with Diagnostic
and starter switch is in short or open. Trouble Code (DTC).>
13 Camshaft position sensor • No signal entered from camshaft <Ref. to EN(w/oOBD)-70, DTC 13 CAMSHAFT
position sensor, but signal entered POSITION SENSOR, Diagnostic Procedure with
from crankshaft position sensor. Diagnostic Trouble Code (DTC).>
and camshaft position sensor is in
short or open.
21 Engine coolant tempera- • Engine coolant temperature sensor <Ref. to EN(w/oOBD)-72, DTC 21 ENGINE
ture sensor signal is abnormal. COOLANT TEMPERATURE SENSOR, Diagnos-
• Harness connector between ECM tic Procedure with Diagnostic Trouble Code
and engine coolant temperature sen- (DTC).>
sor is in short or open.
22 Knock sensor • Knock sensor signal is abnormal. <Ref. to EN(w/oOBD)-76, DTC 22 KNOCK SEN-
• Harness connector between ECM SOR, Diagnostic Procedure with Diagnostic Trou-
and knock sensor is in short or open. ble Code (DTC).>
24 Idle air control solenoid • Idle air control solenoid valve is not <Ref. to EN(w/oOBD)-78, DTC 24 IDLE AIR
valve in function. CONTROL SOLENOID VALVE, Diagnostic Pro-
• Harness connector between ECM cedure with Diagnostic Trouble Code (DTC).>
and idle air control solenoid valve is in
short or open.
26 Intake air temperature • Intake air temperature sensor sig- <Ref. to EN(w/oOBD)-82, DTC 26 INTAKE AIR
sensor nal is abnormal. TEMPERATURE SENSOR, Diagnostic Proce-
• Harness connector between ECM dure with Diagnostic Trouble Code (DTC).>
and intake air temperature sensor is
in short or open.
31 Throttle position sensor • Throttle position sensor signal is <Ref. to EN(w/oOBD)-86, DTC 31 THROTTLE
abnormal. POSITION SENSOR, Diagnostic Procedure with
• Throttle position sensor is installed Diagnostic Trouble Code (DTC).>
abnormally.
and throttle position sensor is in short
or open.
32 Oxygen sensor • Oxygen sensor is not in function. <Ref. to EN(w/oOBD)-88, DTC 32 OXYGEN
• Harness connector between ECM SENSOR, Diagnostic Procedure with Diagnostic
and oxygen sensor is in short or open. Trouble Code (DTC).>
33 Vehicle speed signal • Vehicle speed signal is abnormal. <Ref. to EN(w/oOBD)-92, DTC 33 VEHICLE
• Harness connector between ECM SPEED SIGNAL, Diagnostic Procedure with Diag-
and vehicle speed sensor is in short nostic Trouble Code (DTC).>
or open.
35 Purge control solenoid • Purge control solenoid valve is not <Ref. to EN(w/oOBD)-94, DTC 35 PURGE CON-
valve in function. TROL SOLENOID VALVE, Diagnostic Procedure
• Harness connector between ECM with Diagnostic Trouble Code (DTC).>
and purge control solenoid valve is in
short or open.
EN(w/oOBD)-63
Trouble
Item Contents of diagnosis Index
code
38 Torque control signal (AT) • Abnormal signal is entered from <Ref. to EN(w/oOBD)-98, DTC 38 TORQUE
TCM. CONTROL SIGNAL, Diagnostic Procedure with
• Harness connector between ECM Diagnostic Trouble Code (DTC).>
and TCM is in short or open.
45 Pressure sensor • Pressure sensor signal is abnor- <Ref. to EN(w/oOBD)-100, DTC 45 PRESSURE
mal. SENSOR, Diagnostic Procedure with Diagnostic
• Harness connector between ECM Trouble Code (DTC).>
and pressure sensor is in short or
open.
46 CO resistor (General • CO resistor signal is abnormal. <Ref. to EN(w/oOBD)-102, DTC 46 CO RESIS-
spec. vehicles) • Harness connector between ECM TOR (GENERAL SPEC. VEHICLES), Diagnostic
and CO resistor is in short or open. Procedure with Diagnostic Trouble Code (DTC).>
• CO valve is not adjusted to specifi-
cation.
51 Neutral position switch • Neutral position switch signal is <Ref. to EN(w/oOBD)-104, DTC 51 NEUTRAL
(MT) abnormal. POSITION SWITCH (MT VEHICLE), Diagnostic
• Harness connector between ECM Procedure with Diagnostic Trouble Code (DTC).>
and neutral position switch is in short
or open.
Park/Neutral position • Park/neutral position switch signal <Ref. to EN(w/oOBD)-106, DTC 51 PARK/NEU-
switch (AT) is abnormal. TRAL POSITION SWITCH (AT VEHICLE), Diag-
• Shift cable is connected abnor- nostic Procedure with Diagnostic Trouble Code
mally. (DTC).>
and inhibitor switch is in short or
open.
53* Immobilizer system Faulty immobilizer system. <Ref. to IM-2, Basic Diagnostic Procedure.>
85 Charge system Charge system is abnormal. <Ref. to EN(w/oOBD)-108, DTC 85 CHARGE
SYSTEM, Diagnostic Procedure with Diagnostic
*: Immobilizer system equipped model only
EN(w/oOBD)-64
EN(w/oOBD)-65

A: DTC 11 CRANKSHAFT POSITION SENSOR
• DIAGNOSIS:
• No signal entered from crankshaft position sensor when ignition switch is ON.
• The harness connector between ECM and crankshaft position sensor is open or shorted.
• Engine stalls.
• Restarting impossible
CAUTION:
Inspection Mode.>
• WIRING DIAGRAM:
WITH IMMOBILIZER :2
CRANKSHAFT WITHOUT IMMOBILIZER :1 E10
POSITION
SENSOR 1 2
2
1
E10
LHD: B83
1 2 3 4
5 6 7 8
E2
19
17
B21 RHD: B83
1 2 3 4 5 6 7 8 9 10 11 12
LHD RHD B21

1 7
5 9 1 2 3 4
LHD RHD 5 6 7 8
B83 B83 9 10 11 12
13 14 15 16
17 18 19 20
10
8
B135
B135 ECM 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 28
EN1453
EN(w/oOBD)-66
Step Check Yes No

1 CHECK CONDITION OF CRANKSHAFT PO- Are the crankshaft position Go to step 2. Tighten the crank-
SITION SENSOR INSTALLATION. sensor installing bolts tight- shaft position sen-
ened securely? sor installing bolts
securely.
2 CHECK CRANKSHAFT POSITION SENSOR. Is the resistance between 1 Go to step 3. Replace the crank-
1)Remove the crankshaft position sensor. and 4 kΩ? shaft position sen-
2)Measure the resistance between connector sor.
terminals of crankshaft position sensor.
Terminals
No. 1 — No. 2:
CRANKSHAFT POSITION SENSOR CON- and 5 kΩ? ness and connec-
NECTOR. tor.
1)Connect the connector to crankshaft position NOTE:
sensor. In this case, repair
2)Disconnect the connector from ECM. the following:
ECM. crankshaft posi-
•With Immobilizer ECM connector
•Without Immobilizer coupling connector
(B135) No. 8 — (B135) No. 1 (B21)
CRANKSHAFT POSITION SENSOR CON- Ω? short circuit in har-
ECM connector and chassis ground. tion sensor and
Connector & terminal ECM connector.
5 CHECK INPUT SIGNAL FOR ECM. Is the voltage more than 400 Go to step 6. Replace the crank-
1)Turn the ignition switch to OFF. mV? shaft position sen-
2)Set the positive (+) probe and ground lead of sor.
oscilloscope at ECM connector terminals.
3)Measure the voltage indicated on oscillo-
scope while cranking engine.
•With Immobilizer
(B135) No. 2 (+) — (B135) No. 8 (−)
(B135) No. 1 (+) — (B135) No. 8 (−)
connector.
7 CHECK ECM. Is the same DTC as in current Replace the gen- Go to step 8.
1)Connect all connectors. diagnosis still being output? erator.
2)Erase the memory. <Ref. to EN(w/oOBD)-
30, OPERATION, Clear Memory Mode.>
4)Read any DTC on the display. <Ref. to
EN(w/oOBD)-26, OPERATION, Read Diag-
8 CHECK ANY OTHER DIAGNOSTIC TROU- Is any other DTC displayed? Proceed with the A temporary poor
BLE CODES (DTCs) APPEARANCE. diagnosis corre- contact.
sponding to the
DTC.
EN(w/oOBD)-67
B: DTC 12 STARTER SWITCH

• DIAGNOSIS:
• The starter switch signal is abnormal.
• The harness connector between ECM and starter switch is open or shorted.
CAUTION:
Inspection Mode.>
• WIRING DIAGRAM:
BATTERY
SBF-4 SBF-1
1
IGNITION
SWITCH
B72
3
INHIBITOR SWITCH
P R N D 3 2 1
AT 12 12
11 7
MT
B12 T3 T7
MT
B135 ECM 28 AT
B14
STARTER
MOTOR
B72 B12 T7 B135
1 2 3 4 1 2 3 4 5 6 1 2 3 4 5 6 7
1 2
5 6 7 8 7 8 9 10 11 12 8 9 10 11 12 13 14 15 16 17 18 19
3 4
9 10 11 12 20 21 22 23 24 25 26 27 28
EN0862
Step Check Yes No

1 CHECK OPERATION OF STARTER MOTOR. Does the starter motor oper- Go to step 2. Check the starter
ate when ignition switch is motor circuit.
turned to START?
EN(w/oOBD)-68
Step Check Yes No

2 CHECK HARNESS BETWEEN ECM AND IG- Is the voltage more than 10 V? Repair the poor Repair the open or
NITION SWITCH CONNECTOR. contact in ECM ground short cir-
1)Turn the ignition switch to OFF. connector. cuit in harness
2)Disconnect the connector from ECM. between ECM and
3)Turn the ignition switch to START. ignition switch
4)Measure the power supply voltage between connector.
EN(w/oOBD)-69
C: DTC 13 CAMSHAFT POSITION SENSOR

• DIAGNOSIS:
• No signal entered from camshaft position sensor, but signal entered from crankshaft position sensor.
• The harness connector between ECM and camshaft position sensor is open or shorted.
• Engine stalls.
CAUTION:
Inspection Mode.>
• WIRING DIAGRAM:
WITH IMMOBILIZER :1
CAMSHAFT WITHOUT IMMOBILIZER : 2
E15
POSITION
SENSOR
1 2
2
1
E15
LHD: B83
1 2 3 4
5 6 7 8
E2
20
18
B21 RHD: B83
1 2 3 4 5 6 7 8 9 10 11 12
LHD RHD B21

2 8
5 9 1 2 3 4
LHD RHD 5 6 7 8
B83 B83 9 10 11 12
13 14 15 16
17 18 19 20
10
8
B135
B135 ECM 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 28
EN1454
Step Check Yes No

1 CHECK CONDITION OF CAMSHAFT POSI- Are the camshaft position sen- Go to step 2. Tighten the cam-
TION SENSOR INSTALLATION. sor installing bolts tightened shaft position sen-
securely? sor installing bolts
securely.
EN(w/oOBD)-70
Step Check Yes No

2)Measure the resistance between connector sor.
terminals of camshaft position sensor.
Terminals
No. 1 — No. 2:
CAMSHAFT POSITION SENSOR CONNEC- and 5 kΩ? ness and connec-
TOR. tor.
1)Connect the connector to camshaft position NOTE:
sensor. In this case, repair
2)Disconnect the connector from ECM. the following:
camshaft position sensor connector and ECM. harness between
Connector & terminal camshaft position
•With Immobilizer sensor and ECM
(B135) No. 8 — (B135) No. 1: connector
•Without Immobilizer • Poor contact in
(B135) No. 8 — (B135) No. 2: coupling connector
(B21)
CAMSHAFT POSITION SENSOR CONNEC- Ω? short circuit in har-
TOR. ness between
ECM connector and chassis ground. sensor and ECM
5 CHECK INPUT SIGNAL FOR ECM. Is the voltage more than 400 Go to step 6. Replace the cam-
1)Turn the ignition switch to OFF. mV? shaft position sen-
2)Disconnect the connector from ECM. sor.
3)Set the positive (+) probe and ground lead of
oscilloscope at ECM connector terminals.
4)Measure the voltage indicated on oscillo-
scope while cranking engine.
•With Immobilizer
(B135) No. 1 (+) — (B135) No. 8 (−):
(B135) No. 2 (+) — (B135) No. 8 (−):
connector.
2)Erase the memory. <Ref. to EN(w/oOBD)- put?
sponding to the
DTC.
EN(w/oOBD)-71
D: DTC 21 ENGINE COOLANT TEMPERATURE SENSOR

• DIAGNOSIS:
• The engine coolant temperature sensor signal is abnormal.
• The harness connector between ECM and engine coolant temperature sensor is open or shorted.
• Hard to start
CAUTION:
Inspection Mode.>
• WIRING DIAGRAM:
E8
ENGINE
COOLANT
TEMPERATURE 1 2
SENSOR 3
1
2
E8
LHD: B122
1 2 3
4 5 6
E2
13
9
B21
RHD: B83
1 2 3 4 5 6 7 8 9 10 11 12
LHD RHD
4 5
1 4
LHD RHD
B122 B83
B21
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
17 18 19 20
14
16
B136
1 2 3 4 5 6 7
B136 ECM 8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
EN1455
EN(w/oOBD)-72
Step Check Yes No

2)Remove the generator. coolant tempera-
3)Disconnect the connector from engine cool- ture sensor con-
ant temperature sensor. nector.
4)Measure the voltage between engine coolant
ground.
ground. nector.
ECM CONNECTOR. tor.
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
coupling connector
(B21)
EN(w/oOBD)-73
Step Check Yes No

4 CHECK HARNESS BETWEEN ENGINE Is the resistance less than 5 Go to step 5. Repair the har-
COOLANT TEMPERATURE SENSOR AND Ω? ness and connec-
ECM CONNECTOR. tor.
engine coolant temperature sensor connector the following:
and engine ground. • Open circuit in
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
(B21)
• Poor contact in
sensor ground
joint connector
(B83) or (B122)
5 CHECK ENGINE COOLANT TEMPERATURE Is the resistance between 2 Go to step 6. Replace the
SENSOR. and 3 kΩ at 20°C (68°F)? engine coolant
Measure the resistance between engine cool- temperature sen-
ant temperature sensor terminals. sor.
Terminals
No. 1 — No. 2:
6 CHECK ENGINE COOLANT TEMPERATURE Is the resistance between 0.35 Go to step 7. Replace the
SENSOR. and 0.4 kΩ at 80°C (176°F)? engine coolant
Terminals
No. 1 — No. 2:
7 CHECK ENGINE COOLANT TEMPERATURE Is the resistance between 0.2 Replace the ECM. Replace the
SENSOR. and 0.3 kΩ at 90°C (194°F)? engine coolant
Terminals
No. 1 — No. 2:
EN(w/oOBD)-74
EN(w/oOBD)-75
E: DTC 22 KNOCK SENSOR

• DIAGNOSIS:
• The knock sensor signal is abnormal.
• The harness connector between ECM and knock sensor is open or shorted.
CAUTION:
Inspection Mode.>
• WIRING DIAGRAM:
KNOCK
SENSOR E14
1 2
2
E14
LHD: B83
1 2 3 4
5 6 7 8
RHD: B83
1 2 3 4 5 6 7 8 9 10 11 12
E2
1 LHD : 3
16
B21 RHD : 2
2 LHD : 7 B21
RHD : 3
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
17 18 19 20
1
162
B136
B83
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
25
4
B136 ECM
EN1456
EN(w/oOBD)-76
Step Check Yes No

Control Module.>
3 CHECK KNOCK SENSOR. Is the resistance between 530 Go to step 4. Repair the har-
1)Disconnect the connector from knock sen- kΩ and 590 kΩ? ness and connec-
sor. tor.
harness between
knock sensor and
ECM connector
• Poor contact in
knock sensor con-
nector
• Poor contact in
coupling connector
(B21)
4 CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 Go to step 5. Replace the knock
ECM AND KNOCK SENSOR. Ω? sensor. <Ref. to
Measure the resistance of harness connector FU(w/oOBD)-33,
between ECM and knock sensor. Knock Sensor.>
(E14) No. 2 — Chassis ground:
5 CHECK HARNESS CONNECTOR BETWEEN Is the resistance more than 1 Go to step 6. Repair the ground
ECM AND KNOCK SENSOR. MΩ? short circuit
Measure the resistance of harness of harness between ECM and
connector between ECM connector and knock knock sensor.
sensor.
Control Module.>
EN(w/oOBD)-77
F: DTC 24 IDLE AIR CONTROL SOLENOID VALVE

• DIAGNOSIS:
• The idle air control solenoid valve is not in function.
• The harness connector between ECM and idle air control solenoid valve is open or shorted.
• Hard to start
CAUTION:
Inspection Mode.>
• WIRING DIAGRAM:
MAIN RELAY
B47
6 BATTERY
RHD
RHD
4 1 2
SBF-5 3 4
5 LHD 2 LHD 5 6
3
B61 F44
2
1
B47 E7
E22 1 2 3
1
4 5 6
E3
F44
5
2
1 2 3 4
IDLE 5 6 7 8
AIR CONTROL
SOLENOID
VALVE
E7 B22
1 2 3 4
6
3
4
1
5 6 7 8
9 10 11 12
13 14 15 16
E2
B21
3
4
1
2
B21
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
17 18 19 20
19
20
5
6
B134
1 2 3 4 5 6 7 8
B134 ECM 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25 26 27 28 29 30 31 32 33 34 35
EN1457
EN(w/oOBD)-78
Step Check Yes No

solenoid valve connector and engine ground. harness between
(E7) No. 5 (+) — Engine ground (−): main relay con-
nector
• Poor contact in
coupling connector
(B22)
CONNECTOR. tor.
2)Measure the resistance between ECM and In this case, repair
idle air control solenoid valve connector. the following:
#1; (B134) No. 20 — (E7) No. 3: harness between
#2; (B134) No. 6 — (E7) No. 1: ECM and idle air
#3; (B134) No. 19 — (E7) No. 6: control solenoid
#4; (B134) No. 5 — (E7) No. 4: valve connector
• Poor contact in
coupling connector
(B21)
IDLE AIR CONTROL SOLENOID VALVE MΩ? short circuit in har-
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.
#1; (B134) No. 20 — Chassis ground:
Check poor contact in ECM connector and idle connector or idle air control contact in ECM
air control solenoid valve connector. solenoid valve connector? connector or idle
air control solenoid
valve connector.
5 CHECK IDLE SPEED. Is the idling speed higher than Go to step 6. Go to step 8.
standard?
6 CHECK AIR INTAKE SYSTEM. Is there a fault in the air intake Repair the air suc- Go to step 7.
1)Turn the ignition switch to ON. system? tion and leaks.
gasket
EN(w/oOBD)-79
Step Check Yes No

7 CHECK AIR BY-PASS LINE. Are foreign particles in the by- Remove the for- Replace the idle
1)Turn the ignition switch to OFF. pass air line? eign particles from air control solenoid
2)Remove the idle air control solenoid valve by-pass air line. valve. <Ref. to
from throttle body. <Ref. to FU(w/oOBD)-39, FU(w/oOBD)-39,
Idle Air Control Solenoid Valve.> Idle Air Control
3)Confirm that there are no foreign particles in Solenoid Valve.>
the by-pass air line.
8 CHECK AIR BY-PASS LINE. Does air flow out? Replace the idle Replace the throt-
2)Remove the idle air control solenoid valve valve. <Ref. to FU(w/oOBD)-16,
from throttle body. <Ref. to FU(w/oOBD)-39, FU(w/oOBD)-39, Throttle Body.>
3)Remove the throttle body from intake mani- Solenoid Valve.>
fold. <Ref. to FU(w/oOBD)-16, Throttle Body.>
4)Confirm that there are no foreign particles in
the throttle body.
5)Using an air gun, force air into the idle air
control solenoid valve installation area. Con-
the throttle body interior.
EN(w/oOBD)-80
EN(w/oOBD)-81
G: DTC 26 INTAKE AIR TEMPERATURE SENSOR

• DIAGNOSIS:
• The intake air temperature sensor signal is abnormal.
• The harness connector between ECM and intake air temperature sensor is open or shorted.
• Hard to start
CAUTION:
Inspection Mode.>
• WIRING DIAGRAM:
E20
INTAKE AIR
TEMPERATURE
1 2 3 4
AND
PRESSURE
SENSOR
1
3
2
E20 B122
1 2 3
4 5 6
LHD: B83
E2
12
14
15
9
B21
E20 1 2 3
4 5 6
RHD: B83
LHD RHD 1 2 3 4 5 6 7 8 9 10 11 12
4
1 5
LHD RHD 4
B122 1
3
LHD RHD B21
4 B83
7 1 2 3 4
LHD RHD
5 6 7 8
B83 9 10 11 12
13 14 15 16
17 18 19 20
B136
15
13
25
16
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
B136 ECM
EN1458
EN(w/oOBD)-82
Step Check Yes No

1 CHECK INTAKE AIR TEMPERATURE SEN- Is the resistance between 2 Go to step 2. Replace the intake
SOR. and 3 kΩ at 20°C (68°F)? air temperature
1)Turn the ignition switch to OFF. sensor. <Ref. to
2)Disconnect the connector from intake air FU(w/oOBD)-38,
temperature sensor. Intake Air Temper-
3)Measure the resistance between intake air ature and Pres-
temperature sensor terminals. sure Sensor.>
Terminals
No. 2 — No. 3:
2 CHECK INTAKE AIR TEMPERATURE SEN- Is the resistance between 0.66 Go to step 3. Replace the intake
SOR. and 1 kΩ at 50°C (122°F)? air temperature
Measure the resistance between intake air sensor. <Ref. to
temperature sensor terminals. FU(w/oOBD)-38,
Terminals Intake Air Temper-
No. 2 — No. 3: ature and Pres-
sure Sensor.>
TAKE AIR TEMPERATURE SENSOR CON- Ω? ness and connec-
NECTOR. tor.
2)Measure the resistance of harness connec- In this case, repair
tor between ECM and intake air temperature the following:
sensor connector. • Open circuit in
(B136) No. 15 — (E20) No. 3: ECM and intake
air temperature
and pressure sen-
sor connector
• Poor contact in
coupling connector
(B21)
TAKE AIR TEMPERATURE SENSOR CON- Ω? ness and connec-
NECTOR. tor.
Measure the resistance of harness connector
between ECM and intake air temperature sen-
sor connector.
(B136) No. 13 — (E20) No. 2:
5 CHECK HARNESS BETWEEN ECM AND IN- Is the resistance more than 1 Go to step 6. Repair the ground
TAKE AIR TEMPERATURE SENSOR CON- MΩ? short circuit in har-
Measure the resistance of harness between ECM and idle air
ECM connector and chassis ground. control solenoid
6 CHECK HARNESS BETWEEN ECM AND IN- Is the resistance more than 1 Go to step 7. Repair the ground
TAKE AIR TEMPERATURE SENSOR CON- MΩ? short circuit in har-
ECM connector and chassis ground. control solenoid
EN(w/oOBD)-83
Step Check Yes No

connector. service.
NOTE:
Inspection by your
Subaru distributor
service is required,
because probable
cause is deteriora-
tion of multiple
parts.
EN(w/oOBD)-84
EN(w/oOBD)-85
H: DTC 31 THROTTLE POSITION SENSOR

• DIAGNOSIS:
• The throttle position sensor signal is abnormal.
• The throttle position sensor is installed abnormally.
• The harness connector between ECM and throttle position sensor is open or shorted.
• Engine stalls
CAUTION:
Inspection Mode.>
• WIRING DIAGRAM:
THROTTLE
POSITION E13
SENSOR
1 2 3 4
LHD : B122
4
3
2
E13 1 2 3
4 5 6
RHD : B83
1 2 3 4 5 6 7 8 9 10 11 12
E2
12
11
9
B21
B21
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
17 18 19 20
LHD RHD
4 5
1 4
LHD RHD
B83 B136
B122
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
15
17
16
B136 ECM
EN1459
EN(w/oOBD)-86
Step Check Yes No

THROTTLE POSITION SENSOR. Ω? circuit between
1)Disconnect the connector from ECM and ECM and throttle
throttle position sensor. position sensor.
throttle position sensor.
(B136) No. 16 — (E13) No. 2:
(B136) No. 17 — (E13) No. 3:
(B136) No. 15 — (E13) No. 4:
THROTTLE POSITION SENSOR CONNEC- MΩ? short circuit
1)Disconnect the connector from TCM. (AT chassis ground.
vehicle)
chassis ground.
1)Connect the connector to ECM and throttle
position sensor.
2)Ignition the switch to ON.
3)Measure the voltage between ECM termi-
nals while throttle valve is fully closed.
(B136) No. 15 (+) — No. 17 (−):
Measure the voltage between ECM terminals
while throttle valve is fully opened.
(B136) No. 15 (+) — No. 17 (−):
connector. position sensor
connector.
6 CHECK CONDITION OF THROTTLE POSI- Are the throttle position sensor Replace the throt- Adjust the throttle
TION SENSOR INSTALLATION. installing screw tightened tle position sensor. position sensor
securely? and tighten throt-
tle position sensor
installing screws
securely.
EN(w/oOBD)-87
I: DTC 32 OXYGEN SENSOR

• DIAGNOSIS:
• The oxygen sensor is not in function.
• The harness connector between ECM and oxygen sensor is open or shorted.
• Engine stalls.
CAUTION:
Inspection Mode.>
• WIRING DIAGRAM:
MAIN RELAY BATTERY

RHD
RHD
B61 F44
SBF-5 B18
6 LHD 2 LHD
4
2 1
5 4 3
3
2
1 B47
B47 1 2
3 4
5 6
2
F44
OXYGEN SENSOR
1 2 3 4
B18
5 6 7 8
4
1
B22 E3
15
B22
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
B136
1 2 3 4 5 6 7
23
7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
B136 ECM
EN0940
EN(w/oOBD)-88
Step Check Yes No

1 CHECK FOR OTHER CAUSES AFFECTING Is CO % more than 2 % after Check the fuel Go to step 2.
EXHAUST GAS. the engine warm up? system.
NOTE:
•Check for use of improper fuel.
•Check if engine oil or coolant level is
extremely low.
2 CHECK EXHAUST SYSTEM. Is there a fault in the exhaust Repair the exhaust Go to step 3.
system? system.
NOTE:
• Loose installa-
tion of front portion
of exhaust pipe
onto cylinder
heads
• Loose connec-
tion between front
exhaust pipe and
front catalytic con-
verter
• Damage of
exhaust pipe
resulting in hole
3 CHECK INPUT VOLTAGE FOR OXYGEN Is the voltage more than 10 V? Go to step 4. Repair the open
SENSOR. circuit between
1)Disconnect the connector from oxygen sen- main relay and
sor connector. oxygen sensor.
2)Measure the voltage between main relay and
oxygen sensor.
4 CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1Ω? Go to step 5. Repair the open
OXYGEN SENSOR AND ENGINE GROUND circuit between
CABLE. oxygen sensor
Measure the resistance between oxygen sen- and chassis
sor and chassis ground. ground.
5 CHECK OXYGEN SENSOR. Is the resistance less than 30 Repair poor con- Go to step 6.
Measure the resistance between oxygen sen- Ω? tact.
sor terminals.
No. 1 — No. 2:
6 CHECK HARNESS BETWEEN ECM AND OX- Is the resistance more than 1 Go to step 7. Repair the ground
YGEN SENSOR. MΩ? short circuit
2)Measure the resistance between ECM and chassis ground.
chassis ground.
7 CHECK HARNESS BETWEEN ECM AND OX- Is the voltage more than 0.2 V? Go to step 8. Repair the battery
YGEN SENSOR. short circuit
1)Turn the ignition switch to ON. between ECM and
2)Measure the voltage between ECM and oxygen sensor.
chassis ground.
EN(w/oOBD)-89
Step Check Yes No

8 CHECK INPUT VOLTAGE FOR ECM. Do 0.1 and 1 V waveform pat- Go to step 9. Replace the oxy-
1)Connect the connector to ECM and oxygen terns alternately appear on the gen sensor.
sensor. oscilloscope screen?
chassis ground.
9 CHECK POOR CONTACT. Is there poor contact in ECM Replace the oxy- Replace the ECM.
Check poor contact in ECM connector. connector? gen sensor con- <Ref. to FU(w/
nector. oOBD)-48, Engine
Control Module.>
EN(w/oOBD)-90
EN(w/oOBD)-91
J: DTC 33 VEHICLE SPEED SIGNAL

• DIAGNOSIS:
• The vehicle speed signal is abnormal.
• The harness connector between ECM and vehicle speed sensor is open or shorted.
• Engine stalls.
CAUTION:
Inspection Mode.>
• WIRING DIAGRAM:
BATTERY B17
IGNITION SWITCH B72 SBF-4 SBF-1
1 2 3
1
No.18
4
B72
1 2
LHD : 9 3 4
RHD : 7
i10
1 2 3 4 5 6 7 8 9 10
3
B22
B56 TCM VEHICLE
SPEED 1 2 3 4
SENSOR 5 6 8
7
B17 9 10 11 12
13 14 15 16
17
1
2
B56
AT MT 1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18
19 20 21 22 23 24
COMBINATION
i10 METER LHD : i2
B22
16
1 2 3 4 5 6 7 8 9 10 11
2
E3 12 13 14 15 16 17 18 19 20 21 22 23 24
i2 B37
B135
1 2 3 4 5 6 7
24
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 28
B135 ECM RHD : i2
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
EN1460
Step Check Yes No

cle speed sensor.
EN(w/oOBD)-92
Step Check Yes No

1)Lift-up the vehicle.
2)Set the positive (+) terminal and ground lead
of oscilloscope at ECM connector terminals.
1)Start the engine.
2)Shift on the gear position, and put the vehicle
at constant speed.
3)Measure the signal voltage indicated on
oscilloscope.
Check poor contact in ECM connector. connector? contact in ECM. <Ref. to FU(w/
oOBD)-48, Engine
Control Module.>
4 CHECK HARNESS BETWEEN ECM AND Is the voltage more than 2 V? Repair the har- Go to step 5.
COMBINATION METER CONNECTOR. ness and connec-
Measure the voltage between ECM and chas- tor.
sis ground. NOTE:
(B135) No. 24 (+) — Chassis ground (−): the following:
Battery short cir-
cuit in harness
between ECM and
combination meter
connector
COMBINATION METER CONNECTOR. Ω? short circuit in har-
2)Measure the resistance of harness between ECM and combi-
ECM connector and chassis ground. nation meter con-
oOBD)-48, Engine
Control Module.>
EN(w/oOBD)-93
K: DTC 35 PURGE CONTROL SOLENOID VALVE

• DIAGNOSIS:
• The purge control solenoid valve is not in function.
• The harness connector between ECM and purge control solenoid valve is open or shorted.
CAUTION:
Inspection Mode.>
• WIRING DIAGRAM:
MAIN RELAY BATTERY

RHD
RHD
SBF-5 E4
6 LHD 2 LHD
4 1 2
B61 F44
5
3
2
1
B47
B47
1 2
3 4
5 6
B134 ECM
F44
1 2 3 4
5 6 7 8
2
B22
1 2 3 4
5 6 7 8
9 10 11 12
B22 13 14 15 16
3
2
E3
B134
E4
1
2
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25 26 27 28 29 30 31 32 33 34 35
PURGE CONTROL
SOLENOID VALVE
EN0942
EN(w/oOBD)-94
Step Check Yes No

1 CHECK OPERATION SOUND OF PURGE Does the purge control sole- Go to step 2. Go to step 3.
CONTROL SOLENOID VALVE. noid valve produce operating
1)Turn the ignition switch to OFF. sound?
2)Connect the test mode connector at lower
portion of instrument panel (on driver’s side).
4)Make sure that the ON/OFF operating sound
of purge control solenoid valve occurs at about
10 Hz.
oOBD)-48, Engine
Control Module.>
2)Disconnect the test mode connector. control solenoid
3)Disconnect the connector from purge control valve connector.
solenoid valve. After repair,
4)Turn the ignition switch to ON. replace the ECM.
chassis ground.
1)Turn the ignition switch to OFF. purge control sole-
2)Disconnect the connector from ECM. noid valve connec-
ECM and purge control solenoid valve of har-
ness connector.
(B134) No. 2 — (E4) No. 2:
1)Remove the purge control solenoid valve. valve. <Ref. to
2)Measure the resistance between purge con- EC(w/oOBD)-8,
trol solenoid valve terminals. Purge Control
Terminals Solenoid Valve.>
No. 1 — No. 2:
6 CHECK POWER SUPPLY TO PURGE CON- Is the voltage more than 10 V? Go to step 7. Repair the har-
1)Turn the ignition switch to ON. tor.
2)Measure the voltage between purge control NOTE:
solenoid valve and engine ground. In this case, repair
(E4) No. 1 (+) — Engine ground (−): • Open circuit in
harness between
main relay and
purge control sole-
noid valve connec-
tor
• Poor contact in
main relay con-
nector
• Poor contact in
coupling connector
(B22)
EN(w/oOBD)-95
Step Check Yes No

Inspection by your
Subaru distributor
service is required,
because probable
cause is deteriora-
tion of multiple
parts.
EN(w/oOBD)-96
EN(w/oOBD)-97
L: DTC 38 TORQUE CONTROL SIGNAL

• DIAGNOSIS:
• Abnormal signal entered from TCM
• The harness connector between ECM and TCM is shorted.
CAUTION:
Inspection Mode.>
• WIRING DIAGRAM:
B56
1 2 3 4 5 6 7 8 9
B56 10 11 12 13 14 15 16 17 18
19 20 21 22 23 24
TCM
14
5
B135
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 28
16
17
B135 ECM
EN1461
EN(w/oOBD)-98
Step Check Yes No

1)Disconnect the connectors from ECM and ness between
TCM. ECM and TCM
2 CHECK HARNESS BETWEEN ECM AND Is there resistance less than 10 Repair the ground Replace the TCM.
TCM CONNECTOR. Ω? short circuit in har- <Ref. to AT-46,
Measure the resistance of harness between ness between Transmission Con-
ECM and chassis ground. ECM and TCM trol Module
Connector & terminal connector. (TCM).>
EN(w/oOBD)-99
M: DTC 45 PRESSURE SENSOR

• DIAGNOSIS:
• The pressure sensor signal is abnormal.
• The harness connector between ECM and pressure sensor is open or shorted.
• Engine stalls.
CAUTION:
Inspection Mode.>
• WIRING DIAGRAM:
E20
INTAKE AIR
TEMPERATURE
1 2 3 4
AND
PRESSURE
SENSOR
1
3
2
E20 B122
1 2 3
4 5 6
LHD: B83
E2
12
14
15
9
B21
E20 1 2 3
4 5 6
RHD: B83
LHD RHD 1 2 3 4 5 6 7 8 9 10 11 12
4
1 5
LHD RHD 4
B122 1
3
LHD RHD B21
4 B83
7 1 2 3 4
LHD RHD
5 6 7 8
B83 9 10 11 12
13 14 15 16
17 18 19 20
B136
15
13
25
16
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
B136 ECM
EN1458
EN(w/oOBD)-100
Step Check Yes No

1 CHECK HARNESS BETWEEN ECM AND Is the voltage between 4.5 and Go to step 2. Repair the open or
PRESSURE SENSOR CONNECTOR. 5.5 V? ground short cir-
1)Disconnect the connector from pressure cuit in harness
sensor. between ECM and
2)Turn the ignition switch to ON. pressure sensor.
3)Measure the voltage between pressure sen-
sor connector and engine ground.
PRESSURE SENSOR CONNECTOR. Ω? circuit in harness
2)Measure the resistance of harness between pressure sensor
ECM and pressure sensor connector. connector.
(B136) No. 16 — (E20) No. 1:
(B136) No. 5 — (E20) No. 4:
PRESSURE SENSOR CONNECTOR. MΩ? short circuit in har-
ECM connector and chassis ground. ECM and pressure
Connector & terminal sensor connector.
4 CHECK INPUT SIGNAL FOR ECM. Is the voltage between 2.3 and Go to step 5. Replace the pres-
1)Turn the ignition switch to OFF. 2.5 V? sure sensor. <Ref.
2)Connect the connector to ECM and pressure to FU(w/oOBD)-
sensor. 38, Intake Air
3)Turn the ignition switch to ON. Temperature and
4)Measure the voltage between ECM and Pressure Sensor.>
chassis ground.
5 CHECK INPUT SIGNAL FOR ECM. Is the voltage between 1.2 and Go to step 6. Replace the pres-
1)Start the engine, and idle it. 1.8 V? sure sensor. <Ref.
2)Measure the voltage between ECM and to FU(w/oOBD)-
chassis ground. 38, Intake Air
Connector & terminal Temperature and
(B136) No. 5 (+) — Chassis ground (–): Pressure Sensor.>
6 CHECK POOR CONTACT. Is there poor contact in pres- Repair the poor Replace the pres-
Check poor contact in pressure sensor con- sure sensor connector? contact in pressure sensor. <Ref.
nector. sure sensor con- to FU(w/oOBD)-
nector. 38, Intake Air
Temperature and
Pressure Sensor.>
EN(w/oOBD)-101
N: DTC 46 CO RESISTOR (GENERAL SPEC. VEHICLES)

• DIAGNOSIS:
• The CO resistor signal is abnormal.
• The harness connector between ECM and CO resistor is open or shorted.
• The CO value is not adjusted to specifications.
• Mixture ratio is too rich or too lean.
CAUTION:
Inspection Mode.>
• WIRING DIAGRAM:
CO RESISTOR
B28
1 2 3
1
2
3
B28
B83
1 2 3 4 5 6 7 8 9 10 11 12
LHD RHD
5 6
B136
1 4
LHD RHD 1 2 3 4 5 6 7
B122 B83 8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
B122
1 2 3
4 5 6
15
12
16
B136 ECM
EN1462
EN(w/oOBD)-102
Step Check Yes No

1)Turn the ignition switch to ON. 4.5 V?
chassis ground.
connector? contact in ECM <Ref. to FU(w/
Control Module.>
3 CHECK HARNESS BETWEEN CO RESIS- Is the resistance less than 1 Go to step 4. Repair the open
TOR AND ECM CONNECTOR. Ω? circuit in harness
2)Disconnect the connector from ECM and CO CO resistor con-
resistor. nector.
ECM and CO resistor connector.
(B136) No. 15 — (B155) No. 1:
(B136) No. 12 — (B155) No. 2:
(B136) No. 16 — (B155) No. 3:
4 CHECK HARNESS BETWEEN CO RESIS- Is the resistance more than 1 Go to step 5. Repair the short
TOR AND ECM CONNECTOR. MΩ? circuit in harness
Measure the resistance of harness between between ECM and
ECM connector and chassis ground. CO resistor con-
5 CHECK CO RESISTOR. Is the resistance between 4 Go to step 6. Replace the CO
Measure the resistance between CO resistor and 6 kΩ? resistor.
terminals.
Terminals
No. 1 — No. 3:
6 CHECK CO RESISTOR. Is the resistance between 0 Replace the ECM. Replace the CO
Measure the variable resistance between CO and 6 kΩ? resistor.
resistor terminals while rotating the screw of NOTE:
CO resistor. Ensure resistance
Terminals varies in response
No. 1 — No. 2: to screw rotation.
EN(w/oOBD)-103
O: DTC 51 NEUTRAL POSITION SWITCH (MT VEHICLE)

• DIAGNOSIS:
• The neutral position switch signal is abnormal.
• The harness connector between ECM and neutral position switch is open or shorted.
CAUTION:
Inspection Mode.>
• WIRING DIAGRAM:
B135 ECM
B25
1 2
26
B25
1
T2 B22
1 2 3 4
NEUTRAL 5 6 7 8
POSITION 9 10 11 12
SWITCH 13 14 15 16
T2
2
B25
B22 B135
16
1 2 3 4 5 6 7
E3 8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 28
EN1463
EN(w/oOBD)-104
Step Check Yes No

1)Turn the ignition switch to ON. 5.5 V in neutral position?
chassis ground.
2 CHECK INPUT SIGNAL FOR ECM. Is the voltage less than 1 V in Go to step 3. Go to step 4.
Measure the voltage between ECM and chas- other positions?
sis ground.
Control Module.>
4 CHECK NEUTRAL POSITION SWITCH. Is the resistance more than 1 Go to step 5. Repair the short
1)Turn the ignition switch to OFF. MΩ in neutral position? circuit in transmis-
2)Disconnect the connector from transmission sion harness or
harness. replace neutral
3)Measure the resistance between transmis- position switch.
sion harness and connector terminals.
(T2) No. 1 — No. 2:
5 CHECK NEUTRAL POSITION SWITCH. Is the resistance less than 10 Go to step 6. Repair the open
Measure the resistance between transmission Ω in other positions? circuit in transmis-
harness connector terminals. sion harness or
Connector & terminal replace neutral
(T2) No. 1 — No. 2: position switch.
NEUTRAL POSITION SWITCH CONNEC- Ω? circuit in harness
1)Disconnect the connector from ECM. transmission har-
2)Measure the resistance of harness between ness connector.
ECM and transmission harness connector.
(B135) No. 26 — (B25) No. 1:
NEUTRAL POSITION SWITCH CONNEC- Ω? short circuit in har-
TOR. ness between
Measure the resistance between ECM and ECM and trans-
chassis ground. mission harness
8 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(w/
nector. oOBD)-48, Engine
Control Module.>
EN(w/oOBD)-105
P: DTC 51 PARK/NEUTRAL POSITION SWITCH (AT VEHICLE)

• DIAGNOSIS:
• The park/neutral position switch signal is abnormal.
• The shift cable is connected abnormally.
• The harness connector between ECM/TCM and inhibitor switch is open or shorted.
CAUTION:
Inspection Mode.>
• WIRING DIAGRAM:
EN1464
EN(w/oOBD)-106
Step Check Yes No

positions.
connector.
switch connector
• Poor contact in
coupling connector
(B12)
• Poor contact in
inhibitor switch
connector
• Poor contact in
ECM connector
Measure the resistance of harness between Ω? circuit in inhibitor
inhibitor switch connector and engine ground. switch ground line.
ECM connector and chassis ground. ECM and trans-
Connector & terminal mission harness
(B135) No. 26 — Chassis ground: connector.
Control Module.>
EN(w/oOBD)-107
Q: DTC 85 CHARGE SYSTEM

• DIAGNOSIS:
• Power source voltage of the ECM is low or high.
CAUTION:
Inspection Mode.>
• WIRING DIAGRAM:
GENERATOR
SBF-1
MAIN RELAY
6 BATTERY
RHD
RHD
4
SBF-5
5 LHD 2 LHD
3
B61 F44
2
1
B47
2
1
B136 ECM
B47 F44 B136

1 2 1 2 3 4 1 2 3 4 5 6 7
3 4 5 6 7 8 8 9 10 11 12 13 14 15 16 17 18 19 20
5 6 21 22 23 24 25 26 27 28 29 30
EN1465
EN(w/oOBD)-108
Step Check Yes No

1 CHECK GENERATOR. Is the voltage between 10.8 V Go to step 2. Repair the genera-
1)Start the engine. and 16.2 V? tor. <Ref. to SC-
2)Idle after warm-up. 14, Generator.>
3)Measure the voltage between generator B
Terminal
ground (–):
2 CHECK GENERATOR. Is the voltage between 10.8 V Go to step 3. Repair the genera-
1)Run the engine at 5,000 rpm. and 16.2 V? tor. <Ref. to SC-
2)Measure the voltage between generator B 14, Generator.>
Terminal
ground (−):
clamped?
4 CHECK INPUT VOLTAGE OF ECM. Is the voltage between 10.8 V Go to step 5. Repair the har-
1)Run the engine at idle. and 16.2 V? ness connector
5 CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in the Repair the con- Go to step 6.
connectors between generator, nector.
battery and ECM?
2)Erase the memory. <Ref. to EN(w/oOBD)- put?
sponding to the
DTC.
EN(w/oOBD)-109

A: INSPECTION
NOTE:
• Malfunction of parts other than those listed is also possible.
• The right-hand priority column indicates inspection priority of probable causes of the symptom. Carry out
the check starting from A.
Symptom Problem parts Priority
1. Engine does not start. (Internal combustion does 1) ECM power supply A
not occur.) 2) Engine ground cable A
3) Crankshaft position sensor B
4) Camshaft position sensor B
5) Fuel pump B
6) Pressure regulator B
7) Ignition coil & ignitor C
8) Spark plug C
9) Fuel injector C
2. Engine does not start. (Internal combustion 1) ECM power supply A
occurs.) 2) Spark plug A
3) Engine coolant temperature sensor B
5) Pressure sensor C
6) Fuel pump C
7) Fuel injector C
8) Camshaft position sensor C
9) Crankshaft position sensor C
10) Idle air control solenoid valve C
3. Engine does not start. (Engine stalls after internal 1) ECM power supply A
combustion.) 2) Pressure sensor A
4) Spark plug B
5) Ignition coil C
6) Fuel pump C
7) Pressure regulator C
8) Fuel injector C
4. Engine stalls. 1) Idle air control solenoid valve A
2) Pressure sensor B
3) Spark plug B
4) Accelerator cable is out of adjustment B
5) ECM power supply C
6) Throttle position sensor C
8) Vehicle speed sensor C
9) Ignition coil C
10) Fuel pump C
EN(w/oOBD)-110

5. Rough idling 1) Spark plug A
5) Idle air control solenoid valve B
6) Air leak in air intake system B
7) ECM power supply C
9) Camshaft position sensor C
11) Oxygen sensor C
12) Fuel pump C
13) Fuel injector C
14) Test mode or read memory connectors are connected C
15) Intake air temperature sensor C
6. Hard to drive at constant speed 1) Pressure regulator A
2) Fuel injector B
4) Engine coolant temperature sensor C
6) Fuel pump C
7. Poor acceleration/deceleration 1) Spark plug A
2) Throttle position sensor B
3) Ignition coil B
4) Fuel pump B
6) Fuel injector B
10) Knock sensor C
8. Poor return to idling 1) Accelerator cable is out of adjustment A
3) Idle air control solenoid valve B
9. Back fire 1) Spark plug A
2) Fuel injector B
3) Ignition coil and ignitor C
4) Fuel pump C
5) Pressure regulator C
10. Knocking 1) Pressure sensor A
2) Fuel pump B
3) Knock sensor B
11. Excessive fuel consumption 1) Pressure sensor A
12. Shocks while driving 1) Pressure regulator A
2) ECM power supply B
EN(w/oOBD)-111

13. Poor engine revving 1) Pressure regulator A
4) Throttle sensor B
5) Fuel pump B
14. Remarks 1) ECM power supply A*
2) Pressure sensor B*
3) Pressure regulator B*
4) Idle air control solenoid valve B*
5) Air leak in air intake system B*
A*: Including ECM ground circuit
B*: Check hoses.
EN(w/oOBD)-112
FU(TURBO)
Page
2. Throttle Body.............................................................................................14
3. Intake Manifold..........................................................................................15
7. Knock Sensor............................................................................................32
9. Mass Air Flow and Intake Air Temperature Sensor ..................................34
10. Pressure Sensor .......................................................................................35
12. Fuel Injector ..............................................................................................37
13. Tumble Generator Valve Assembly ..........................................................41
14. Tumble Generator Valve Actuator.............................................................42
15. Wastegate Control Solenoid Valve ...........................................................43
16. Front Oxygen (A/F) Sensor .......................................................................44
17. Rear Oxygen Sensor.................................................................................46
18. Exhaust Temperature Sensor ...................................................................48
20. Main Relay ................................................................................................50
21. Fuel Pump Relay.......................................................................................51
22. Fuel Pump Controller ................................................................................52
23. Fuel ...........................................................................................................53
24. Fuel Tank ..................................................................................................54
25. Fuel Filler Pipe ..........................................................................................56
26. Fuel Pump.................................................................................................60
29. Fuel Filter ..................................................................................................65
30. Fuel Cut Valve...........................................................................................66
GENERAL DESCRIPTION
A: SPECIFICATIONS
Capacity 60 2 (15.9 US gal, 13.2 Imp gal)
Fuel tank
Type Impeller
Shutoff discharge pressure 450 — 677 kPa (4.59 — 6.9 kg/cm2, 65.27 — 98.2 psi)
Fuel pump
Discharge flow
[12 V at 300 kPa (3.06 kg/cm2, 43.5 psi)]
FU(TURBO)-2
GENERAL DESCRIPTION
FU(TURBO)-3
GENERAL DESCRIPTION
B: COMPONENT
1. INTAKE MANIFOLD
T6
T2 (19)
(18)
T6
(22)
(17) T6
T3
T6
T3
(20)
(16) (24)
(23)
T3
T6
(21)
(14) T6
T5
(15) T5 (26)
(26) (12)
(13)
T7 T6
(25)
T7
T1
(12)
(11)
(27)
(27)
(8) T1
(10)
(8)
(9)
(7) (11)
(6) T6
T4
(16)
(5)
(4)
(2) (9)
(3) (10)
T1
(1) (14)
(15)
(3)
(2) T1
(3) (2)
EN1389
FU(TURBO)-4
GENERAL DESCRIPTION
(1) Fuel pipe ASSY (13) Accelerator cable bracket (25) Fuel pipe protector LH
(2) Fuel hose (14) Fuel injector (26) Nipple
(3) Clip (15) Insulator (27) Tumble generator valve actuator
(4) Purge control solenoid valve (16) Fuel injector pipe
(5) Vacuum hose (17) Pressure regulator Tightening torque: N·m (kgf-m, ft-lb)
(6) Vacuum control hose (18) Pressure regulator hose T1: 4.9 (0.5, 3.6)
(7) Purge valve (19) Fuel pipe protector RH T2: 6.4 (0.65, 4.7)
(8) Purge hose (20) Blow-by hose stay T3: 8.25 (0.84, 6.1)
(9) Intake manifold gasket (21) Intake manifold T4: 16 (1.6, 11.8)
(10) Guide pin (22) Solenoid valve cover T5: 17 (1.7, 12.5)
(11) Tumble generator valve ASSY (23) Solenoid valve cover stay T6: 19 (1.9, 14.0)
(12) Tumble generator valve gasket (24) Wastegate control solenoid valve T7: 25 (2.5, 18.4)
ASSY
FU(TURBO)-5
GENERAL DESCRIPTION
T1 (3)
T2
(5)
(7)
(6)
T3
(1)
(2)
(4)
T1
EN1134
(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, 16.2)
FU(TURBO)-6
GENERAL DESCRIPTION
T2
(3)
T1 T1
(1)
(2)
EN0780
(2) Knock sensor T1: 6.4 (0.65, 4.7)
T2: 24 (2.4, 17.4)
FU(TURBO)-7
GENERAL DESCRIPTION
4. FUEL TANK
T1
T1
(30)
(17)
(10) E
(9) (11) (12)

(7) D (12)
C
B (12)
A (15)
(14)
(8) (29)
T1 T1 (29)
(13)
(12)
D
(9) (12)
(8)
E (28)
(6) (16)
B (12)
(12)
(18)
(27) (21) (20) (22)
(19) A
(5) (12)
(12)
(23) F
(12)
(24)
(2)
T3 (20)
T3
(12)
(25)
(4)
(2)
T2
T2
(1)
(3) T2
T2
EN0998
FU(TURBO)-8
GENERAL DESCRIPTION
FU(TURBO)-9
GENERAL DESCRIPTION
5. FUEL LINE
(19)
(18)
B
(24) (20) (17)
A (16)
(25) (15)
(24)
(22)
(21) (13)
T
(23) (14)
B
(1) (1)
C
A C
(12)
(8)
(1) (1) (10)

(9) (1)
(1)
(1)
(1)
(10) (11)
(7)
(1)
(6) (2)
(1)
(5)
(4)
(3)
EN0440
FU(TURBO)-10
GENERAL DESCRIPTION
FU(TURBO)-11
GENERAL DESCRIPTION
6. FUEL FILLER PIPE
(9)
(8)
(10)
(11)
(1)
(3)
T
(5) (2)
T
(3)
(6)
T
(4)
(3)
(7)
EN0441
(1) Fuel filler pipe ASSY (6) Air vent pipe (11) Filler pipe protector
(2) Evaporation hose holder (7) Air vent pipe holder
(3) Clip (8) Filler pipe packing
(4) Clamp (9) Filler ring Tightening torque: N·m (kgf-m, ft-lb)
(5) Air vent hose (10) Filler cap T: 7.5 (0.76, 5.5)
FU(TURBO)-12
GENERAL DESCRIPTION

D: PREPARATION TOOL
(Newly adopted
tool)
B2M3876
B2M3877
FU(TURBO)-13
THROTTLE BODY
2. Throttle Body 5) Disconnect the engine coolant hoses from throt-

tle body.
A: REMOVAL
EN0784
6) Remove the bolts which secure throttle body to

G6M0095
intake manifold.
2) Remove the intercooler. <Ref. to IN(TURBO)-
10, REMOVAL, Intercooler.>
B: INSTALLATION
3) Disconnect the connector from the throttle posi-
tion sensor (A) and idle air control solenoid valve NOTE:
(B) and pressure sensor (C). Always use a new gasket.
(B)
Tightening torque:
22 N·m (2.2 kgf-m, 16.2 ft-lb)
(C)
(A)
EN0782
4) Disconnect the accelerator cable.

EN0785
H2M1890
FU(TURBO)-14
INTAKE MANIFOLD
3. Intake Manifold 12) Remove the power steering pump.

(1) Remove the front side V-belt.
A: REMOVAL <Ref. to ME(TURBO)-44, REMOVAL, V-belt.>
1) Release the fuel pressure. <Ref. to FU(TUR- (2) Disconnect the power steering switch con-
BO)-53, RELEASING OF FUEL PRESSURE, OP- nector.
ERATION, Fuel.>
cap.
EN0360
(3) Remove the bolts which secure power

steering pipe brackets to intake manifold.
G6M0095 NOTE:
Do not disconnect the power steering hose.
6) Drain the coolant about 3.0 2 (3.2 US qt, 2.6
Imp qt).
S2M2248
(4) Remove the bolts which secure power

steering pump bracket.
EN0073
7) Remove the air cleaner upper cover and air in-

take boot. <Ref. to IN(TURBO)-7, REMOVAL, Air
Cleaner.>
10) Disconnect the accelerator cable.
H2M1954
H2M1890
11) Remove the coolant filler tank. <Ref. to CO-53,

REMOVAL, Coolant Filler Tank.>
FU(TURBO)-15
INTAKE MANIFOLD
(5) Remove the power steering tank from the 15) Disconnect the brake booster hose.
EN0204
EN0361
16) Disconnect the pressure hose from intake duct.
(6) Place the power steering pump on right side
wheel apron.
EN0787
EN0208
17) Disconnect the engine harness connectors
from bulkhead harness connectors.
13) Disconnect the emission hose from PCV valve.
EN0788
EN0789
14) Disconnect the engine coolant hoses from

throttle body.
S2M2260
EN0784
FU(TURBO)-16
INTAKE MANIFOLD
18) Disconnect the connectors from the engine 22) Disconnect the engine harness fixed by clip (A)
coolant temperature sensor (A), oil pressure switch from the bracket.
(B) and crankshaft position sensor (C).
(A)
(B)
(C)
S2M2256A
EN0790
19) Disconnect the knock sensor connector. and evaporation hose.
WARNING:
• Do not spill fuel.
cloth.
S2M1613

tion sensor.
EN0214
24) Remove the bolts which secure intake manifold

to the cylinder heads.
B2M1251
21) Disconnect the connector from ignition coil.
EN0792
25) Remove the intake manifold.
EN0854
FU(TURBO)-17
INTAKE MANIFOLD
B: INSTALLATION 4) Connect the connector to knock sensor.

1) Install the intake manifold onto cylinder heads.
NOTE:
Tightening torque:
25 N·m (2.5 kgf-m, 18.4 ft-lb)
S2M1613

sor.
EN0792
2) Connect the fuel delivery hose, return hose, and

evaporation hose.
B2M1251
6) Connect the connector to ignition coil.
EN0214
3) Connect the connector to the oil pressure switch

(B), crankshaft position sensor (C) and engine
coolant temperature sensor (A).
EN0854
(A)
(B)
7) Connect the engine harness with clip (A) to the
bracket.
(C)
EN0790
S2M2256A
FU(TURBO)-18
INTAKE MANIFOLD
8) Connect the engine harness connector to bulk- 11) Connect the emission hose to PCV valve.
head harness connectors.
EN0789
EN0788
12) Connect the pressure hose to intake duct.
S2M2260 EN0787
9) Connect the brake booster vacuum hose. 13) Install the power steering pump.
EN0204
EN0361
10) Connect the engine coolant hoses to throttle
body. (2) Connect the connector to power steering
pump switch.
EN0784
EN0360
FU(TURBO)-19
INTAKE MANIFOLD
(3) Install the power steering pump, and then 19) Connect the connector to fuel pump relay.
tighten the bolts.
Tightening torque:
22 N·m (2.2 kgf-m, 16.2 ft-lb)
EN0344
H2M1954
(4) Install the power steering pipe brackets on

right side intake manifold.
G6M0095

23) Fill the coolant. <Ref. to CO-26, FILLING OF
EN0206 ENGINE COOLANT, Engine Coolant.>
(5) Install the front side V-belt.
<Ref. to ME(TURBO)-44, REMOVAL, V-belt.>
14) Install the cooler filler tank. <Ref. to CO-53, IN-
STALLATION, Coolant Filler Tank.>
15) Connect the accelerator cable.
H2M1890
16) Install the intercooler. <Ref. to IN(TURBO)-11,

INSTALLATION, Intercooler.>
17) Install the air cleaner element.
18) Install the air cleaner upper cover and air intake
duct as a unit. <Ref. to IN(TURBO)-7, INSTALLA-
TION, Air Cleaner.>
FU(TURBO)-20
INTAKE MANIFOLD
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.
EN0793
2) Remove the fuel pipe protector RH.

S2M2249A
6) Remove the throttle body from intake manifold.
EN0794
3) Remove the engine ground cable from intake

manifold. EN0785
EN0795
EN0798
8) Disconnect the connector from tumble generator

valve actuator.
EN0796
EN0799
FU(TURBO)-21
INTAKE MANIFOLD
9) Disconnect the connector from tumble generator 13) Disconnect the evaporation hoses from purge
valve sensor. valve.
EN0800 EN0804
10) Disconnect the connector from purge control 14) Remove the two bolts which hold fuel pipes on
solenoid valve. the left side of intake manifold.
EN0801 EN0805
11) Remove the purge control solenoid valve.
EN0802
12) Disconnect the evaporation hose from intake

manifold.
EN0803
FU(TURBO)-22
INTAKE MANIFOLD
15) Remove the bolts which hold fuel injector pipe 16) Remove the fuel injector.
onto intake manifold.
• LH SIDE
EN0810
EN0806
17) Remove the harness bracket which holds en-
gine harness onto intake manifold.
EN0807 EN0811
• RH SIDE 18) Remove the engine harness from intake mani-

fold.
19) Loosen the clamp which holds front left side
fuel hose to injector pipe, and remove the pipe from
clamp.
EN0808
EN0812
20) Remove the fuel injector pipe LH.

21) Remove the bolts which install fuel pipe on in-
take manifold.
EN0809
EN0813
FU(TURBO)-23
INTAKE MANIFOLD
22) Remove the fuel pipe assembly and pressure 2) Install the air intake duct to intake manifold.
regulator from intake manifold.
Tightening torque:
23) Remove the intake duct from intake manifold.
19 N·m (1.9 kgf-m, 14.0 ft-lb)
EN1115
EN1115
24) Remove the tumble generator valve assembly
from intake manifold. 3) Install the fuel pipe assembly and pressure reg-
ulator to intake manifold.
Tightening torque:
4.9 N·m (0.5 kgf-m, 3.6 ft-lb)
EN0815
D: ASSEMBLY
NOTE: EN0813
4) Install the fuel injector pipe LH.
1) Install the tumble generator valve assembly to
intake manifold. 5) Connect the left side fuel hose to injector pipe,
Tightening torque:
8.25 N·m (0.84 kgf-m, 6.1 ft-lb)
EN0812
EN0815
6) Install the engine harness to intake manifold.
FU(TURBO)-24
INTAKE MANIFOLD
7) Install the harness bracket which holds engine 9) Tighten the bolts which install fuel injector pipe
harness onto intake manifold. onto intake manifold.
• LH SIDE
EN0811
EN0806
8) Install the fuel injector.
EN0810 EN0807
• RH SIDE
EN0808
EN0809
FU(TURBO)-25
INTAKE MANIFOLD
10) Tighten the two bolts which install fuel pipes on 12) Connect the evaporation hose to intake mani-
the left side of intake manifold. fold.
Tightening torque:
4.9 N·m (0.5 kgf-m, 3.6 ft-lb)
EN0803
13) Install the purge control solenoid valve.

EN0805
Tightening torque:
11) Connect the evaporation hoses to purge valve. 16 N·m (1.6 kgf-m, 11.8 ft-lb)
CAUTION:
(B)
(A)
EN0802
14) Connect the hoses to purge control solenoid

valve.
CAUTION:
(C)
(D)
EN0816 (A)
(B)
(A) To fuel pipe ASSY EN0817
(B) To intake duct
(C) To purge control solenoid valve (A) To intake manifold
(D) To intake manifold (B) To purge valve
FU(TURBO)-26
INTAKE MANIFOLD
15) Connect the connector to purge control sole- 19) Install the throttle body to intake manifold.
noid valve. NOTE:
Tightening torque:
22 N·m (2.2 kgf-m, 16.2 ft-lb)
EN0801
16) Connect the connector to tumble generator

valve sensor.
EN0785
20) Connect the connector to the throttle position

sensor (A), idle air control solenoid valve (B) and
pressure sensor (C).
21) Connect the engine harness with clip (D) to the
intake manifold.
EN0800
17) Connect the connector to tumble generator

valve actuator.
S2M2249A
EN0799
18) Connect the connector to fuel injector.
EN0798
FU(TURBO)-27
INTAKE MANIFOLD
22) Install the engine ground cable to intake mani- 24) Install the fuel pipe protector LH.
fold.
Tightening torque:
Tightening torque: 19 N·m (1.9 kgf-m, 14.0 ft-lb)
19 N·m (1.9 kgf-m, 14.0 ft-lb)
EN0793
EN0795
E: INSPECTION
Make sure the fuel pipe and fuel hoses are not
EN0796
23) Install the fuel pipe protector RH.

Tightening torque:
19 N·m (1.9 kgf-m, 14.0 ft-lb)
EN0794
FU(TURBO)-28

Tightening torque:
G6M0095
2) Remove the generator <Ref. to SC-14, REMOV-

AL, Generator.>
temperature sensor.
EN0851
FU(TURBO)-29

A: REMOVAL
T: 6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
G6M0095
B2M1252B
G2M0408
3) Remove the crankshaft position sensor, and dis-

connect the connector from it.
G2M0409
FU(TURBO)-30
6. Camshaft Position Sensor B: INSTALLATION

A: REMOVAL
T: 6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
G6M0095
G2M0417
tion sensor.
G2M0416
3) Remove the camshaft position sensor from cam-

shaft support LH.
G2M0417
FU(TURBO)-31
KNOCK SENSOR

A: REMOVAL
24 N·m (2.4 kgf-m, 17.4 ft-lb)
NOTE:
G6M0095

H2M3511C
(A) Front side
B2M4262
B2M4262

S2M1673
G6M0095
FU(TURBO)-32

A: REMOVAL
1.6 N·m (0.16 kgf-m, 1.2 ft-lb)
G6M0095
EN0820
sensor.
EN0819

EN0820
FU(TURBO)-33
MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR
9. Mass Air Flow and Intake Air B: INSTALLATION

Temperature Sensor Install in the reverse order of removal.
Tightening torque:
G6M0095
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.
EN1045
FU(TURBO)-34
PRESSURE SENSOR
10.Pressure Sensor B: INSTALLATION

A: REMOVAL
1) Disconnect the ground cable from battery. NOTE:
Replace the O-ring for the pressure sensor with
new ones.
Tightening torque:
1.6 N·m (0.16 kgf-m, 1.2 ft-lb)
G6M0095
2) Remove the idle air control solenoid valve. <Ref.

to FU(TURBO)-36, REMOVAL, Idle Air Control So-
lenoid Valve.>
3) Disconnect the connectors from pressure sen-
sor.
EN0821
4) Remove the pressure sensor from throttle body.
FU(TURBO)-35

NOTE:
Tightening torque:
2.8 N·m (0.29 kgf-m, 2.1 ft-lb)
G6M0095
2) Disconnect the connector from idle air control EN0823

solenoid valve.
EN0822

throttle body.
EN0823
4) Remove the gasket from throttle body.
EN1122
FU(TURBO)-36
FUEL INJECTOR
12.Fuel Injector 7) Remove the bolts which hold injector pipe to in-
take manifold.
A: REMOVAL
1. RH SIDE
1) Release the fuel pressure. <Ref. to FU(TUR-
BO)-53, RELEASING OF FUEL PRESSURE, OP-
ERATION, Fuel.>
cap.
EN0808
G6M0095
4) Remove the intake manifold. <Ref. to FU(TUR-

BO)-15, REMOVAL, Intake Manifold.> EN0809
5) Remove the fuel pipe protector RH. 8) Remove the fuel injector while lifting up the fuel
injector pipe.
EN0794
6) Disconnect the connector from fuel injector. EN0810
EN0798
FU(TURBO)-37
FUEL INJECTOR
2. LH SIDE 7) Remove the bolts which hold injector pipe to in-

take manifold.
ERATION, Fuel.>
cap.
EN0805
G6M0095

BO)-15, REMOVAL, Intake Manifold.>
EN0807
EN0793

EN0806
8) Remove the fuel injector while lifting up the fuel

injector pipe.
EN0798
EN0824
FU(TURBO)-38
FUEL INJECTOR
B: INSTALLATION Tightening torque:

19 N·m (1.9 kgf-m, 14.0 ft-lb)
1. RH SIDE
NOTE:
Replace the O-ring and insulators with new ones.
EN0794
2. LH SIDE
S2M2250A NOTE:
Replace the O-ring and insulators with new ones.
(A) O-ring
(B) Fuel injector
(C) Insulator
Tightening torque:
19 N·m (1.9 kgf-m, 14.0 ft-lb)
S2M2250A
(A) O-ring
(B) Fuel injector
(C) Insulator
EN0808 Tightening torque:

4.9 N·m (0.5 kgf-m, 3.6 ft-lb)
Tightening torque:
19 N·m (1.9 kgf-m, 14.0 ft-lb)
EN0805
EN0809
FU(TURBO)-39
FUEL INJECTOR
Tightening torque:
19 N·m (1.9 kgf-m, 14.0 ft-lb)
EN0806
Tightening torque:
19 N·m (1.9 kgf-m, 14.0 ft-lb)
EN0807
Tightening torque:
19 N·m (1.9 kgf-m, 14.0 ft-lb)
EN0793
FU(TURBO)-40
TUMBLE GENERATOR VALVE ASSEMBLY
13.Tumble Generator Valve As- 8) Remove the tumble generator valve body from
intake manifold.
sembly
A: REMOVAL
ERATION, Fuel.>
cap.
EN0815
B: INSTALLATION
NOTE:
Tightening torque:
8.25 N·m (0.84 kgf-m, 6.1 ft-lb)
G6M0095

valve sensor.
EN0815
EN0800

valve actuator.
EN0799
7) Remove the fuel injector. <Ref. to FU(TURBO)-

37, REMOVAL, Fuel Injector.>
FU(TURBO)-41
TUMBLE GENERATOR VALVE ACTUATOR
14.Tumble Generator Valve Ac- 3) Remove the tumble generator valve actuator LH.
tuator
A: REMOVAL
1. RH SIDE
ERATION, Fuel.>
cap.
EN1391
B: INSTALLATION
1. RH SIDE
2. LH SIDE
G6M0095

valve actuator RH.
6) Remove the tumble generator valve RH.
EN1390
2. LH SIDE
G6M0095

valve LH.
FU(TURBO)-42
WASTEGATE CONTROL SOLENOID VALVE
15.Wastegate Control Solenoid 5) Remove the wastegate control solenoid valve

from bracket
Valve
A: REMOVAL
EN0830
B: INSTALLATION
G6M0095
Tightening torque:
2) Remove the solenoid valve cover. 6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
EN0828
EN0830
3) Disconnect the connector (A) from wastegate
control solenoid valve.
4) Disconnect the pressure hoses (B) from waste-
gate control solenoid valve.
(A)
(B) EN0829
FU(TURBO)-43
16.Front Oxygen (A/F) Sensor 7) Remove the service hole cover.
A: REMOVAL
EN0832

threaded portion of front oxygen (A/F) sensor, and
G6M0095
leave it for 1 minute or more.
2) Remove the solenoid valve cover.
9) Remove the front oxygen (A/F) sensor.
CAUTION:
When removing the oxygen (A/F) sensor, wait
until the exhaust pipe cools, otherwise it will
damage exhaust pipe.
EN0828
3) Disconnect the connector from front oxygen

(A/F) sensor.
EN0833
EN0831
4) Disconnect the engine harness fixed by clip (A)

from the bracket (B).
S2M2253A
5) Remove the front right side wheel.

FU(TURBO)-44
B: INSTALLATION 7) Connect the connector of front oxygen (A/F)

1) Before installing the front oxygen (A/F) sensor, sensor.
apply anti-seize compound only to the threaded
portion of front oxygen (A/F) sensor to make the
next removal easier.
SS-30 by JET LUBE
CAUTION:
tor of front oxygen (A/F) sensor.
2) Install the front oxygen (A/F) sensor. EN0831
Tightening torque:
21 N·m (2.1 kgf-m, 15.2 ft-lb) 8) Install the solenoid valve cover.
EN0828
EN0833
3) Install the service hole cover.
G6M0095
EN0832

5) Install the front right side wheel.
6) Connect the engine harness with clip (A) to the
bracket (B).
S2M2253A
FU(TURBO)-45
REAR OXYGEN SENSOR
17.Rear Oxygen Sensor 6) Remove the rear oxygen sensor.

CAUTION:
A: REMOVAL When removing the oxygen sensor, wait until
1) Disconnect the ground cable from battery. the exhaust pipe cools, otherwise it will dam-
age exhaust pipe.
G6M0095
2) Lift-up the vehicle. EN0835

sor. B: INSTALLATION
1) Before installing the rear oxygen sensor, apply
anti-seize compound only to the threaded portion of
rear oxygen sensor to make the next removal eas-
ier.
CAUTION:
tor of rear oxygen sensor.
SS-30 by JET LUBE
EN0834 2) Install the rear oxygen sensor.
4) Remove the clip by pulling out from the upper Tightening torque:
side of crossmember. 21 N·m (2.1 kgf-m, 15.2 ft-lb)
S2M2254 EN0835
5) Apply SUBARU CRC or its equivalent to the 3) Connect the connector to rear oxygen sensor.
threaded portion of rear oxygen sensor, and leave
it for 1 minute or more.
EN0834
FU(TURBO)-46
REAR OXYGEN SENSOR
4) Connect the clip to crossmember.
S2M2254

G6M0095
FU(TURBO)-47
EXHAUST TEMPERATURE SENSOR
18.Exhaust Temperature Sensor B: INSTALLATION

1) Before installing the exhaust temperature sen-
A: REMOVAL sor, apply anti-seize compound only to the thread-
1) Disconnect the ground cable from battery. ed portion of rear oxygen sensor to make the next
removal easier.
CAUTION:
tor of exhaust temperature sensor.
SS-30 by JET LUBE
2) Install the exhaust temperature sensor.
NOTE:
G6M0095 Align the marking (A) of exhaust temperature sen-
sor to the marking (B) of joint pipe, and tighten the
2) Remove the joint pipe. <Ref. to EX(TURBO)-12, screws.
REMOVAL, Joint Pipe.>
3) Apply SUBARU CRC or its equivalent to the Tightening torque:
threaded portion of exhaust temperature sensor, 21 N·m (2.1 kgf-m, 15.2 ft-lb)
and leave it for 1 minute or more.
4) Remove the exhaust temperature sensor.
CAUTION:
When removing the exhaust temperature sen-
sor, wait until the exhaust pipe cools, otherwise
it will damage exhaust pipe.
S2M2255A
3) Install the joint pipe <Ref. to EX(TURBO)-12, IN-

STALLATION, Joint Pipe.>.
EN0836
G6M0095
FU(TURBO)-48

A: REMOVAL
G6M0095

EN1188

(A)
(A)
(B)
EN1189

the ECM.
FU(TURBO)-49
MAIN RELAY

A: REMOVAL
G6M0095

er.
on body.
EN0534
FU(TURBO)-50
FUEL PUMP RELAY

A: REMOVAL
G6M0095

er.
bracket on body.
EN0535

bracket.
FU(TURBO)-51
FUEL PUMP CONTROLLER
22.Fuel Pump Controller B: INSTALLATION

A: REMOVAL
G6M0095
2) Remove the rear quarter trim. <Ref. to EI-46,

REMOVAL, Rear Quarter Trim.>
3) Disconnect the connector from fuel pump control
unit.
EN0837
4) Remove the fuel pump control unit.
EN0838
FU(TURBO)-52
FUEL

WARNING:
EN0839
6) Tighten the fuel drain plug.

Tightening torque:
26 N·m (2.7 kgf-m, 19.2 ft-lb)
EN0344

onds.
2. DRAINING FUEL
WARNING:
• Place “NO FIRE” signs near the working area. EN0839
G6M0095
cap.
FU(TURBO)-53
FUEL TANK
A: REMOVAL
WARNING:
ERATION, Fuel.>
3) Drain fuel from the fuel tank. <Ref. to FU(TUR-
BO)-53, DRAINING FUEL, OPERATION, Fuel.> EN0539
5) Disconnect the connector (A) of fuel tank cord to 10) Move the clips, and disconnect quick connec-
rear harness. tor. <Ref. to FU(TURBO)-68, REMOVAL, Fuel De-
6) Push the grommet (B) which holds fuel tank cord livery, Return and Evaporation Lines.>
(B)
(A) EN0540
EN0537
(A) (B)
EN0840
EN0541
B: INSTALLATION
1) Support the fuel tank with transmission jack and
push the fuel tank harness into access hole with
grommet.
FU(TURBO)-54
FUEL TANK
2) Set the fuel tank and temporarily tighten the 6) Tighten the band mounting bolts.
Tightening torque:
WARNING: 33 N·m (3.4 kgf-m, 24.3 ft-lb)
EN0541
EN0541
3) Connect the two-way valve hose (A) to two-way INSTALLATION, Rear Crossmember.>
valve and connect the canister hose (B) to canister. 8) Connect the connector (A) to fuel tank cord and
plug the service hole with grommet (B).
(A) (B)
(B)
EN0840
(A)
EN0537
4) Connect the fuel filler hose and air vent hose.
EN0539
5) Connect the fuel hoses, and secure them with EN0344

clips and quick connector. <Ref. to FU(TURBO)-
69, INSTALLATION, Fuel Delivery, Return and C: INSPECTION
Evaporation Lines.> 1) Make sure there are no cracks, holes, or other
EN0540
FU(TURBO)-55
FUEL FILLER PIPE
A: REMOVAL tank.
WARNING:
ERATION, Fuel.>
cap.
4) Disconnect the ground cable from battery. EN0839
Tightening torque:
26 N·m (2.7 kgf-m, 19.2 ft-lb)
G6M0095
EN0839
11) Remove the fuel filler pipe protector.
EN0542
6) Loosen the rear right side wheel nuts.

EN0544
12) Separate the evaporation hoses from clip of

fuel filler pipe.
B2M1748
EN0545
FU(TURBO)-56
FUEL FILLER PIPE
13) Disconnect the air vent hose from fuel filler B: INSTALLATION
pipe. 1) Hold the fuel filler flap open.
2) Set the fuel saucer (A) with rubber packing (C)
and insert the fuel filler pipe into hole from the inner
side of apron.
3) Align the holes in fuel filler pipe neck and set cup
NOTE:
side, straighten it with a screwdriver.
EN0546
14) Remove the bolts which hold fuel filler pipe

bracket on body.
B2M1196A
4) Install the air vent pipe.
EN0547

16) Move the clip and separate air vent hose (B).
(A)
(B) EN0549
5) Connect the air vent hose to fuel filler pipe.
EN0548
17) Remove the fuel filler pipe to under side of the

vehicle.
from body.
EN0546
EN0549
FU(TURBO)-57
FUEL FILLER PIPE
6) Insert the fuel filler hose (A) approx. 35 to 40 mm 9) Tighten the bolts which hold evaporation hoses
(1.38 to 1.57 in) over the lower end of fuel filler pipe onto clip of fuel filler pipe.
and tighten the clamp.
CAUTION:
Do not allow clips to touch the air vent hose (B)
and rear suspension crossmember.
(A)
(B)
EN0545
EN0548
7) Insert the air vent hose approx. 25 to 30 mm

and hold clip.
L = 27.5±2.5 mm (1.083±0.098 in)
EN0544
B2M1195A
(1) Hose
(2) Clip
(3) Pipe B2M1748
8) Tighten the bolt which holds fuel filler pipe brack- 12) Lower the vehicle.
et on body. 13) Tighten the wheel nuts.
Tightening torque: 14) Connect the connector to fuel pump relay.
7.4 N·m (0.75 kgf-m, 5.4 ft-lb)
EN0344
EN0547
FU(TURBO)-58
FUEL FILLER PIPE
G6M0095
FU(TURBO)-59
FUEL PUMP

26 N·m (2.7 kgf-m, 19.2 ft-lb)
WARNING:
NOTE:
level sensor.
ERATION, Fuel.>
EN0839
cap.
3) Disconnect the ground cable from battery. 7) Raise the rear seat and turn floor mat up.
8) Remove the access hole lid.
G6M0095
EN0553
5) Drain fuel from the fuel tank. Set a container un- 9) Disconnect the connector from fuel pump.
tank.
S2M0172
EN0839 10) Disconnect the quick connector and then dis-

connect fuel delivery hose (A). <Ref. to FU(TUR-
BO)-68, Fuel Delivery, Return and Evaporation
Lines.>
FU(TURBO)-60
FUEL PUMP
11) Move the clips, and then disconnect the fuel re- B: INSTALLATION
turn hose (B) and jet pump hose (C). Install in the reverse order of removal. Do the fol-
lowing:
Tightening torque:
4.4 N·m (0.45 kgf-m, 3.3 ft-lb)
S2M0060A

sembly onto fuel tank.
S2M0063A
C: INSPECTION
S2M0061
whether the pump operates.
13) Take off the fuel pump assembly from fuel tank. WARNING:
• Wipe off the fuel completely.
as possible.
G2M0366
FU(TURBO)-61
FUEL LEVEL SENSOR
27.Fuel Level Sensor B: INSTALLATION

A: REMOVAL
WARNING:
NOTE:
Fuel level sensor is built in fuel pump assembly.
1) Remove the fuel pump assembly. <Ref. to
FU(TURBO)-60, REMOVAL, Fuel Pump.>
2) Disconnect the connector from fuel pump brack-
et.
S2M0145
3) Remove the bolt which installs fuel level sensor

EN0846
FU(TURBO)-62
A: REMOVAL
WARNING:
G2M0863

G6M0095

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

unit on fuel tank.
EN0839
4) Tighten the fuel drain plug.

Tightening torque:
26 N·m (2.7 kgf-m, 19.2 ft-lb)
S2M0152
10) Remove the fuel sub meter unit.
EN0839

S2M0153
FU(TURBO)-63
B: INSTALLATION
Tightening torque:
4.4 N·m (0.45 kgf-m, 3.3 ft-lb)
B2M3178
FU(TURBO)-64
FUEL FILTER
29.Fuel Filter C: INSPECTION

A: REMOVAL sediment.
WARNING: 2) If it is clogged, or if replacement interval has
• Place “NO FIRE” signs near the working area. been reached, replace it.
• Be careful not to spill fuel on the floor. 3) If water is found in it, shake and expel the water
1) Release the fuel pressure. <Ref. to FU(TUR- from inlet port.
ERATION, Fuel.>
ter.
EN1117

B: INSTALLATION
CAUTION:
new ones.
Tightening torque:
1.25 N·m (0.13 kgf-m, 0.94 ft-lb)
EN1117
FU(TURBO)-65
FUEL CUT VALVE

A: REMOVAL
Tightening torque:
1) Remove the fuel tank. <Ref. to FU(TURBO)-54,
REMOVAL, Fuel Tank.>
S2M0177
S2M0176
FU(TURBO)-66
FUEL DAMPER VALVE

A: REMOVAL
ERATION, Fuel.>
line.
EN0852
FU(TURBO)-67
cap.
2) Release the fuel pressure. <Ref. to FU(TUR- return pipes and hoses, evaporation pipes and hos-
BO)-53, RELEASING OF FUEL PRESSURE, OP- es.
ERATION, Fuel.>
EN1392
6) In the engine compartment, detach the fuel de- 8) Disconnect the two-way valve hose (A) from
livery hoses, return hoses and evaporation hose. two-way valve and disconnect the canister hose (B)
from canister.
(A) (B)
S2M0500
EN0840
FU(TURBO)-68
9) Separate the quick connector on fuel delivery (1) Set the new retainer (B) to connector (A).
and return line. (2) Push the pipe into connector completely.
(1) Clean the pipe and connector, if they are NOTE:
covered with dust. At this time, two clicking sounds are heard.
down.
NOTE:
S2M0230A
(A) Connector
(B) Retainer
(C) Pipe
S2M0228A
CAUTION:
(A) Connector • Pull the connector to ensure it is connected
(B) Retainer securely.
(C) Pipe • Ensure the two retainer pawls are engaged in
B: INSTALLATION • Be sure to inspect the hoses and their con-
1) Connect the quick connector on fuel delivery and nections for any leakage of fuel.
return line.
NOTE:
• Make sure that the connected portion is not dam-
aged or has dust. If necessary, clean the seal sur-
face of pipe.
S2M0231A
(A) Connector
(B) Retainer
(C) Pipe
S2M0229A
FU(TURBO)-69
2) Connect the fuel delivery hose to pipe with an C: INSPECTION

overlap of 20 to 25 mm (0.79 to 0.98 in). 1) Make sure that there are no cracks on the fuel
Type A: When the fitting length is specified. pipes and fuel hoses.
Type B: When the fitting length is not specified. 2) Make sure that the fuel pipe and fuel hose con-
2 : 2.5±1.5 mm (0.098±0.059 in) nections are tight.
L: 22.5±2.5 mm (0.886±0.098 in)
B2M1194B
(1) Fitting
(2) Clamp
(3) Hose

L = 17.5±2.5 mm (0.689±0.098 in)
CAUTION:
B2M1195A
(1) Hose
(2) Clip
(3) Pipe
FU(TURBO)-70

A: INSPECTION
securely.
tube.
1) Retightening.
filler pipe.
1) Defective operation of fuel level sensor. Replace.
5. Noise
NOTE: level drops to about one-half. After the winter
• When the vehicle is left unattended for an ex- season, drain the water which may have accu-
tended period of time, water may accumulate in the mulated in the fuel filter and fuel tank in the man-
fuel tank. ner same as that described under “Affected
To prevent water condensation. areas” below.
(1) Top off the fuel tank or drain the fuel com- (4) Affected areas:
pletely. When the water condensation is notched in the
(2) Drain the water condensation from the fuel fuel filter, drain the water from both the fuel filter
filter. and fuel tank or use a water removing agent (or
• Refilling the fuel tank. anti-freeze solution) in the fuel tank.
water condensation.
(3) Cold areas:
FU(TURBO)-71
FU(TURBO)-72
EMISSION CONTROL
EC(TURBO)
Page
4. Precatalytic Converter.................................................................................5
5. Canister.......................................................................................................6
7. Two-way Valve............................................................................................8
GENERAL DESCRIPTION
A: CAUTION
tion.
points.
cable from battery.
EC(TURBO)-2
2. Front Catalytic Converter

A: REMOVAL
1) Remove the center exhaust pipe. <Ref. to
EX(TURBO)-8, REMOVAL, Center Exhaust Pipe.>
2) Separate the front catalytic converter (A) from
rear catalytic converter (B).
(A)
(B)
EN0993
B: INSTALLATION
NOTE:
C: INSPECTION
nections and welds.
EC(TURBO)-3

A: REMOVAL
2) Separate the rear catalytic converter (B) from
front catalytic converter (A).
(A)
(B)
EN0993
B: INSTALLATION
NOTE:
C: INSPECTION
nections and welds.
EC(TURBO)-4
PRECATALYTIC CONVERTER
4. Precatalytic Converter
A: REMOVAL
Precatalytic converter (A) is built in the joint pipe.
Refer to the removal of joint pipe for removal
procedure. <Ref. to EX(TURBO)-12, REMOVAL,
Joint Pipe.>
(A)
EN0994
B: INSTALLATION
Precatalytic converter is built in the joint pipe. Refer
to the installation of joint pipe for installation proce-
dure. <Ref. to EX(TURBO)-12, INSTALLATION,
Joint Pipe.>
C: INSPECTION
nections and welds.
EC(TURBO)-5
CANISTER
5. Canister
A: REMOVAL
from canister.
EN0898
B2M4166
B: INSTALLATION
Tightening torque:
23 N·m (2.3 kgf-m, 17 ft-lb)
B2M4166
C: INSPECTION
cracked or loose.
EC(TURBO)-6

A: REMOVAL
16 N·m (1.6 kgf-m, 11.6 ft-lb)
G6M0095
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.
(A)
(B)
EN0817
EN0899
(A) To intake manifold
(B) To purge valve
C: INSPECTION
Make sure the hoses are not cracked or loose.
EC(TURBO)-7
TWO-WAY VALVE
7. Two-way Valve
A: REMOVAL
2) Remove the canister from body. <Ref. to
EC(TURBO)-6, REMOVAL, Canister.>
gle unit from body.
EN0901

B: INSTALLATION
C: INSPECTION
Make sure that the hoses are not cracked or loose.
EC(TURBO)-8
INTAKE (INDUCTION)
IN(TURBO)
Page
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
8. Resonator Chamber..................................................................................15
GENERAL DESCRIPTION
INTAKE (INDUCTION)
A: COMPONENT
1. AIR CLEANER
T4
(1)
(2)
T1 (3)
T3
(12)
(8) T3
T1
(14) T1
(13)
(11) (12)
(6)
T2
(7)
(6) (4)
(10)
(5)
(9)
T1
EN1178
(1) Mass air flow and intake air tem- (8) Cushion rubber Tightening torque: N·m (kgf-m, ft-lb)
perature sensor (9) Air intake duct T1: 7.5 (0.76, 5.5)
(2) Air cleaner upper cover (10) Resonator chamber ASSY T2: 33 (3.4, 24.6)
(3) Air cleaner element (11) Cushion rubber T3: 2.5 (0.25, 1.8)
(4) Spacer (12) Clamp T4: 1.7 (0.17, 1.2)
(5) Bush (13) Air intake boot
(6) Clip (14) Cushion
(7) Air cleaner lower case
IN(TURBO)-2
GENERAL DESCRIPTION
INTAKE (INDUCTION)
2. INTAKE DUCT
(4)
(3)
(5)
(1)
(2)
T1
(6) (7)
EN1114
(1) Clamp (5) Air by-pass hose C Tightening torque: N·m (kgf-m, ft-lb)
(2) PCV hose ASSY (6) Intake duct T1: 16 (1.6, 11.7)
(3) Air by-pass hose A (7) Clamp
(4) Air by-pass hose B
IN(TURBO)-3
GENERAL DESCRIPTION
INTAKE (INDUCTION)
3. INTERCOOLER
T2
(2)
(1)
(4)
(5)
(4)
T1
T2 (6) (7)
T2
(8)
(3)
(9)
(11)
(10)
T2
EN1508
(1) Intercooler (7) Gasket Tightening torque: N·m (kgf-m, ft-lb)

(2) Intercooler bracket RH (8) Clamp T1: 3 (0.3, 2.2)
(3) Intercooler bracket LH (9) Air by-pass hose A T2: 16 (1.6, 11.6)
(4) Clamp (10) Intercooler duct
(5) Air intake duct (11) Clamp
(6) Air by-pass valve
IN(TURBO)-4
GENERAL DESCRIPTION
INTAKE (INDUCTION)
4. TURBOCHARGER
EN1116
(1) Oil inlet pipe (8) Oil outlet pipe Tightening torque: N·m (kgf-m, ft-lb)
(2) Metal gasket (9) Clip T1: 4.4 (0.45, 3.3)
(3) Turbocharger (10) Oil outlet hose T2: 4.9 (0.50, 3.6)
(4) Water pipe (11) 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: 16 (1.6, 11.6)
IN(TURBO)-5
GENERAL DESCRIPTION
INTAKE (INDUCTION)
B: CAUTION
tion.
points.
sensor or units, be sure to disconnect the ground
cable from battery.
IN(TURBO)-6
AIR CLEANER
INTAKE (INDUCTION)
2. Air Cleaner 7) Remove the air cleaner lower case.
A: REMOVAL
EN0905
B: INSTALLATION
G6M0095
2) Disconnect the connector from mass air flow Tightening torque:

sensor. 33 N·m (3.4 kgf-m, 24.6 ft-lb)
EN0031 EN0905
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 the holes with protruding portions of air
cover. cleaner lower case, then secure the upper cov-
er to lower case.
(B)
(A)
EN0992
EN0906
5) Remove the air cleaner upper cover.
6) Remove the air cleaner element. C: INSPECTION
Replace if excessively damaged or dirty.
IN(TURBO)-7
AIR INTAKE DUCT
INTAKE (INDUCTION)
3. Air Intake Duct

A: REMOVAL
1) Remove the bolts which install air intake duct on
the front side of body.
EN0108
B: INSTALLATION
C: INSPECTION
1) Inspect for cracks and loose connections.
2) Inspect that no foreign objects are mixed in the
air intake duct.
IN(TURBO)-8
INTAKE DUCT
INTAKE (INDUCTION)
4. Intake Duct
A: REMOVAL
G6M0095

3) Remove the sensor, engine harness, and fuel
pipe attached to intake manifold. <Ref. to FU(TUR-
BO)-21, DISASSEMBLY, Intake Manifold.>
4) Remove the intake duct from intake manifold.
EN1115
B: INSTALLATION
IN(TURBO)-9
INTERCOOLER
INTAKE (INDUCTION)
5. Intercooler 5) Separate the intercooler from throttle body.
A: REMOVAL
1) Disconnect the air by-pass hoses from intercool-
er.
EN0916
EN0907
2) Separate the air by-pass valve from intercooler.
EN0908
3) Remove the bolts which secure intercooler to

bracket.
EN0915
EN0909
4) Separate the intercooler air duct from turbo-

charger.
IN(TURBO)-10
INTERCOOLER
INTAKE (INDUCTION)
B: INSTALLATION C: DISASSEMBLY
Install in the reverse order of removal. 1) Remove the intercooler ducts from intercooler.
Tightening torque:
16 N·m (1.6 kgf-m, 11.6 ft-lb)
H2M1886
D: ASSEMBLY
EN0915 Assemble in the reverse order of disassembly.
Tightening torque:
16 N·m (1.6 kgf-m, 11.7 ft-lb)
EN0909
H2M1886
EN0908
IN(TURBO)-11
TURBOCHARGER
INTAKE (INDUCTION)
6. Turbocharger 7) Loosen the clamp which secures turbocharger to

air inlet duct.
A: REMOVAL
H2M1936
8) Remove the bolt which secures bracket of oil

pipe to turbocharger.
G6M0095 9) Remove the oil pipe from turbocharger.
5) Separate the turbocharger joint pipe from turbo-
charger.
EN0913
10) Remove the turbocharger bracket.
EN0911
6) Disconnect the engine coolant hose which is

connected to coolant filler tank.
H2M1940
11) Disconnect the oil outlet hose from pipe.
EN0912
H2M1941
12) Take out the turbocharger from engine com-

partment.
IN(TURBO)-12
TURBOCHARGER
INTAKE (INDUCTION)
B: INSTALLATION 5) Install the turbocharger bracket.

1) Connect the oil outlet hose to outlet pipe.
H2M1940
H2M1941 6) Connect the engine coolant hose which is con-

2) Install the turbocharger to air intake duct. nected to coolant filler tank.
EN0912
H2M1936
3) Install the oil pipe to turbocharger. 7) Lift-up the vehicle.

8) Install the center exhaust pipe. <Ref. to EX(TUR-
BO)-9, INSTALLATION, Center Exhaust Pipe.>
EN0913
4) Install the joint pipe to turbocharger.

NOTE:
Tightening torque:
30 N·m (3.1 kgf-m, 22.4 ft-lb)
EN0911
IN(TURBO)-13
AIR BY-PASS VALVE
INTAKE (INDUCTION)
7. Air By-pass Valve B: INSTALLATION

A: REMOVAL
1) Remove the air by-pass valve from intercooler. Tightening torque:
16 N·m (1.6 kgf-m, 11.6 ft-lb)
EN0908
EN0908
2) Disconnect the air by-pass hoses from air by-
pass valve.
IN(TURBO)-14
RESONATOR CHAMBER
INTAKE (INDUCTION)
8. Resonator Chamber
A: REMOVAL
2) Remove the air intake duct. <Ref. to IN(TUR-
BO)-8, Removal.>
3) Remove the air cleaner lower case. <Ref. to
IN(TURBO)-7, Removal.>
4) Remove the resonator chamber mounting bolt
on the right of engine compartment.
B2M4556
5) Remove the front right tire, and lift the vehicle.

6) Remove the front mudguard RH.
7) Remove the resonator chamber (A) from the in-
side front fender.
(A)
EN1377
B: INSTALLATION
C: INSPECTION
Inspect for cracks and loose connections. Check
that no foreign objects are mixed in the resonator
chamber.
IN(TURBO)-15
RESONATOR CHAMBER
INTAKE (INDUCTION)
IN(TURBO)-16
MECHANICAL
ME(TURBO)
Page
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
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 ...........................................................................................71
21. Engine Trouble in General ........................................................................91
22. Engine Noise.............................................................................................96
GENERAL DESCRIPTION
MECHANICAL
A: SPECIFICATIONS
Horizontally opposed, liquid cooled, 4-cylinder,
Type
4-stroke gasoline engine
Valve arrangement Belt driven, double overhead camshaft, 4-valve/cylinder
Bore x Stroke mm (in) 92 x 75 (3.62 x 2.95)
Piston displacement 3 1,994 (121.67)
cm (cu in)
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
Intake mm (in) 0.20±0.02 (0.0079±0.0008)
Valve clearance
Exhaust mm (in) 0.25±0.02 (0.0098±0.0008)
750±100 (No load)
MT
Idling speed [At neutral position] rpm
750±100 (No load)
AT
Firing order 1→3→2→4
Ignition timing BTDC/rpm 12°±3°/750 rpm
ME(TURBO)-2
GENERAL DESCRIPTION
MECHANICAL
NOTE:
STD: Standard I.D.: Inner Diameter O.D.: Outer Diameter OS: Oversize US: Undersize
Belt
tension 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. 18.0 — 18.08 mm (0.7087 — 0.7118 in)
Belt STD 0.025 — 0.125 mm (0.0010 — 0.0049 in)
Clearance between spacer and bush
tensioner 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)
STD 0.015 — 0.070 mm (0.0006 — 0.0028 in)
Thrust clearance
Limit 0.10 mm (0.0039 in)
STD 46.25 — 46.35 mm (1.821 — 1.825 in)
Intake
Limit 46.15 mm (1.817 in)
Cam lobe height
STD 46.15 — 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 mm (1.1790 — 1.1796 in)
rear
STD 0.037 — 0.072 mm (0.0015 — 0.0028 in)
Oil clearance
Limit 0.10 mm (0.0039 in)
Surface warpage limit 0.05 mm (0.0020 in)
Cylinder
head
Standard height 127.5 mm (5.02 in)
Refacing angle 90°
STD 1.0 mm (0.039 in)
Intake
Valve seat Limit 1.7 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)
STD 1.2 mm (0.047 in)
Intake
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)
Intake 5.950 — 5.965 mm (0.2343 — 0.2348 in)
Stem diameter
Valve Exhaust 5.945 — 5.960 mm(0.2341 — 0.2346 in)
Intake 0.035 — 0.062 mm (0.0014 — 0.0024 in)
STD
Stem oil clearance Exhaust 0.040 — 0.067 mm (0.0016 — 0.0026 in)
Limit — 0.15 mm (0.0059 in)
Intake 104.4 mm (4.110 in)
Overall length
Exhaust 104.7 mm (4.122 in)
Valve 205.0 — 236.4 N (20.9 — 24.1 kgf, 46.1 — 53.1 lb)
spring /36.0 mm (1.417 in)
Tension/spring height
485.4 — 536.4 N (49.5 — 54.7 kgf, 109.2 — 120.6 lb)
/26.6 mm (1.047 in)
ME(TURBO)-3
GENERAL DESCRIPTION
MECHANICAL
Surface warpage limit (mating with cylinder head) 0.05 mm (0.0020 in)
A 92.005 — 92.015 mm (3.6222 — 3.6226 in)
Cylinder bore STD
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 — 0.0012 in)
Piston clearance
Limit 0.050 mm (0.0020 in)
Enlarging (boring) limit 0.5 mm (0.020 in)
A 91.985 — 91.995 mm (3.6214 — 3.6218 in)
STD
B 91.975 — 91.985 mm (3.6211 — 3.6214 in)
Piston Outer diameter 0.25 mm (0.0098 in)
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
Piston pin must be fitted into position with thumb at 20°C
Degree of fit
(68°F).
STD 0.20 — 0.25 mm (0.0079 — 0.0098 in)
Top ring
Limit 1.0 mm (0.039 in)
Second STD 0.35 — 0.50 mm (0.0138 — 0.0197 in)
Piston ring gap
STD 0.20 — 0.50 mm (0.0079 — 0.0197 in)
Piston ring Oil ring
Limit 1.5 mm (0.059 in)
STD 0.055 — 0.090 mm (0.0022 — 0.0035 in)
Clearance between pis- Top ring
Limit 0.15 mm (0.0059 in)
ton ring and piston ring
groove Second STD 0.030 — 0.070 mm (0.0012 — 0.0028 in)
Bend twist per 100 mm (3.94 in) in
Limit 0.10 mm (0.0039 in)
Connecting length
rod STD 0.070 — 0.330 mm (0.0028 — 0.0130 in)
Side clearance
Limit 0.4 mm (0.016 in)
STD 0.020 — 0.046 mm (0.0008 — 0.0018 in)
Oil clearance
Limit 0.05 mm (0.0020 in)
STD 1.486 — 1.498 mm (0.0585 — 0.0590 in)
0.03 mm
(0.0012 1.504 — 1.512 mm (0.0592 — 0.0595 in)
Connecting in) US
rod bearing 0.05 mm
Thickness at center portion
(0.0020 1.514 — 1.522 mm (0.0596 — 0.0599 in)
in) US
0.25 mm
(0.0098 1.614 — 1.622 mm (0.0635 — 0.0639 in)
in) US
Connecting Clearance between piston pin and STD 0 — 0.022 mm (0 — 0.0009 in)
rod bushing bushing Limit 0.030 mm (0.0012 in)
ME(TURBO)-4
GENERAL DESCRIPTION
MECHANICAL

Crank pin and crank jour- Out-of-roundness 0.020 mm (0.0008 in) or less
nal Grinding limit 0.25 mm (0.0098 in)
STD 51.984 — 52.000 mm (2.0466 — 2.0472)
0.03 mm
(0.0012 51.954 — 51.970 mm (2.0454 — 2.0461)
in) US
Crank pin outer diameter 0.05 mm
(0.0020 51.934 — 51.950 mm (2.0447 — 2.0453)
in) US
0.25 mm
(0.0098 51.734 — 51.750 mm (2.0368 — 2.0374)
in) US
STD 59.992 — 60.008 mm (2.3619 — 2.3625 in)
0.03 mm
(0.0012 59.962 — 59.978 mm (2.3607 — 2.3613 in)
in) US
#1, #3, #5 0.05 mm
Crankshaft (0.0020 59.942 — 59.958 mm (2.3599 — 2.3605 in)
in) US
0.25 mm
(0.0098 59.742 — 59.758 mm (2.3520 — 2.3527 in)
Crank journal outer diam- in) US
eter 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
#2, #4 0.05 mm
(0.0020 59.942 — 59.958 mm (2.3599 — 2.3605 in)
in) US
0.25 mm
(0.0098 59.742 — 59.758 mm (2.3520 — 2.3527 in)
in) US
STD 0.030 — 0.115 mm (0.0012 — 0.0045 in)
Thrust clearance
Limit 0.25 mm (0.0098 in)
STD 0.010 — 0.030 mm (0.0004 — 0.0012 in)
Oil clearance
Limit 0.040 mm (0.0016 in)
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
#1, #3 0.05 mm
(0.0020 2.027 — 2.030 mm (0.0798 — 0.0799 in)
in) US
0.25 mm
(0.0098 2.127 — 2.130 mm (0.0837 — 0.0839 in)
Crankshaft Crankshaft bearing thick- in) US
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
0.05 mm
#2, #4, #5
(0.0020 2.029 — 2.032 mm (0.0799 — 0.0800 in)
in) US
0.25 mm
(0.0098 2.129 — 2.132 mm (0.0838 — 0.0839 in)
in) US
ME(TURBO)-5
GENERAL DESCRIPTION
MECHANICAL
B: COMPONENT
1. TIMING BELT
(2) (1)
(2)
T2 T2
(3)
T1
(2)
(4)
T2
T1 (5)
T3
(6)
(12)
(9)
(7)
(8)
(14)
T1 T5 T1
T3 T4
T4
(10) (2)
(14)
T2
T4 (11)
(17)
(13) T5
T1
(15)
(16)
T6 (18)
T1
EN1136
(1) Belt cover No. 2 (RH) (9) Intake camshaft sprocket (RH) Tightening torque: N·m (kgf-m, ft-lb)
(2) Timing belt guide (MT vehicles (10) Intake camshaft sprocket (LH) T1: 5 (0.5, 3.6)
only) (11) Exhaust camshaft sprocket (LH) T2: 10 (1.0, 7.2)
(3) Crankshaft sprocket (12) Timing belt T3: 25 (2.5, 18.1)
(4) Belt cover No. 2 (LH) (13) Belt idler No. 2 T4: 39 (4.0, 28.9)
(5) Tensioner bracket (14) Belt idler T5: 98 (10, 72.4)
(6) Automatic belt tension adjuster (15) Belt cover (LH) T6: <Ref. to ME(TURBO)-46,
ASSY (16) Front belt cover INSTALLATION, Crankshaft
(7) Belt idler (17) Belt cover (RH) Pulley.>
(8) Exhaust camshaft sprocket (RH) (18) Crankshaft pulley
ME(TURBO)-6
GENERAL DESCRIPTION
MECHANICAL
ME(TURBO)-7
GENERAL DESCRIPTION
MECHANICAL
2. CYLINDER HEAD AND CAMSHAFT
EN1480
ME(TURBO)-8
GENERAL DESCRIPTION
MECHANICAL
(1) Rocker cover (RH) (15) Cylinder head (RH) (29) Gasket
(2) Rocker cover gasket (RH) (16) Cylinder head gasket (RH) (30) Oil filler duct
(3) Oil separator cover (17) Cylinder head (LH) (31) O-ring
(4) Gasket (18) Intake camshaft (LH) (32) Stud bolt
(5) Intake camshaft cap (Front RH) (19) Exhaust camshaft (LH)
(6) Intake camshaft cap (Center RH) (20) Intake camshaft cap (Front LH) Tightening torque: N·m (kgf-m, ft-lb)
(7) Intake camshaft cap (Rear RH) (21) Intake camshaft cap (Center LH) T1: <Ref. to ME(TURBO)-64,
(8) Intake camshaft (RH) (22) Intake camshaft cap (Rear LH) INSTALLATION, Cylinder Head
(9) Exhaust camshaft cap (Front RH) (23) Exhaust camshaft (Front LH) Assembly.>
(10) Exhaust camshaft cap (Center RH) (24) Exhaust camshaft cap (Center LH) T2: 5 (0.5, 3.6)
(11) Exhaust camshaft cap (Rear RH) (25) Exhaust camshaft cap (Rear LH) T3: 10 (1.0, 7.2)
(12) Exhaust camshaft (RH) (26) Rocker cover gasket (LH) T4: 6.4 (0.65, 4.7)
(13) Cylinder head bolt (27) Rocker cover (LH)
(14) Oil seal (28) Oil filler cap
ME(TURBO)-9
GENERAL DESCRIPTION
MECHANICAL
3. CYLINDER HEAD AND VALVE ASSEMBLY
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 (10) Shim
ME(TURBO)-10
GENERAL DESCRIPTION
MECHANICAL
4. CYLINDER BLOCK
EN0144
(1) Oil pressure switch (15) Oil cooler Tightening torque: N·m (kgf-m, ft-lb)
(2) Cylinder block (RH) (16) Waster by-pass pipe T1: 5 (0.5, 3.6)
(3) Service hole plug (17) Connector T2: 6.4 (0.65, 4.7)
(4) Gasket (18) Oil strainer T3: 10 (1.0, 7.2)
(5) Oil separator cover (19) Gasket T4: 25 (2.5, 18.1)
(6) Water by-pass pipe (20) Oil pan T5: 47 (4.8, 34.7)
(7) Oil pump (21) Drain plug T6: 69 (7.0, 50.6)
(8) Front oil seal (22) Metal gasket T7: First 12 (1.2, 8.7)
(9) Rear oil seal (23) Oil level gauge guide Second 12 (1.2, 8.7)
(10) O-ring (24) Oil filter T8: 16 (1.6, 11.6)
(11) Service hole cover (25) Gasket T9: 44 (4.5, 33)
(12) Cylinder block (LH) (26) Water pump hose T10: 25 (2.5, 18.1)
(13) Water pump (27) Plug T11: 55 (5.5, 40)
(14) Baffle plate
ME(TURBO)-11
GENERAL DESCRIPTION
MECHANICAL
5. CRANKSHAFT AND PISTON
EN0415
(1) Flywheel (MT vehicles only) (9) Piston pin (17) Crankshaft bearing #1, #3
(2) Ball bearing (MT vehicles only) (10) 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, ft-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(TURBO)-12
GENERAL DESCRIPTION
MECHANICAL
6. ENGINE MOUNTING
S2M1783A
(1) Heat shield cover (3) Front engine mounting bracket Tightening torque: N·m (kgf-m, ft-lb)
(2) Front cushion rubber T1: 34 (3.5, 25.3)
T2: 42 (4.3, 30.9)
T3: 85 (8.7, 62.7)
ME(TURBO)-13
GENERAL DESCRIPTION
MECHANICAL
C: CAUTION • Rotating parts and sliding parts such as piston,

• Wear working clothing, including a cap, protec- bearing and gear should be coated with oil prior to
tive goggles, and protective shoes during opera- assembly.
tion. • Be careful not to let oil, grease or coolant contact
• Remove contamination including dirt and corro- the timing belt, clutch disc and flywheel.
sion before removal, installation or disassembly. • All removed parts, if to be reused, should be re-
• Keep the disassembled parts in order and pro- installed in the original positions and directions.
tect them from dust or dirt. • Bolts, nuts and washers should be replaced with
• Before removal, installation or disassembly, be new ones as required.
sure to clarify the failure. Avoid unnecessary re- • Even if necessary inspections have been made
moval, installation, disassembly, and replacement. in advance, proceed with assembly work while
• Be careful not to burn your hands, because each making rechecks.
part in the vehicle is hot after running. • Remove or install the engine in an area where
• Be sure to tighten fasteners including bolts and chain hoists, lifting devices, etc. are available for
nuts to the specified torque. ready use.
• Place shop jacks or safety stands at the specified • Be sure not to damage coated surfaces of body
points. panels with tools or stain seats and windows with
• Before disconnecting electrical connectors of coolant or oil. Place a cover over fenders, as re-
sensors or units, be sure to disconnect the ground quired, for protection.
cable from battery. • Prior to starting work, prepare the following:
• All parts should be thoroughly cleaned, paying Service tools, clean cloth, containers to catch cool-
special attention to the engine oil passages, pis- ant and oil, wire ropes, chain hoist, transmission
tons and bearings. jacks, etc.
• Lift-up or lower the vehicle when necessary.
Make sure to support the correct positions.
D: PREPARATION TOOL
1. SPECIAL TOOLS

498267600 CYLINDER • Used for replacing valve guides.
HEAD TABLE • Used for removing and installing valve springs.
EN0147
ADAPTER RH
B2M3851
ME(TURBO)-14
GENERAL DESCRIPTION
MECHANICAL

ADAPTER LH
B2M3852
STOPPER ening and tightening crankshaft pulley bolt, etc.
B2M3853
398744300 PISTON GUIDE Used for installing piston in cylinder for 2000 cc
engine.
B2M3854
498857100 VALVE OIL Used for press-fitting of intake and exhaust valve
SEAL GUIDE guide oil seals.
B2M3855
ME(TURBO)-15
GENERAL DESCRIPTION
MECHANICAL

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
SPROCKET sprocket. (Except intake camshaft sprocket
WRENCH sprocket LH)
B2M4158
ME(TURBO)-16
GENERAL DESCRIPTION
MECHANICAL

18231AA010 CAMSHAFT Used for removing and installing camshaft
(Newly adopted SPROCKET sprocket. (Intake camshaft sprocket LH)
tool) WRENCH
B2M3859
499587700 CAMSHAFT OIL Used for installing cylinder head plug for DOHC
SEAL engine.
INSTALLER
B2M3860
OIL SEAL • Used with CRANKSHAFT OIL SEAL GUIDE
B2M3861
OIL SEAL GUIDE • Used with CRANKSHAFT OIL SEAL
B2M3863
ME(TURBO)-17
GENERAL DESCRIPTION
MECHANICAL

499718000 VALVE SPRING Used for removing and installing valve spring.
REMOVER
B2M3864
498267700 VALVE GUIDE Used for installing intake and exhaust valve
ADJUSTER guides.
B2M3865
499767200 VALVE GUIDE Used for removing valve guides.
REMOVER
B2M3867
499767400 VALVE GUIDE Used for reaming valve guides.
REAMER
B2M3868
ME(TURBO)-18
GENERAL DESCRIPTION
MECHANICAL

499817000 ENGINE STAND • Stand used for engine disassembly and assem-
bly.
• Used with ENGINE STAND ADAPTER RH
(498457000) & LH (498457100).
B2M3869
bolts.
B2M4157
499987500 CRANKSHAFT Used for rotating crankshaft.
SOCKET
B2M3871
WRENCH
B2M3872
ME(TURBO)-19
GENERAL DESCRIPTION
MECHANICAL

INSTALLER
B2M3875
499587600 OIL SEAL GUIDE Used for installing camshaft oil seal for DOHC
engine.
S1H0136
499597200 OIL SEAL GUIDE • Used for installing camshaft oil seal for DOHC
engine.
• Used with OIL SEAL GUIDE (499587600).
EN0168
498187200 SHIM Used for correct valve clearance.
REPLACER
EN0169
ME(TURBO)-20
GENERAL DESCRIPTION
MECHANICAL

498277200 STOPPER SET Used for installing automatic transmission assem-
bly to engine.
H1H0492
(Newly adopted
tool)
B2M3876
B2M3877

TOOL NAME REMARKS
Compression Gauge Used for measuring compression.
Timing Light 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
• Camshaft
• Cylinder Head
ME(TURBO)-21
COMPRESSION
MECHANICAL
2. Compression
A: INSPECTION
CAUTION:
ment.
1) After warming-up the engine, turn the ignition
switch to OFF.
2) Make sure that the battery is fully charged.
ERATION, Fuel.>
4) Remove all the spark plugs. <Ref. to IG(TUR-
BO)-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 spark
plug hole.
CAUTION:
When using a screw-in type compression
gauge, the screw (put into cylinder head spark
plug hole) should be less than 18 mm (0.71 in)
long.
8) Crank the engine by means of starter motor, and
then read the maximum value on the gauge when
the pointer is steady.
EN0172
9) Perform at least two measurements per cylinder,

and make sure that the values are correct.
Compression (350 rpm and fully open throttle):
Standard;
951 — 1,147 kPa (9.7 — 11.7 kgf/cm2, 138 —
166 psi)
Limit;
834 kPa (8.5 kgf/cm2, 121 psi)
Difference between cylinders;
49 kPa (0.5 kgf/cm2, 7 psi)
ME(TURBO)-22
IDLE SPEED
MECHANICAL
3. Idle Speed
A: INSPECTION
1) Before checking the idle speed, check the fol-
lowing:
(1) Ensure the air cleaner element is free from
clogging, ignition timing is correct, spark plugs
are in good condition, and that the hoses are
connected properly.
3) Stop the engine, and then turn the ignition switch
to OFF.
4) Insert the cartridge to SUBARU SELECT MONI-
TOR.
5) Connect the SUBARU SELECT MONITOR to
data link connector.
6) Turn the ignition switch to ON, and SUBARU
SELECT MONITOR switch to ON.
Menu.
Menu.
9) Select the {1. Current Data Display & Save} in
Menu.
11) Start the engine, and then read the engine idle
speed.
12) Check the idle speed when unloaded. (With
headlights, heater fan, rear defroster, radiator fan,
air conditioning, etc. OFF)
Idle speed [No load and gears in neutral]:
750±100 rpm
13) Check the idle speed when loaded. (Turn the
air conditioning switch to “ON” and operate the
compressor for at least 1 minute before measure-
ment.)
Idle speed [A/C “ON”, no load and gears in neu-
tral]:
800±150 rpm (MT models)
825±150 rpm (AT models)
CAUTION:
Never rotate the idle adjusting screw. If the idle
speed is out of specifications, refer to General
On-board Diagnosis Table under “Engine Con-
trol System”. <Ref. to EN(TURBO)-2, Basic Di-
agnostic Procedure.>
ME(TURBO)-23
IGNITION TIMING
MECHANICAL
4. Ignition 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.
3) Stop the engine, and then turn the ignition switch
to OFF.
4) Insert the cartridge to SUBARU SELECT MONI-
TOR.
5) Connect the SUBARU SELECT MONITOR to
data link connector.
6) Turn the ignition switch to ON, and SUBARU
SELECT MONITOR switch to ON.
Menu.
Menu.
9) Select the {1. Current Data Display & Save} in
Menu.
11) Start the engine, at idle speed and check the ig-
nition timing.
Ignition timing [BTDC/rpm]:
12°±3°/750
If the timing is not correct, check the ignition control
system. Refer to Engine Control System. <Ref. to
EN(TURBO)-2, Basic Diagnostic Procedure.>
ME(TURBO)-24
INTAKE MANIFOLD VACUUM
MECHANICAL
5. Intake Manifold Vacuum 3) Keep the engine at the idle speed, and then read
the vacuum gauge indication.
A: INSPECTION By observing the gauge needle movement, the in-
1) Warm-up the engine. ternal condition of engine can be diagnosed as de-
2) Disconnect the brake vacuum hose, and then in- scribed below.
stall the vacuum gauge to hose fitting on manifold.
H2M1767
Vacuum pressure (at idling, A/C “OFF”):

Less than −60.0 kPa (−450 mmHg, −17.72
inHg)
Diagnosis of engine condition by measurement of manifold vacuum
Vacuum gauge indication Possible engine condition
1. Needle is steady but lower than normal position. This ten- Leakage around intake manifold gasket or disconnection or
dency becomes more evident as engine temperature rises. damaged vacuum hose
2. When engine speed is reduced slowly from higher speed, Back pressure too high, or exhaust system clogged
needle stops temporarily when it is lowering or becomes steady
above normal position.
3. Needle intermittently drops to position lower than normal Leakage around cylinder
position.
4. Needle drops suddenly and intermittently from normal posi- Sticky valves
tion.
5. When engine speed is gradually increased, needle begins to Weak or broken valve springs
vibrate rapidly at certain speed, and then vibration increases as
engine speed increases.
6. Needle vibrates above and below normal position in narrow Defective ignition system or throttle chamber idle adjustment
range.
ME(TURBO)-25
ENGINE OIL PRESSURE
MECHANICAL
6. Engine Oil Pressure 5) After measuring the oil pressure, install the oil
pressure switch. <Ref. to LU-21, INSTALLATION,
A: INSPECTION Oil Pressure Switch.>
1) Remove the oil pressure switch from engine cyl-
Tightening torque:
inder block. <Ref. to LU-21, REMOVAL, Oil Pres-
25 N·m (2.5 kgf-m, 18.1 ft-lb)
sure Switch.>
2) Connect the oil pressure gauge hose to cylinder
block.
G6M0095
4) Start the engine, and then measure the oil pres-

sure.
S2M0242
Oil pressure:
98 kPa (1.0 kg/cm2, 14 psi) or more at 800 rpm
294 kPa (3.0 kg/cm2, 43 psi) or more at 5,000
rpm
CAUTION:
• If the oil pressure is out of specification,
check oil pump, oil filter and lubrication line.
<Ref. to LU-25, INSPECTION, Engine 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-25, 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(TURBO)-26
FUEL PRESSURE
MECHANICAL
7. Fuel Pressure 6) Measure the fuel pressure while disconnecting

the pressure regulator vacuum hose from intake
A: INSPECTION manifold.
WARNING: Fuel pressure:
Before removing the fuel pressure gauge, re- Standard; 284 — 314 kPa (2.9 — 3.2 kgf/cm2,
lease the fuel pressure. 41 — 46 psi)
NOTE:
If out of specification, check or replace the pressure
regulator and pressure regulator vacuum hose.
ERATION, Fuel.>
2) Open the fuel flap lid, and then remove the fuel
filler cap.
ter, and then connect the fuel pressure gauge.
S2M0554
7) After connecting the pressure regulator vacuum

hose, measure the fuel pressure.
Fuel pressure:
Standard; 230 — 260 kPa (2.35 — 2.65
kgf/cm2, 33 — 38 psi)
EN1117
4) Connect the connector of fuel pump relay.
S2M0554
NOTE:
The fuel pressure gauge registers 10 to 20 kPa (0.1
to 0.2 kgf/cm2, 1 to 3 psi) higher than standard val-
ues during high-altitude operations.
EN0344
ME(TURBO)-27
VALVE CLEARANCE
MECHANICAL
8. Valve Clearance 10) When inspecting the #2 and #4 cylinders:

(1) Disconnect the battery cable, and then re-
A: INSPECTION move the battery and battery carrier.
CAUTION:
Inspection and adjustment of the valve clear-
ance should be performed while engine is cold.
H6M0426
(2) Remove the bolt which secures engine har-

ness bracket onto body.
G6M0095
3) Remove the air intake duct. <Ref. to IN(TUR-

BO)-8, REMOVAL, Air Intake Duct.>
4) Remove the bolt which secures belt cover (RH).
7) Loosen the remaining bolts which secure belt
cover (RH), and then remove the belt cover. H6M0429
9) When inspecting the #1 and #3 cylinders: (3) Disconnect the washer motor connectors.
(1) Pull out the engine harness connector with
bracket from air cleaner upper cover.
H6M0430
(4) Remove the washer tank mounting bolts.

H2M1958
(2) Remove the air cleaner case. <Ref. to

IN(TURBO)-7, REMOVAL, Air Cleaner.>
plugs (#1 and #3 cylinders).
(4) Place a suitable container under the vehicle.
(5) Disconnect the PCV hose from rocker cover
(RH).
rocker cover (RH).
B6M0561
ME(TURBO)-28
VALVE CLEARANCE
MECHANICAL
(5) Move the washer tank upward. 12) Measure the #1 cylinder intake valve and #3
cylinder exhaust valve clearance by using thick-
ness gauge (A).
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: 0.20±0.02 mm (0.0079±0.0008 in)
H6M0431 Exhaust: 0.25±0.02 mm (0.0098±0.0008 in)
(6) Disconnect the spark plug cords from spark NOTE:
plugs (#2 and #4 cylinders). If the measured value is not within specification,
(7) Place a suitable container under the vehicle. take notes of the value in order to adjust the valve
(8) Disconnect the PCV hose from rocker cover clearance later on.
(LH).
rocker cover (LH).
11) Turn the crankshaft pulley clockwise until arrow
mark on the camshaft sprocket is set to position
NOTE:
Turn the crankshaft using ST.
B2M1234B
13) If necessary, adjust the valve clearance. <Ref.

to ME(TURBO)-30, ADJUSTMENT, Valve Clear-
ance.>
14) Further turn the crankshaft pulley clockwise.
Using the same procedures described previously,
and then measure the valve clearances again.
(1) Set the arrow mark on camshaft sprocket to
position shown in the figure, and then measure
S2M1192B the #2 cylinder exhaust valve and #3 cylinder in-
take valve clearances.
S2M1194B
ME(TURBO)-29
VALVE CLEARANCE
MECHANICAL
(2) Set the arrow mark on camshaft sprocket to B: ADJUSTMENT

the #2 cylinder intake valve and #4 cylinder ex- CAUTION:
haust valve clearances. Adjustment of the valve clearance should be
performed while engine is cold.
1) Measure all valve clearances. <Ref. to ME(TUR-
BO)-28, INSPECTION, Valve Clearance.>
NOTE:
Record each valve clearance after it has been
measured.
S2M1195B
(3) Set the arrow mark on camshaft sprocket to

the #1 cylinder exhaust valve and #4 cylinder in-
take valve clearances.
B2M1234
2) Remove the shim from valve lifter.

(1) Prepare the ST.
ST 498187200 SHIM REPLACER
S2M1196B
15) After inspection, install the related parts in the

reverse order of removal.
Tightening torque:
32 N·m (3.3 kgf-m, 24 ft-lb) H2M3622
(2) Rotate the notch of the valve lifter outward

by 45°.
EN0191
H2M1777A
ME(TURBO)-30
VALVE CLEARANCE
MECHANICAL
(3) Adjust the SHIM REPLACER notch to valve (6) Insert tweezers into the notch of valve lifter,
lifter and set it. and then take the shim out.
H2M3628 H2M3629
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 the bolt (A), and then install it to the
cylinder head.
(5) Tighten the bolt (B), and then insert the
valve lifter.
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(TURBO)-31
VALVE CLEARANCE
MECHANICAL
Part No. Thickness mm (in) Part No. Thickness mm (in)

13218 AK010 2.00 (0.0787) 13218 AF120 2.63 (0.1035)
13218 AK020 2.02 (0.0795) 13218 AF130 2.64 (0.1039)
13218 AK030 2.04 (0.0803) 13218 AF140 2.65 (0.1043)
13218 AK040 2.06 (0.0811) 13218 AF150 2.66 (0.1047)
13218 AK050 2.08 (0.0819) 13218 AF160 2.67 (0.1051)
13218 AK060 2.10 (0.0827) 13218 AF170 2.68 (0.1055)
13218 AK070 2.12 (0.0835) 13218 AF180 2.69 (0.1059)
13218 AK080 2.14 (0.0843) 13218 AF190 2.70 (0.1063)
13218 AK090 2.16 (0.0850) 13218 AF200 2.71 (0.1067)
13218 AK100 2.18 (0.0858) 13218 AF210 2.72 (0.1071)
13218 AK110 2.20 (0.0866) 13218 AF220 2.73 (0.1075)
13218 AE710 2.22 (0.0874) 13218 AF230 2.74 (0.1079)
13218 AE720 2.23 (0.0878) 13218 AF240 2.75 (0.1083)
13218 AE730 2.24 (0.0882) 13218 AF250 2.76 (0.1087)
13218 AE740 2.25 (0.0886) 13218 AF260 2.77 (0.1091)
13218 AE750 2.26 (0.0890) 13218 AF270 2.78 (0.1094)
13218 AE760 2.27 (0.0894) 13218 AF280 2.79 (0.1098)
13218 AE770 2.28 (0.0898) 13218 AF290 2.80 (0.1102)
13218 AE780 2.29 (0.0902) 13218 AF300 2.81 (0.1106)
13218 AE790 2.30 (0.0906) 13218 AK010 2.00 (0.0787)
13218 AE800 2.31 (0.0909) 13218 AK020 2.02 (0.0795)
13218 AE810 2.32 (0.0913) 13218 AK030 2.04 (0.0803)
13218 AE820 2.33 (0.0917) 13218 AK040 2.06 (0.0811)
13218 AE830 2.34 (0.0921) 13218 AK050 2.08 (0.0819)
13218 AE840 2.35 (0.0925) 13218 AK060 2.10 (0.0827)
13218 AE850 2.36 (0.0929) 13218 AK070 2.12 (0.0835)
13218 AE860 2.37 (0.0933) 13218 AK080 2.14 (0.0843)
13218 AE870 2.38 (0.0937) 13218 AK090 2.16 (0.0850)
13218 AE880 2.39 (0.0941) 13218 AK100 2.18 (0.0858)
13218 AE890 2.40 (0.0945) 13218 AK110 2.20 (0.0866)
13218 AE910 2.42 (0.0953) 6) Inspect all valves for clearance again at this
13218 AE920 2.43 (0.0957) stage. If the valve clearance is not correct, repeat
13218 AE930 2.44 (0.0961) the procedure over again from the first step.
13218 AE940 2.45 (0.0965) 7) After inspection, install the related parts in the
13218 AE950 2.46 (0.0969) reverse order of removal.
13218 AE960 2.47 (0.0972)
13218 AE970 2.48 (0.0976)
13218 AE980 2.49 (0.0980)
13218 AE990 2.50 (0.0984)
13218 AF000 2.51 (0.0988)
13218 AF010 2.52 (0.0992)
13218 AF020 2.53 (0.0996)
13218 AF030 2.54 (0.1000)
13218 AF040 2.55 (0.1004)
13218 AF050 2.56 (0.1008)
13218 AF060 2.57 (0.1012)
13218 AF070 2.58 (0.1016)
13218 AF080 2.59 (0.1020)
13218 AF090 2.60 (0.1024)
13218 AF100 2.61 (0.1028)
13218 AF110 2.62 (0.1031)
ME(TURBO)-32
ENGINE ASSEMBLY
MECHANICAL
9. Engine Assembly 9) Collect refrigerant, and then remove the pres-

sure 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 then support with (2) Collect the refrigerant from A/C system.
the hood stay. (3) Disconnect the A/C pressure hoses from
3) Raise the rear seat, and then turn the floor mat A/C compressor.
up.
(1) Disconnect the fuel pump relay connector.
S2M1584

EN0344
11) Disconnect the following connectors and cable.
(2) Start the engine, and run until stalls. (1) Engine harness connector
(3) After the engine stalls, crank it for 5 seconds
more.
(4) Turn the ignition switch to OFF.
5) Remove the filler cap.
S2M2260
(2) Engine ground terminal
G6M0095
7) Remove the radiator from vehicle. <Ref. to CO-

39, REMOVAL, Radiator.>
8) Remove the coolant filler tank. <Ref. to CO-53,
REMOVAL, Coolant Filler Tank.>
S2M0731
ME(TURBO)-33
ENGINE ASSEMBLY
MECHANICAL
(3) Engine harness connector 12) Disconnect the following hoses.

S2M1930
EN0204
(4) Generator connector, terminal and A/C
compressor connectors (2) Heater inlet outlet hose
B2M1291I EN0205
(A) A/C compressor connector

13) Remove the power steering pump from brack-
et.
(B) Generator connector and terminal
(1) Loosen the lock bolt and slider bolt, and
(5) Accelerator cable then remove the front side V-belt. <Ref. to
ME(TURBO)-44, FRONT SIDE BELT, REMOV-
AL, V-belt.>
(2) Disconnect the power steering switch con-
nector.
S2M1931
(6) Clutch release spring
EN0360
S2M1932
ME(TURBO)-34
ENGINE ASSEMBLY
MECHANICAL
(3) Remove the pipe with bracket from intake 16) Remove the center exhaust pipe. <Ref. to
manifold. EX(TURBO)-8, REMOVAL, Center Exhaust Pipe.>
transmission to engine.
EN0206
(4) Remove the power steering pump from en-

B3M2047
gine.
rubber onto front crossmember.
H2M1954
(5) Remove the power steering tank from

S2M1927
20) Separate the clutch release fork from release
bearing. (MT vehicles)
(1) Remove the clutch operating cylinder from
transmission.
(2) Remove the plug using a 10 mm hexagon
wrench.
EN0361
(6) Place the power steering pump on right side

wheel apron.
S2M1935
EN0208

15) Remove the ATF cooler pipe from frame. (AT
vehicles)
ME(TURBO)-35
ENGINE ASSEMBLY
MECHANICAL
(3) Screw the 6 mm dia. bolt into release fork 22) Remove the pitching stopper.
shaft, and remove it.
H3M1839

and evaporation hose.
CAUTION:
• Catch fuel from the hose into container.
• Disconnect the hose with its end wrapped
with cloth to prevent fuel from splashing.
S2M1936A
(A) Shaft
(B) Bolt
(4) Raise the release fork, and then unfasten

EN0214
the release bearing tabs to free release fork.
CAUTION: 24) Remove the fuel filter and bracket.
Step (4) is required to prevent interference with
engine when removing the engine from trans-
mission.
21) 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
G2M0818
engine using ST.
ST 499977300 CRANK PULLEY WRENCH 25) Support the engine with a lifting device and
wire ropes.
S2M0207
G2M0297
ME(TURBO)-36
ENGINE ASSEMBLY
MECHANICAL
26) Support the transmission with a garage jack. 28) Remove the engine from vehicle.
CAUTION: (1) Slightly raise the engine.
Before moving the engine away from transmis- (2) Raise the transmission with garage jack.
sion, check to be sure no work has been over- (3) Move the engine horizontally until the main-
looked. Doing this is very important in order to shaft is withdrawn from clutch cover.
facilitate re-installation and because transmis- (4) Slowly move the engine away from engine
sion lowers under its own weight. compartment.
CAUTION:
Be careful not to damage adjacent parts or
body panels with crank pulley, oil pressure
gauge, etc.
29) Remove the front cushion rubbers.
S2M1928
27) Separation of the engine and transmission.

(1) Remove the starter. <Ref. to SC-5, RE-
MOVAL, Starter.>
(2) Install the ST to torque converter clutch
case. (AT vehicles)
H2M1961A
(3) Remove the bolts which hold right upper

side of transmission to engine.
B3M2044
ME(TURBO)-37
ENGINE ASSEMBLY
MECHANICAL
B: INSTALLATION (4) Apply grease to the specified points.

1) Install the clutch release fork and bearing onto • Spline FX2200
transmission. (MT vehicles) • Shaft SUNLIGHT 2
(1) Remove the release bearing from clutch
cover with flat type screw driver.
S2M1843
(2) Install the release bearing on transmission.

(3) Install the release fork into release bearing
tab.
S2M1938A
(A) Spline (FX2200)

(B) Shaft (SUNLIGHT 2)
(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.
S2M1845A
(A) Release fork

(B) Release shaft
(C) Spring pin
ME(TURBO)-38
ENGINE ASSEMBLY
MECHANICAL
(6) Tighten the plug. 6) Remove the garage jack.

Tightening torque:
44 N·m (4.5 kgf-m, 32.5 ft-lb)
G2M0297

S2M1846
Tightening torque:
2) Install the front cushion rubbers to engine. T1: 50 N·m (5.1 kgf-m, 37 ft-lb)
T2: 58 N·m (5.9 kgf-m, 43 ft-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 then align it with the transmission.
CAUTION:
body panels with crank pulley, oil pressure
gauge, etc.
(2) Apply a small amount of grease to the
splines of mainshaft. (MT vehicles) H3M1839A
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 ft-lb) Be careful not to drop the ST into torque converter
clutch case when removing ST.
9) Install the starter. <Ref. to SC-6, INSTALLA-
TION, Starter.>
B2M2791
5) Remove the lifting device and wire ropes.
ME(TURBO)-39
ENGINE ASSEMBLY
MECHANICAL
10) Install the torque converter clutch onto drive (2) Install the power steering pump.
plate. (AT vehicles)
Tightening torque:
20.1 N·m (2.05 kgf-m, 14.8 ft-lb)
er clutch to drive plate.
(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.
Tightening torque:
25 N·m (2.5 kgf-m, 18.1 ft-lb)
H2M1954
(3) Install the power steering pipe bracket on

right side intake manifold, and then install the
spark plug cords.
S2M0207
(3) Clog the service hole with plug.

11) Install the fuel filter and bracket.
EN0206
(4) Connect the power steering switch connec-

tor.
G2M0818
12) Install the power steering pump on bracket.

EN0360
(5) Install the front side V-belt, and adjust it.

<Ref. to ME(TURBO)-45, FRONT SIDE BELT,
EN0361
ME(TURBO)-40
ENGINE ASSEMBLY
MECHANICAL
14) Tighten the nuts which hold lower side of trans- 21) Connect the following cables:
mission to engine. (1) Accelerator cable
Tightening torque: (2) Clutch release spring
50 N·m (5.1 kgf-m, 36.9 ft-lb) CAUTION:
After connecting each cable, adjust them.
22) Install the air intake system.
(1) Install the intercooler. <Ref. to IN(TURBO)-
11, INSTALLATION, Intercooler.>
(2) Install the air cleaner element and air clean-
er upper cover.
(3) Install the engine harness connector brack-
et.
(4) Install the filler hose to air cleaner case.
23) Install the A/C pressure hoses.
B2M2790
CAUTION:
15) Tighten the nuts which install front cushion rub- Use new O-rings.
ber onto crossmember.
Tightening torque:
Tightening torque: 25 N·m (2.5 kgf-m, 18.1 ft-lb)
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.
S2M1584
24) Install the radiator. <Ref. to CO-42, INSTALLA-

TION, Radiator.>
25) Install the coolant filler tank. <Ref. to CO-53,
B2M3880A INSTALLATION, Coolant Filler Tank.>
16) Install the ATF cooler pipe to frame. (AT vehi- 26) Install the window washer tank.
cles) 27) Install the battery in the vehicle, and connect
17) Install the center exhaust pipe. cables.
<Ref. to EX(TURBO)-9, INSTALLATION, Center 28) Fill coolant.
Exhaust Pipe.> <Ref. to CO-26, FILLING OF ENGINE COOLANT,
18) Lower the vehicle. REPLACEMENT, Engine Coolant.>
19) Connect the following hoses: 29) Charge the A/C system with refrigerant.
(1) Fuel delivery hose, return hose and evapo- <Ref. to AC-22, OPERATION, Refrigerant Charg-
ration hose ing Procedure.>
(2) Heater inlet and outlet hoses 30) Remove the front hood stay, and close the front
(3) Brake booster vacuum hose hood.
20) Connect the following connectors and termi- 31) Take off the vehicle from lift arms.
nals:
(1) Engine ground terminal
(3) Generator connector and terminal
(4) A/C compressor connectors
ME(TURBO)-41
ENGINE MOUNTING
MECHANICAL
10.Engine Mounting
A: REMOVAL
1) Remove the engine assembly. <Ref. to
ME(TURBO)-33, REMOVAL, Engine Assembly.>
2) Remove the engine mounting from engine as-
sembly.
B: INSTALLATION
Tightening torque:
Engine mounting;
34 N·m (3.5 kgf-m, 25.3 ft-lb)
C: INSPECTION
Make sure there are no cracks or other damage.
ME(TURBO)-42
MECHANICAL
11.Preparation for Overhaul

A: PROCEDURE
1) After removing the engine from body, secure it in
the ST shown below.
RH
LH
ST3 499817000 ENGINE STAND
S2M1876A
2) In this section the procedures described under

each index are all connected and stated in order. It
will be the complete procedure for overhauling of
the engine itself when you go through all steps in
the process.
Therefore, in this section, to conduct the particular
procedure within the flow of a section, you need to
go back and conduct the procedure described pre-
viously in order to do that particular procedure.
ME(TURBO)-43
V-BELT
MECHANICAL
12.V-belt 4) Remove the A/C belt tensioner.
A: REMOVAL
1. FRONT SIDE BELT
NOTE:
Perform the following procedures 1) to 4) with the
engine installed to body.
S2M0113
EN0048
2) Loosen the lock bolt (A).

4) Remove the front side belt (C).
(B)
(C)
(A)
EN0225
2. REAR SIDE BELT

(B)
(A)
EN0226
3) Remove the A/C belt.
ME(TURBO)-44
V-BELT
MECHANICAL
1) Replace the belts, if cracks, fraying or wear is
1. FRONT SIDE BELT found.
CAUTION: 2) Check the drive belt tension and adjust it if nec-
Wipe off any oil or water on the belt and pulley. essary by changing generator installing position
1) Install the belt (C), and tighten the slider bolt so and/or idler pulley installing position.
as to obtain the specified belt tension <Ref. to Belt tension
ME(TURBO)-45, INSPECTION, V-belt.> (A)
2) Tighten the lock bolt (A) replaced: 7 — 9 mm (0.276 — 0.354 in)
3) Tighten the slider bolt (B). reused: 9 — 11 mm (0.354 — 0.433 in)
Tightening torque: (B)*
Lock bolt through bolt: replaced: 7.5 — 8.5 mm (0.295 — 0.335 in)
25 N·m (2.5 kgf-m, 18.1 ft-lb) reused: 9.0 — 10.0 mm (0.354 — 0.394 in)
Slider bolt: *: with air conditioner
8 N·m (0.8 kgf-m, 5.5 ft-lb)
(B)
(C)
(A)
EN1179
EN0225
C/P Crankshaft pulley
2. REAR SIDE BELT GEN Generator
1) Install the belt, and tighten the slider bolt (B) so P/S Power steering oil pump pulley
as to obtain the specified belt tension. <Ref. to A/C Air conditioning compressor pulley
ME(TURBO)-45, INSPECTION, V-belt.> I/P Idler pulley
2) Tighten the lock nut (A).
Tightening torque:
Lock nut (A);
22.6 N·m (2.3 kgf-m, 16.6 ft-lb)
(B)
(A)
EN0226
ME(TURBO)-45
CRANKSHAFT PULLEY
MECHANICAL
13.Crankshaft Pulley 3) Confirm that the tightening angle of crankshaft

pulley bolt is 45 degrees or more. If not, conduct the
A: REMOVAL following procedures (1) through (4).
1) Remove the V-belt. <Ref. to ME(TURBO)-44, CAUTION:
REMOVAL, V-belt.> If the tightening angle of crankshaft pulley bolt
2) Remove the crankshaft pulley bolt. To lock the 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.
12369AA011
gun.
degrees.
H2M2393C
CAUTION:
3) Remove the crankshaft pulley. Conduct the tightening procedures by confirm-
B: INSTALLATION ing the turning angle of the crankshaft pulley
bolt referring to the gauge indicated on the belt
1) Install the crankshaft pulley.
cover.
2) Install the pulley bolt.
To lock the crankshaft, use ST. 4) Install the A/C belt tensioner.
WRENCH
(1) Clean the crankshaft pulley thread using an
air gun.
(2) Apply engine oil to the crankshaft pulley bolt
seat and thread.
(4) Tighten the crankshaft pulley bolts.
Tightening torque: S2M0113
127 N·m (13 kgf-m, 94.0 ft-lb) 5) Install the V-belt. <Ref. to ME(TURBO)-45, IN-
STALLATION, V-belt.>
C: INSPECTION
1) Make sure the V-belt is not worn or otherwise
damaged.
2) Check the tension of the belt. <Ref. to ME(TUR-
BO)-45, INSPECTION, V-belt.>
H2M2393A
ME(TURBO)-46
BELT COVER
MECHANICAL
14.Belt Cover
A: REMOVAL
1) Remove the V-belt. <Ref. to ME(TURBO)-44,
REMOVAL, V-belt.>
2) Remove the crankshaft pulley. <Ref. to
ME(TURBO)-46, REMOVAL, Crankshaft Pulley.>
3) Remove the belt cover (LH) (A).
4) Remove the belt cover (RH) (B).
5) Remove the front belt cover (C).
S2M1221A
B: INSTALLATION
1) Install the front belt cover (C).
Tightening torque:
5 N·m (0.5 kgf-m, 3.6 ft-lb)
2) Install the belt cover (RH) (B).
Tightening torque:
5 N·m (0.5 kgf-m, 3.6 ft-lb)
3) Install the belt cover (LH) (A).
Tightening torque:
5 N·m (0.5 kgf-m, 3.6 ft-lb)
S2M1221A
4) Install the crankshaft pulley. <Ref. to ME(TUR-

BO)-46, INSTALLATION, Crankshaft Pulley.>
5) Install the V-belt. <Ref. to ME(TURBO)-45, IN-
C: INSPECTION
Make sure the cover is not damaged.
ME(TURBO)-47
MECHANICAL
15.Timing Belt Assembly

A: REMOVAL
1. TIMING BELT
REMOVAL, V-belt.>
3) Remove the belt cover. <Ref. to ME(TURBO)-
47, REMOVAL, Belt Cover.> EN0259
4) Remove the timing belt guides. (MT vehicles) 5) If the alignment mark and/or arrow mark (which
indicates rotation direction) on timing belt fade
away, put new marks before removing the timing
belt as follows:
(1) Turn the crankshaft using ST, and align the
alignment marks on crankshaft sprocket, intake
camshaft sprocket (LH), exhaust camshaft
sprocket (LH), intake camshaft sprocket (RH)
and exhaust camshaft sprocket (RH) with notch-
es of belt cover and cylinder block.
S2M0294
S2M1878A
EN0257
EN0258
ME(TURBO)-48
MECHANICAL
(2) Using white paint, put alignment and/or ar- 7) Remove the timing belt.
row marks on the timing belts in relation to the CAUTION:
sprockets. 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).
EN0233
S2M1226A
2) Remove the belt idler No. 2.

S2M1225

Z2: 51 tooth length
Z3: 28 tooth length
S2M0411
3) Remove the automatic belt tension adjuster as-

sembly.
S2M1223A
6) Remove the belt idler (A).
S2M0412
S2M1226A
ME(TURBO)-49
MECHANICAL
B: INSTALLATION 2) Install the automatic belt tension adjuster as-

sembly.
ER ASSEMBLY AND BELT IDLER Tightening torque:
39 N·m (4.0 kgf-m, 28.9 ft-lb)
sion adjuster assembly:
CAUTION:
• Push the adjuster rod vertically.
• Be sure to slowly move the adjuster rod down
applying a pressure of 294 N (30 kgf, 66 lb).
ing more than 3 minutes. S2M0416
• Do not allow press pressure to exceed 9,807 3) Install the belt idler No. 2.
N (1,000 kgf, 2,205 lb).
• Press the adjuster rod as far as the end sur- Tightening torque:
face of cylinder. Do not press the adjuster rod 39 N·m (4.0 kgf-m, 28.9 ft-lb)
into the cylinder. Doing so may damage the cyl-
inder.
• 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 lb) until the adjust-
er rod is aligned with the stopper pin hole in the
cylinder.
S2M0411
4) Install the belt idler.

Tightening torque:
39 N·m (4.0 kgf-m, 28.9 ft-lb)
H2M2382
(3) With a 2 mm (0.08 in) dia. stopper pin or a 2

mm (0.08 in) (nominal) dia. hex bar wrench in-
serted into the stopper pin hole in the cylinder,
secure the adjuster rod. S2M0410
H2M2383
ME(TURBO)-50
MECHANICAL
2. TIMING BELT (4) Align single line mark (A) on exhaust cam-
shaft sprocket (LH) with notch (B) on belt cover
by turning the sprocket counterclockwise (as
sion adjuster assembly. <Ref. to ME(TURBO)-50,
viewed from front of engine).
AUTOMATIC BELT TENSION ADJUSTER AS-
SEMBLY AND BELT IDLER, Timing Belt Assem-
bly.>
2) Crankshaft and camshaft sprocket alignment.
(1) Align mark (A) on the crankshaft sprocket
with mark on the oil pump cover at cylinder
block.
(A)
S2M1229B
(5) Align the single line mark (A) on intake cam-

shaft sprocket (LH) with notch (B) on belt cover
by turning the sprocket clockwise (as viewed
from front of engine).
Ensure the double lines (C) on intake and ex-
EN0243 haust camshaft sprockets are aligned.
(2) Align single line mark (A) on the exhaust
camshaft sprocket (RH) with notch (B) on belt
cover.
S2M1230B
S2M1227B
(3) Align single line mark (A) on the intake cam-

shaft sprocket (RH) with notch (B) on belt cover.
(Make sure double lines (C) on intake camshaft
and exhaust camshaft sprockets are aligned.)
S2M1228B
ME(TURBO)-51
MECHANICAL
(6) Ensure the camshaft and crankshaft sprock- • When the timing belts are not installed, four
ets are positioned properly. camshafts are held at the “zero-lift” position,
CAUTION: where all cams on camshafts do not push the
• Intake and exhaust camshafts for this DOHC intake and exhaust valves down. (Under this
engine can be independently rotated with the condition, all valves remain unlifted.)
timing belts removed. As can be seen from the • When the camshafts are rotated to install the
figure, if the intake and exhaust valves are lifted timing belts, #2 intake and #4 exhaust cam of
simultaneously, their heads will interfere with left-hand camshafts are held to push their cor-
each other, resulting in bent valves. 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.
B2M1392B
(A) Intake camshaft

(B) Exhaust camshaft
S2M1231A
ME(TURBO)-52
MECHANICAL
3) Installation of timing belt:
S2M0418
Align the alignment mark on timing belt with marks on sprockets in alphabetical order shown in the figure.
While aligning marks, position the timing belt properly.
CAUTION:
• Disengagement of more than three timing belt teeth may result in interference between the valve
and piston.
• Ensure the belt’s rotating direction is correct.
S2M1232A
ME(TURBO)-53
MECHANICAL
4) Install the belt idlers.

Tightening torque:
39 N·m (4.0 kgf-m, 28.9 ft-lb)
CAUTION:
Make sure that the marks on the timing belt and
sprockets are aligned.
EN0255
H2M2398
5) After ensuring that the marks on the timing belt

and sprockets are aligned, remove the stopper pin
from tensioner adjuster.
6) Install the timing belt guide. (MT vehicles) EN0256
(1) Temporarily tighten the remaining bolts. (3) Tighten the remaining bolts.
(2) Check and adjust the clearance between
timing belt and timing belt guide. Tightening torque:
10 N·m (1.0 kgf-m, 7.2 ft-lb)
Clearance:
1.0±0.5 mm (0.039±0.020 in)
S2M0294
S2M0297
EN0257
EN0254
ME(TURBO)-54
MECHANICAL
C: INSPECTION
1. TIMING BELT
1) Check the timing belt teeth for breaks, cracks,
and wear. If any fault is found, replace the belt.
2) Check the condition of back side of belt; if any
crack is found, replace the belt.
CAUTION:
• Be careful not to let oil, grease or coolant
EN0258 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
EN0259
7) Install the belt cover. <Ref. to ME(TURBO)-47,

INSTALLATION, Belt Cover.>
8) Install the crankshaft pulley. <Ref. to ME(TUR- G2M0115
BO)-46, REMOVAL, Crankshaft Pulley.>
9) Install the V-belt. <Ref. to ME(TURBO)-45, IN- 2. AUTOMATIC BELT TENSION ADJUST-
STALLATION, V-belt.> ER
1) Visually check the oil seals for leaks, and rod
ends for abnormal wear or scratches. If necessary,
replace the automatic belt tension adjuster assem-
bly.
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 lb) is applied to it.
This is to check adjuster rod stiffness.
ME(TURBO)-55
MECHANICAL
3) If the adjuster rod is not stiff and moves freely 4. BELT IDLER
when applying 294 N (30 kgf, 66 lb), check it using
1) Check the idler for smooth rotation. Replace if
the following procedures:
noise or excessive play is noted.
(1) Slowly press the adjuster rod down to the
2) Check the outer contacting surfaces of idler pul-
end surface of the cylinder. Repeat this motion 2
ley for abnormal wear and scratches.
or 3 times.
3) Check the idler for grease leakage.
(2) With the adjuster rod moved all the way up,
apply a pressure of 294 N (30 kgf, 66 lb) to it.
Check the adjuster rod stiffness.
(3) If the the adjuster rod is not stiff and moves
down, replace the automatic belt tension adjust-
er assembly with a new one.
CAUTION:
• Push the adjuster rod vertically.
ing more than 3 minutes.
• Do not allow press pressure to exceed 9,807
N (1,000 kgf, 2,205 lb).
• Press the adjuster rod as far as the end sur-
face of the cylinder. Do not press the adjuster
rod into the cylinder. Doing so may damage the
cylinder.
4) Measure the extension of rod beyond the body.
If it is not within specifications, replace with a new
one.
Rod extension: H
5.7±0.5 mm (0.224±0.020 in)
H2M2381A
3. BELT TENSION PULLEY

1) Check the mating surfaces of timing belt and
contact point of adjuster rod for abnormal wear or
scratches. Replace the belt tension pulley if faulty.
2) Check the belt tension pulley for smooth rota-
tion. Replace if noise or excessive play is noted.
3) Check the belt tension pulley for grease leakage.
ME(TURBO)-56
CAMSHAFT SPROCKET
MECHANICAL
16.Camshaft Sprocket B: INSTALLATION

1) Install the camshaft sprocket No. 1. and No. 2.
A: REMOVAL To lock the camshaft, use ST.
1) Remove the V-belt. <Ref. to ME(TURBO)-44, ST 18231AA010 CAMSHAFT SPROCKET
REMOVAL, V-belt.> WRENCH (Intake LH)
2) Remove the crankshaft pulley. <Ref. to ST 499207400 CAMSHAFT SPROCKET
ME(TURBO)-46, REMOVAL, Crankshaft Pulley.> WRENCH (Except Intake LH)
47, REMOVAL, Belt Cover.> Tightening torque:
4) Remove the timing belt assembly. <Ref. to 98 N·m (10 kgf-m, 72.4 ft-lb)
ME(TURBO)-48, REMOVAL, Timing Belt Assem- CAUTION:
bly.> Do not confuse the right and left side camshaft
5) Remove the camshaft position sensor. <Ref. to sprockets during installation. The camshaft
FU(TURBO)-31, REMOVAL, Camshaft Position sprocket No. 2 is identified by a projection used
Sensor.> to monitor camshaft position sensor.
6) Remove the camshaft sprockets. To lock the
camshaft, use ST.
WRENCH (Intake LH)
WRENCH (Except Intake LH)
ST
EN1320
ST 2) Install the camshaft position sensor. <Ref. to

FU(TURBO)-31, INSTALLATION, Camshaft Posi-
tion Sensor.>
3) Install the timing belt assembly. <Ref. to
EN1320 ME(TURBO)-50, INSTALLATION, Timing Belt As-
sembly.>
C: INSPECTION
scratches.
et and key.
3) Check the crankshaft sprocket notch used for
sensor for damage and contamination of foreign
matter.
ME(TURBO)-57
CRANKSHAFT SPROCKET
MECHANICAL
17.Crankshaft Sprocket B: INSTALLATION

1) Install the crankshaft sprocket.
A: REMOVAL
REMOVAL, V-belt.>
47, REMOVAL, Belt Cover.>
4) Remove the timing belt assembly. <Ref. to
ME(TURBO)-48, REMOVAL, Timing Belt Assem-
bly.>
5) Remove the camshaft sprocket. <Ref. to EN0263
ME(TURBO)-57, REMOVAL, Camshaft Sprocket.>
6) Remove the crankshaft sprocket. 2) Install the camshaft sprocket. <Ref. to ME(TUR-
BO)-57, INSTALLATION, Camshaft Sprocket.>
ME(TURBO)-50, INSTALLATION, Timing Belt As-
sembly.>
EN0263
C: INSPECTION
scratches.
et and key.
3) Check the crankshaft sprocket notch used for
sensor for damage and contamination of foreign
matter.
ME(TURBO)-58
CAMSHAFT
MECHANICAL
18.Camshaft 11) Remove the spark plug cord.

12) Remove the rocker cover and gasket.
A: REMOVAL 13) Loosen the intake camshaft cap bolts equally, a
1) Remove the V-belt. <Ref. to ME(TURBO)-45, little at a time in alphabetical sequence shown in
INSTALLATION, V-belt.> the figure.
bly.>
5) Remove the camshaft sprocket. <Ref. to
6) Remove the crankshaft sprocket. <Ref. to
ME(TURBO)-58, REMOVAL, Crankshaft Sprock- S2M1233A
et.> 14) Remove the camshaft caps and intake cam-
7) Remove the belt cover No.2 (RH). shaft.
15) Loosen the exhaust camshaft cap bolts equal-
ly, a little at a time in alphabetical sequence shown
in the figure.
B2M0738
S2M1234A
16) Remove the camshaft caps and exhaust cam-

shaft.
CAUTION:
Arrange the camshaft caps in order so that they
can be installed in their original positions.
17) Similarly, remove the camshafts (RH) and re-
lated parts.
S2M1163
S2M1162
10) Remove the oil level gauge guide. (LH side

only)
ME(TURBO)-59
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.
• Camshaft (RH) need not be rotated when set
at the position shown in the figure.
Intake camshaft (LH): Rotate 80°° clockwise.
Exhaust camshaft (LH): Rotate 45°° counter-
clockwise.
S2M1839A
(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:
T1: 10 N·m (1.0 kgf-m, 7.2 ft-lb)
T2: 20 N·m (2.0 kgf-m, 14.5 ft-lb)
T2
(A) (E) (C)
T1
(F) (D)
(B)
B2M1200B
A Left side cylinder head

B Right side cylinder head EN1321
(a) Intake camshaft (4) Similarly, tighten the cap on exhaust side.
(b) Exhaust camshaft After tightening the cap, ensure the camshaft ro-
tates only slightly while holding it at “base” circle.
Tightening torque:
T1: 10 N·m (1.0 kgf-m, 7.2 ft-lb)
T2: 20 N·m (2.0 kgf-m, 14.5 ft-lb)
ME(TURBO)-60
CAMSHAFT
MECHANICAL
3) Camshaft oil seal installation: 7) Install the belt cover No. 2 (RH).
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
B2M0738

Tightening torque:
S2M1880A
25 N·m (2.5 kgf-m, 18.1 ft-lb)
4) Rocker cover installation:
(1) Install the gasket on rocker cover.
Install the peripheral gasket and ignition coil
gasket.
(2) Apply fluid packing to the four front open
edges of peripheral gasket.
Fluid packing:
S2M1163
9) Install the belt cover No. 2 (LH).

Tightening torque:
5 N·m (0.5 kgf-m, 3.6 ft-lb)
S2M0300B
(3) Install the rocker cover on cylinder head.

Ensure the gasket is properly positioned during
installation.
5) Install the spark plug cord.
6) Similarly, install the parts on right-hand side.
S2M1162
10) Install the crankshaft sprocket. <Ref. to

ME(TURBO)-58, INSTALLATION, Crankshaft
Sprocket.>
11) Install the camshaft sprockets. <Ref. to
ME(TURBO)-57, INSTALLATION, Camshaft
Sprocket.>
sembly.>
ME(TURBO)-61
CAMSHAFT
MECHANICAL
14) Install the crankshaft pulley. <Ref. to ME(TUR- C: INSPECTION

BO)-46, INSTALLATION, Crankshaft Pulley.> 1) Measure the bend, and repair or replace if nec-
15) Install the V-belt. <Ref. to ME(TURBO)-45, IN- essary.
Limit:
0.020 mm (0.0008 in)
G2M0746
2) Check the journal for damage and wear. Re-

place if faulty.
3) Measure the outside diameter of camshaft jour-
nal. If the jounal diameter is not as specified, check
the oil clearance.
Camshaft journal
Front Center, rear
37.946 — 37.9635 mm 29.946 — 29.963 mm
Standard
(1.4939 — 1.4946 in) (1.1790 — 1.1796 in)
4) Measurement of the camshaft journal oil clear-

ance:
(1) Clean the bearing caps and camshaft jour-
nals.
(2) Place the camshafts on cylinder head.
(Without installing the valve rocker.)
(3) Place a plastigauge across each of the cam-
shaft journals.
(4) Gradually tighten the cap in at least two
stages in alphabetical sequence shown in the
figure, and then tighten to specified torque.
Tightening torque:
T1: 10 N·m (1.0 kgf-m, 7.2 ft-lb)
T2: 20 N·m (2.0 kgf-m, 14.5 ft-lb)
T2
(A) (E) (C)
T1
(F) (D)
(B)
EN1321
CAUTION:
Do not turn the camshaft.
ME(TURBO)-62
CAMSHAFT
MECHANICAL
(5) Remove the bearing caps. 6) Measure the thrust clearance of camshaft with
(6) Measure the widest point of plastigauge on dial gauge. If the clearance exceeds the limit, re-
each journal. place the caps and cylinder head as a set. If neces-
If the oil clearance exceeds the limit, replace the sary replace the camshaft.
camshaft. If necessary, replace the camshaft Standard:
caps and cylinder head as a set.
0.015 — 0.070 mm (0.0006 — 0.0028 in)
Standard:
Limit:
0.037 — 0.072 mm (0.0015 — 0.0028 in)
0.1 mm (0.004 in)
Limit:
0.10 mm (0.0039 in)
B2M1217
B2M1216
(7) Completely remove the plastigauge.

5) Check the cam face condition; remove the minor
faults by grinding with oil stone. Measure the cam
height H; replace if the limit has been exceeded.
Cam height: H
Standard:
Intake:
46.25 — 46.35 mm (1.821 — 1.825 in)
Exhaust:
46.15 — 46.25 mm (1.817 — 1.821 in)
Limit:
Intake:
46.15 mm (1.817 in)
Exhaust:
46.05 mm (1.813 in)
Cam base circle diameter A:
37.0 mm (1.457 in)
B2M1209A
ME(TURBO)-63
MECHANICAL
19.Cylinder Head Assembly 10) While tapping the cylinder head with a plastic
A: REMOVAL Remove the bolts (A) and (D) to remove cylinder
1) Remove the V-belt. <Ref. to ME(TURBO)-44, head.
REMOVAL, V-belt.>
bly.>
6) Remove the intake manifold. <Ref. to FU(TUR- B2M1397C
BO)-15, REMOVAL, Intake Manifold.> 11) Remove the cylinder head gasket.
7) Remove the bolt which installs A/C compressor
bracket on cylinder head. CAUTION:
8) Remove the camshaft. <Ref. to ME(TURBO)-59, Do not scratch the mating surface of cylinder
REMOVAL, Camshaft.> head and cylinder block.
9) Remove the cylinder head bolts in alphabetical 12) Similarly, remove the right side cylinder head.
sequence shown in the figure. B: INSTALLATION
CAUTION: 1) Install the cylinder head and gaskets on cylinder
Leave bolts (A) and (D) engaged by three or block.
four threads to prevent the cylinder head from CAUTION:
falling. • 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 the washers and
bolt threads.
(2) Tighten all bolts to 29 N·m (3.0 kgf-m, 22 ft-
lb) in alphabetical sequence.
Then tighten all bolts to 69 N·m (7.0 kgf-m, 51 ft-
lb) in alphabetical sequence.
B2M1397C
(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).
B2M1397D
ME(TURBO)-64
MECHANICAL
(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.
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.
B2M1397D • 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(TURBO)-60,
INSTALLATION, Camshaft.> S2M1881A
4) Install the A/C compressor bracket on cylinder
head.
5) Install the intake manifold. <Ref. to FU(TURBO)-
18, INSTALLATION, Intake Manifold.>
6) Install the camshaft sprocket. <Ref. to ME(TUR-
BO)-57, INSTALLATION, Camshaft Sprocket.>
sembly.>
ME(TURBO)-65
MECHANICAL
D: ASSEMBLY
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 (10) Shim
ME(TURBO)-66
MECHANICAL
1) Installation of valve spring and valve: CAUTION:

(1) Coat the stem of each valve with engine oil Uneven torque for the cylinder head nuts can
and insert the valve into valve guide. cause warping. When reassembling, pay spe-
CAUTION: cial attention to the torque so as to tighten
When inserting the valve into valve guide, use evenly.
special care not to damage the oil seal lip.
(2) Set the cylinder head on ST1.
(3) Install the valve spring and retainer using
ST2.
ST2 499718000 VALVE SPRING REMOVER
CAUTION:
Be sure to install the valve springs with their
close-coiled end facing the seat on the cylinder
head. S2M1840A
2. VALVE SEAT
Inspect the intake and exhaust valve seats, and
then correct the contact surfaces with valve seat
cutter if they are defective or when valve guides are
replaced.
Valve seat width: W
Intake
Standard
S2M1881A 1.0 mm (0.039 in)
Limit
(4) Compress the valve spring, and then fit the 1.7 mm (0.067 in)
valve spring retainer key. Exhaust
(5) After installing, tap the valve spring retainers Standard
lightly with wooden hammer for better seating. 1.5 mm (0.059 in)
2) Apply oil to the surface of the valve lifter and Limit
valve shim. 2.2 mm (0.087 in)
3) Install the valve lifter and valve shim.
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).
G2M0761
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)
ME(TURBO)-67
MECHANICAL
3. VALVE GUIDE (3) Turn the cylinder head upside down and
place ST as shown in the figure.
1) Check the clearance between valve guide and
stem. The clearance can be checked by measuring ST 498767700 VALVE GUIDE ADJUSTER
the outside diameter of valve stem and the inside
diameter of valve guide with outside and inside mi-
crometers respectively.
Clearance between the valve guide and valve
stem:
Standard
Intake
0.035 — 0.062 mm (0.0014 — 0.0024 in)
Exhaust
0.040 — 0.067 mm (0.0016 — 0.0026 in) G2M0763
Limit
(4) Before installing a new valve guide, make
0.15 mm (0.0059 in) sure that neither scratches nor damages exist
2) If the clearance between valve guide and stem on the inside surface of the valve guide holes in
exceeds the limit, replace the valve guide or valve cylinder head.
itself whichever shows greater amount of wear. (5) Put a new valve guide, coated with sufficient
See the following procedure for valve guide re- oil, in cylinder, and insert ST1 into valve guide.
placement. Press in until the valve guide upper end is flush
Valve guide inner diameter: with the upper surface of ST2.
6.000 — 6.012 mm (0.2362 — 0.2367 in) ST1 499767200 VALVE GUIDE REMOVER
ST2 498267700 VALVE GUIDE ADJUSTER
Valve stem outer diameters:
Intake
5.950 — 5.965 mm (0.2343 — 0.2348 in)
Exhaust
5.945 — 5.960 mm (0.2341 — 0.2346 in)
(1) Place the cylinder head on ST1 with the
combustion chamber upward so that valve
guides enter the holes in ST1.
(2) Insert the ST2 into valve guide and press it
down to remove the valve guide.
ST1 498267600 CYLINDER HEAD TABLE S2M1883A
ST2 499767200 VALVE GUIDE REMOVER (6) Check the valve guide protrusion.
Valve guide protrusion: L
12.0 — 12.4 mm (0.472 — 0.488 in)
(7) Ream the inside of valve guide with ST.
Gently rotate the reamer clockwise while 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
S2M1882A
CAUTION:
• Apply engine oil to the reamer when reaming.
• If the inner surface of the valve guide is torn,
the edge of the reamer should be slightly
ground with an oil stone.
• If the inner surface of the valve guide be-
comes lustrous and the reamer does not chips,
use a new reamer or remedy the reamer.
ME(TURBO)-68
MECHANICAL
(8) Recheck the contact condition between 5. VALVE SPRINGS

valve and valve seat after replacing the valve
1) Check the valve springs for damage, free length,
guide.
and tension. Replace the valve spring if it is not
4. INTAKE AND EXHAUST VALVE within specifications presented in the table.
2) To measure the squareness of valve spring,
1) Inspect the flange and stem of valve, and re-
stand the spring on a surface plate and measure its
place if damaged, worn, or deformed, or if “H” is
deflection at the top using a try square.
less than the specified limit.
Valve spring
H:
Intake
Standard 205.0 — 236.4 N
(20.9 — 24.1 kgf, 46.1 — 53.1 lb)
1.2 mm (0.047 in)
Tension/spring /36.0 mm (1.417 in)
Limit
height 485.4 — 536.4 N
0.8 mm (0.031 in)
(49.5 — 54.7 kgf, 109.2 — 120.6 lb)
Exhaust /26.6 mm (1.047 in)
Standard Squareness 2.5°, 2.0 mm (0.079 in)
1.5 mm (0.059 in)
Limit
0.8 mm (0.031 in)
Valve overall length:
Intake
104.4 mm (4.110 in)
Exhaust
104.7 mm (4.122 in)
G2M0154
G2M0153
2) Put a small amount of grinding compound on the

seat surface and lap the valve and seat surface. In-
stall a new intake valve oil seal after lapping.
ME(TURBO)-69
MECHANICAL
6. INTAKE AND EXHAUST VALVE OIL 3) Measure the inner diameter of valve lifter mating
SEAL part on cylinder head.
Replace the oil seal with a new one, if the lip is Inner diameter:
damaged or spring out of place, or when the surfac- 34.994 — 35.016 mm (1.3777 — 1.3786 in)
es of intake valve and valve seat are reconditioned
or intake valve guide is replaced.
1) Place the cylinder head on ST1.
2) Press in the oil seal to the specified dimension
indicated in the figure by using ST2.
ST2 498857100 VALVE GUIDE REMOVER
CAUTION:
• Apply engine oil to oil seal before force-fit-
ting. B2M1400
• Differentiate between the intake valve oil seal
and exhaust valve oil seal by noting their dif-
CAUTION:
ference in color.
If difference between outer diameter of valve
Color of rubber part: lifter and inner diameter of valve lifter mating
Intake [Black] part is over the limit, replace the cylinder head.
Exhaust [Brown] Standard:
Color of spring part: 0.019 — 0.057 mm (0.0007 — 0.0022 in)
Intake [Silver] Limit:
Exhaust [Silver]
0.100 mm (0.0039 in)
S2M1924A
7. VALVE LIFTER
1) Check the valve lifter visually.
2) Measure the outer diameter of valve lifter.
Outer diameter:
34.959 — 34.975 mm (1.3763 — 1.3770 in)
B2M1222
ME(TURBO)-70
CYLINDER BLOCK
MECHANICAL
20.Cylinder Block 16) Remove the oil cooler.
A: REMOVAL
NOTE:
Before conducting this procedure, drain the engine
oil completely if applicable.
REMOVAL, V-belt.>
bly.>
7) Remove the crankshaft sprocket. <Ref. to
ME(TURBO)-58, REMOVAL, Crankshaft Sprock-
et.>
8) Remove the generator and A/C compressor with S2M1835B
their brackets.
9) Remove the cylinder head assembly. <Ref. to (a) Gasket
ME(TURBO)-64, REMOVAL, Cylinder Head As- (b) Oil cooler
sembly.> (c) Connector
10) Remove the clutch disc and cover. (MT vehi-
cles) <Ref. to CL-20, REMOVAL, Clutch Disc and 17) Removal of oil pan:
Cover.> (1) Turn the cylinder block with #2 and #4 piston
sides facing upward.
11) Remove the flywheel. (MT vehicles) <Ref. to
CL-24, REMOVAL, Flywheel.> (2) Remove the bolts which secure oil pan to
12) Remove the drive plate. (AT vehicles) cylinder block.
Using the ST, lock crankshaft. (3) Insert a oil pan cutter blade between cylin-
der block-to-oil pan clearance, and then remove
the oil pan.
CAUTION:
Do not use a screwdriver or similar tool in place
of oil pan cutter.
ST
EN1118
13) Remove the oil separator cover.

14) Remove the water by-pass pipe for heater.
15) Remove the oil filter.
S2M1820
18) Remove the oil strainer stay.

21) Remove the water pipes.
22) Remove the water pump.
ME(TURBO)-71
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
S2M1819
EN0294
(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 hexagon wrench [14 mm (0.55 tons to bottom dead center position, and then re-
in)]. move the piston circlip through service hole of #1
and #2 cylinders.
B2M2620
G2M0165
ME(TURBO)-72
CYLINDER BLOCK
MECHANICAL
26) Draw out the piston pin from #1 and #2 pistons 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
CAUTION: on the side of #2 and #4 cylinders.
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.
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 cylinder blocks (LH) and (RH).
CAUTION:
When separating the cylinder block, do not al-
low the connecting rod to fall and damage the
cylinder block.
G2M0166
B2M2408A
(1) Cylinder block (3) Crankshaft (5) Piston

(2) Rear oil seal (4) Crankshaft bearing
32) Remove the rear oil seal. lip.
33) Remove the crankshaft together with connect- 35) Draw out each piston from cylinder block using
ing rod. a wooden bar or hammer handle.
34) Remove the crankshaft bearings from cylinder
CAUTION:
block using a hammer handle.
Do not confuse the combination of piston and
CAUTION: cylinder.
Do not confuse the combination of crankshaft
bearings.
Press the bearing at the end opposite to locking
ME(TURBO)-73
CYLINDER BLOCK
MECHANICAL
B: INSTALLATION
B2M2407A
(1) Crankshaft bearing (4) Rear oil seal Tightening torque: N·m (kgf-m, ft-lb)
(2) Crankshaft T1: 25 (2.5, 18.1)
(3) Cylinder block T2: 47 (4.8, 34.7)
CAUTION:
Remove oil in the mating surface of bearing and
cylinder block before installation. Also apply a
coat of engine oil to crankshaft pins.
1) Position the crankshaft on #2 and #4 cylinder
block.
2) Apply fluid packing to the mating surface of #1
and #3 cylinder block, and position it on #2 and #4
cylinder block.
Fluid packing: S2M1826A
CAUTION:
Do not allow fluid packing to jut into O-ring
grooves, oil passages, bearing grooves, etc.
ME(TURBO)-74
CYLINDER BLOCK
MECHANICAL
3) Temporarily tighten the 10 mm cylinder block 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
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 ft-lb) 7) Position the top ring gap at (A) or (B) in the fig-
ure.
8) Position the second ring gap at 180° on the re-
verse side for the top ring gap.
(A) (B)
B2M0088D
5) Tighten the 8 mm and 6 mm cylinder block con-

necting bolts in alphabetical sequence shown in the EN1509
figure.
9) Position the expander gap at (C) in the figure.
Tightening torque:
(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)
(C) EN1510
B2M0089F
ME(TURBO)-75
CYLINDER BLOCK
MECHANICAL
10) Position the lower rail gap at (D) in the figure. 12) Install the circlip.
Install the circlips in piston holes located opposite
of service holes in cylinder block, when positioning
all pistons in the corresponding cylinders.
NOTE:
Use new circlips.
(D)
EN1511
NOTE:
Align lower rail spin stopper (F) with piston side sur-
face hole (E).
B2M1403A
CAUTION:
Piston front mark faces towards the front of the
engine.
B2M4601A
11) Position the upper rail gap at (G) in the figure. (A)
EN1513
(A) Front mark
(G)
EN1512
CAUTION:
• Ensure ring gaps do not face the same direc-
tion.
• Ensure ring gaps are not within the piston
skirt area.
ME(TURBO)-76
CYLINDER BLOCK
MECHANICAL
B2M1322J
(1) Piston (4) Gasket Tightening torque: N·m (kgf-m, ft-lb)

(2) Piston pin (5) Service hole plug T: 69 (7.0, 50.6)
(3) Circlip
13) Installing the piston: 14) Installing piston pin:
(1) Turn the cylinder block so that #1 and #2 cyl- (1) Insert the ST3 into service hole to align pis-
inders face upward. ton pin hole with connecting rod small end.
(2) Using the ST1, turn the crankshaft so that CAUTION:
#1 and #2 connecting rods are set at bottom Apply a coat of engine oil to ST3 before inser-
dead center. tion.
ST1 499987500 CRANKSHAFT SOCKET
ST3 499017100 PISTON PIN GUIDE
(3) Apply a coat of engine oil to the pistons and
cylinders and insert pistons in their cylinders us-
ing ST2.
ST2 398744300 PISTON GUIDE
G2M0189
(2) Apply a coat of engine oil to the piston pin

and insert piston pin into piston and connecting
S2M0306A rod through service hole.
ME(TURBO)-77
CYLINDER BLOCK
MECHANICAL
(3) Install the circlip.

CAUTION:
Use new circlips.
S2M1828
(4) Apply fluid packing around the service hole

plug.
Fluid packing:
B2M2625
(5) Install the service hole plug and gasket.

CAUTION:
Use a new gasket.
B2M2620
ME(TURBO)-78
CYLINDER BLOCK
MECHANICAL
B2M1323K
(1) 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 the matching surfaces,
inders face upward. Using the same procedures and then install the oil pan.
as used for #1 and #2 cylinders, install the pis-
Fluid packing:
tons and piston pins.
16) Install the baffle plate.
Tightening torque:
6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
17) Install the oil strainer and O-ring
Tightening torque:
10 N·m (1.0 kgf-m, 7 ft-lb)
18) Install the oil strainer stay.
S2M1833A
ME(TURBO)-79
CYLINDER BLOCK
MECHANICAL
20) Apply fluid packing to the matching surfaces, (2) Apply fluid packing to the matching surface
and then install the oil separator cover. of oil pump.
Fluid packing: Fluid packing:
THREE BOND 1215 or equivalent THREE BOND 1215 or equivalent
S2M1834A B2M0390B
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
oil seal.
Tightening torque:
72 N·m (7.3 kgf-m, 52.8 ft-lb)
S2M0118B
ST
EN1118 (4) Install the oil pump on cylinder block. Be
careful not to damage the oil seal during instal-
22) Install the flywheel. (MT vehicles) <Ref. to CL- lation.
24, INSTALLATION, Flywheel.>
23) Install the clutch disc and cover. (MT vehicles) Tightening torque:
<Ref. to CL-20, INSTALLATION, Clutch Disc and 6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
Cover.> CAUTION:
24) Installation of oil pump: • Do not forget to install the O-ring and seal
(1) Discard the front oil seal after removal. Re- when installing the oil pump.
place with a new one using the ST. • Align the flat surface of oil pump's inner rotor
ST 499587100 OIL SEAL INSTALLER with crankshaft before installation.
S2M0235
ME(TURBO)-80
CYLINDER BLOCK
MECHANICAL
25) Install the water pump and gasket. 29) Install the water by-pass pipe between oil cool-
er and water pump.
Tightening torque:
First; 12 N·m (1.2 kgf-m, 8.7 ft-lb)
Second; 12 N·m (1.2 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
EN0321

NOTE:
Always use a new O-ring.
31) Install the cylinder head assembly. <Ref. to
ME(TURBO)-64, INSTALLATION, Cylinder Head
Assembly.>
H2M1846D 32) Install the oil level gauge guide and tighten the
attaching bolt (left side only).
26) Install the water by-pass pipe for heater.
33) Install the rocker cover.
27) Install the oil cooler.
34) Install the crankshaft sprocket. <Ref. to
Tightening torque: ME(TURBO)-58, INSTALLATION, Crankshaft
T1: 55 N·m (5.5 kgf-m, 40 ft-lb) Sprocket.>
T2: 69 N·m (7.0 kgf-m, 50.6 ft-lb) 35) Install the camshaft sprocket. <Ref. to
ME(TURBO)-57, INSTALLATION, Camshaft
Sprocket.>
sembly.>
39) Install the generator and A/C compressor
brackets on cylinder head.
41) Install the intake manifold. <Ref. to FU(TUR-
EN0320
(A) O-ring
(B) Oil cooler
(C) Connector
28) Install the oil filter using ST.

ME(TURBO)-81
CYLINDER BLOCK
MECHANICAL
C: DISASSEMBLY
B2M1320I
(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(TURBO)-82
CYLINDER BLOCK
MECHANICAL
D: ASSEMBLY
B2M1320J
(1) Connecting rod bearing (5) Second ring Tightening torque: N·m (kgf-m, ft-lb)
(2) Connecting rod (6) Top ring T: 44.6 (4.55, 32.9)
(3) Connecting rod cap (7) Circlip
(4) Oil ring
1) Install 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 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 top ring with a piston ring expander.
ME(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 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.
CAUTION:
ature of 20°°C (68°°F).
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)
H2M1732C
(A) Main journal size mark

(B) Cylinder block RH-LH combination mark S2M1821A
(C) #1 cylinder bore size mark
(D) #2 cylinder bore size mark (A) Piston pin direction
(E) #3 cylinder bore size mark (B) Thrust direction
(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(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
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: 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.
(3.6211 — 3.6214 in) CAUTION:
0.25 mm (0.0098 in) oversize Immediately after reboring, the cylinder diame-
92.225 — 92.235 mm 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 mm
(3.6407 — 3.6411 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(TURBO)-84, CYLIN-
DER AND PISTON, INSPECTION, Cylinder
Block.> If any of the clearances is not within speci-
fication, replace the piston or bore the cylinder to
B2M1305A
use an oversize piston.
5) Calculate the clearance between cylinder and
piston.
CAUTION:
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(TURBO)-85
CYLINDER BLOCK
MECHANICAL
3) Make sure that the piston pin can be inserted 4. PISTON RING
into the piston pin hole with a thumb at 20°C (68°F).
1) If the piston ring is broken, damaged, or worn, or
Replace 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) • Marks are shown on the end of top and sec-
Limit ond rings. When installing the rings to piston,
0.020 mm (0.0008 in) face this mark upward.
• Oil ring consists of upper rail, expander and
lower rail. When installing on piston, be careful
of each rail’s direction.
(A)
(B)
B2M1401 (C)
(A)
(B)
(C)
B2M0084A
4) Check the circlip installation groove on piston for

burr (A). If necessary, remove the burr from groove
EN1514
so that the piston pin can lightly move.
(A) Upper rail
(B) Expander
(C) Lower rail
B2M0420B
5) Check the piston pin circlip for distortion, cracks

and wear.
ME(TURBO)-86
CYLINDER BLOCK
MECHANICAL
2) Squarely place the piston ring and oil ring in cyl- 5. CONNECTING ROD
inder, and then measure the piston ring gap with a
1) Replace the connecting rod, if the large or small
thickness gauge.
end thrust surface is damaged.
Unit: mm (in) 2) Check for bend or twist using a connecting rod
Standard Limit aligner. Replace the connecting rod if the bend or
0.20 — 0.25 twist exceeds the limit.
Top ring 1.0 (0.039)
(0.0079 — 0.0098)
Limit of bend or twist per 100 mm (3.94 in) in
Piston Second 0.35 — 0.50 length:
1.0 (0.039)
ring gap ring (0.0138 — 0.0197)
0.10 mm (0.0039 in)
Oil ring 0.20 — 0.50
1.5 (0.059)
rail (0.0079 — 0.0197)
S2M1823
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.
Unit: mm (in)
Standard Limit
B2M1184B
0.055 — 0.090
Clearance Top ring (0.0022 — 0.15 (0.0059)
between pis- 0.0035) (A) Thickness gauge
ton ring and
0.030 — 0.070 (B) Connecting rod
piston ring Second
groove (0.0012 — 0.15 (0.0059)
ring 3) Install the connecting rod fitted with bearing to
0.0028)
crankshaft, and then measure the side clearance
(thrust clearance). Replace the connecting rod if
the side clearance exceeds the specified limit.
Connecting rod side clearance:
Standard
0.070 — 0.330 mm (0.0028 — 0.0130 in)
Limit
0.4 mm (0.016 in)
B2M1402
EN0335
ME(TURBO)-87
CYLINDER BLOCK
MECHANICAL
4) Inspect the connecting rod bearing for scar, 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 connecting rod small end.
ing rod bearings by means of plastigauge. If any oil
Clearance between piston pin and bushing:
clearance is not within specification, replace the
Standard
defective bearing with a new one of standard size
0 — 0.022 mm (0 — 0.0009 in)
or undersize as necessary. (See the table below.)
Limit
Connecting rod oil clearance: 0.030 mm (0.0012 in)
Standard
0.020 — 0.046 mm (0.0008 — 0.0018 in)
Limit
0.05 mm (0.0020 in)
Unit: mm (in)
Bearing size
Outer diameter of
crank pin
ter)
1.486 — 1.498 51.984 — 52.000
Standard
(0.0585 — 0.0590) (2.0466 — 2.0472) B2M0085
0.03
1.504 — 1.512 51.954 — 51.970
(0.0012)
(0.0592 — 0.0595) (2.0454 — 2.0461)
undersize
0.05
1.514 — 1.522 51.934 — 51.950
(0.0020)
(0.0596 — 0.0599) (2.0447 — 2.0453)
undersize
0.25
1.614 — 1.622 51.734 — 51.750
(0.0098)
(0.0635 — 0.0639) (2.0368 — 2.0374)
undersize
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
G2M0177
(3) Make two 3 mm (0.12 in) holes in bushing.

Ream the inside of bushing.
(4) After the completion of reaming, clean the
bushing to remove chips.
ME(TURBO)-88
CYLINDER BLOCK
MECHANICAL
6. CRANKSHAFT AND CRANKSHAFT 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 then
1) Clean the crankshaft completely and check for replace or recondition the crankshaft as necessary.
cracks by means of red lead check etc., and re- When grinding the crank journal or crank pin, finish
place if defective. them to specified dimensions according to the un-
2) Measure the crankshaft bend, and correct or re- dersize bearing 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 the
#1 and #5 crankshaft bearing on cylinder block, 0.020 mm (0.0008 in) or less
position the crankshaft on these bearings and Taper limit
measure the crankshaft bend using a dial 0.07 mm (0.0028 in)
gauge. Grinding limit
0.250 mm (0.0098 in)
Crankshaft bend limit:
0.035 mm (0.0014 in)
G2M0179
EN0339
Unit: mm (in)
Crank journal diameter
Crank pin diameter
#1, #3, #5 #2, #4
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 1.486 — 1.498
(Thickness at cen-
(0.0787 — 0.0792) (0.0787 — 0.0793) (0.0585 — 0.0590)
ter)
59.962 — 59.978 59.962 — 59.978 51.954 — 51.970
Journal O.D.
(2.3607 — 2.3613) (2.3607 — 2.3613) (2.0454 — 2.0461)
0.03 (0.0012)
undersize Bearing size
2.017 — 2.020 2.019 — 2.022 1.504 — 1.512
(Thickness at cen-
(0.0794 — 0.0795) (0.0795 — 0.0796) (0.0592 — 0.0595)
ter)
59.942 — 59.958 59.942 — 59.958 51.934 — 51.950
Journal O.D.
(2.3599 — 2.3605) (2.3599 — 2.3605) (2.0447 — 2.0453)
0.05 (0.0020)
2.027 — 2.030 2.029 — 2.032 1.514 — 1.522
(Thickness at cen-
(0.0798 — 0.0799) (0.0799 — 0.0800) (0.0596 — 0.0599)
ter)
59.742 — 59.758 59.742 — 59.758 51.734 — 51.750
Journal O.D.
(2.3520 — 2.3527) (2.3520 — 2.3527) (2.0368 — 2.0374)
0.25 (0.0098)
2.127 — 2.130 2.129 — 2.132 1.614 — 1.622
(Thickness at cen-
(0.0837 — 0.0839) (0.0838 — 0.0839) (0.0635 — 0.0639)
ter)
O.D.: Outer Diameter
ME(TURBO)-89
CYLINDER BLOCK
MECHANICAL
4) Measure the thrust clearance of crankshaft at

center bearing. If the clearance exceeds the limit,
replace the bearing.
Crankshaft thrust clearance:
Standard
0.030 — 0.115 mm (0.0012 — 0.0045 in)
Limit
0.25 mm (0.0098 in)
EN0341
5) Inspect individual crankshaft bearings for signs

of flaking, seizure, melting, and wear.
6) Measure the oil clearance on each crankshaft
bearing by means of plastigauge. If the measure-
ment is not within the specification, replace the de-
fective bearing with an undersize one, and replace
or recondition the crankshaft as necessary.
Unit: mm (in)
Crankshaft oil clearance
0.010 — 0.030 (0.0004 —
Standard
0.0012)
Limit 0.040 (0.0016)
ME(TURBO)-90
MECHANICAL
21.Engine Trouble in General

A: INSPECTION
NOTE: 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”)
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
• Defective starter B
• Battery • Poor terminal connection A
• Run-down battery A
• Defective charging system B
• Friction • Seizure of crankshaft and connecting rod bearing C
• Seized camshaft C
• Seized or stuck piston and cylinder C
2) Initial combustion does • Starter • Defective starter C
not occur. • Engine control system <Ref. to EN(TURBO)-2, Basic Diagnostic Procedure.> A
• Fuel line • Defective fuel pump and relay A
3) Initial combustion occur. • Engine control system <Ref. to EN(TURBO)-2, Basic Diagnostic Procedure.> A
• Intake system • Defective intake manifold gasket B
ME(TURBO)-91
MECHANICAL

4) Engine stalls after initial • Engine control system <Ref. to EN(TURBO)-2, Basic Diagnostic Procedure.> A
combustion. • Intake system • Loosened or cracked intake duct B
• Loosened or cracked vacuum hose C
• Fuel line • Clogged fuel line C
2. Rough idle and engine • Engine control system <Ref. to EN(TURBO)-2, Basic Diagnostic Procedure.> A
stall • Intake system • Loosened or cracked intake duct A
• Defective PCV valve C
• Belt • Defective timing C
• Defective rocker cover gasket C
• Stuck or damaged throttle valve B
• Accelerator cable out of adjustment C
ME(TURBO)-92
MECHANICAL

3. Low output, hesitation and • Engine control system <Ref. to EN(TURBO)-2, Basic Diagnostic Procedure.> A
poor acceleration • Intake system • Loosened or cracked intake duct A
• Dirty air cleaner element A
• Over cooling C
4. Surging • Engine control system <Ref. to EN(TURBO)-2, Basic Diagnostic Procedure.> A
• Dirty air cleaner element B
ME(TURBO)-93
MECHANICAL

5. Engine does not return to • Engine control system <Ref. to EN(TURBO)-2, Basic Diagnostic Procedure.> A
idle. • Intake system • Loosened or cracked vacuum hose A
• Others • Stuck or damaged throttle valve A
• Accelerator cable out of adjustment B
6. Dieseling (Run-on) • Engine control system <Ref. to EN(TURBO)-2, Basic Diagnostic Procedure.> A
• Others • Malfunction of evaporative emission control system B
7. After burning in exhaust • Engine control system <Ref. to EN(TURBO)-2, Basic Diagnostic Procedure.> A
system • Intake system • Loosened or cracked intake duct C
8. Knocking • Engine control system <Ref. to EN(TURBO)-2, Basic Diagnostic Procedure.> A
• Intake system • Loosened oil filler cap B
• Cooling system • Overheating A
9. Excessive engine oil con- • Intake system • Loosened or cracked PCV hose A
sumption • Defective PCV valve B
• Compression • Defective valve stem A
• Worn or stuck piston rings, cylinder and piston A
• Lubrication system • Loosened oil pump attaching bolts and defective B
gasket
• Defective oil filter o-ring B
• Defective crankshaft oil seal B
• Defective rocker cover gasket B
• Loosened oil drain plug or defective gasket B
• Loosened oil pan fitting bolts or defective oil pan B
ME(TURBO)-94
MECHANICAL

10. Excessive fuel consump- • Engine control system <Ref. to EN(TURBO)-2, Basic Diagnostic Procedure.> A
tion • Intake system • Dirty air cleaner element A
• Others • Accelerator cable out of adjustment B
ME(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 spring
• Worn crankshaft main bearing
Oil pressure is low.
• Worn connecting rod bearing (big end)
Heavy and dull clank
• Loose flywheel mounting bolts
Oil pressure is normal.
• Damaged engine mounting
• Ignition timing advanced
High-pitched clank (Spark Sound is noticeable when • Accumulation of carbon inside combustion chamber
knock) accelerating with an overload. • Wrong spark plug
• Improper gasoline
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
Squeaky sound — • Insufficient generator lubrication
Rubbing sound — • Defective generator brush and rotor contact
Gear scream when starting • Defective ignition starter switch
—
engine • Worn gear and starter pinion
Sound like polishing glass with • Loose drive belt
—
a dry cloth • Defective water pump shaft
• Loss of compression
Hissing sound — • Air leakage in air intake system, hoses, connections or 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(TURBO)-45, OPERATION, Clear Memory Mode.> and INSPEC-
TION MODE <Ref. to EN(TURBO)-42, OPERATION, Inspection Mode.> after connecting the fuel injector connector.
ME(TURBO)-96
EXHAUST
EX(TURBO)
Page
3. Center Exhaust Pipe ...................................................................................8
4. Joint Pipe ..................................................................................................12
6. Muffler .......................................................................................................14
GENERAL DESCRIPTION
EXHAUST
A: COMPONENT
1. FRONT EXHAUST PIPE
(25) T6
(22)
T1
T3
(1)
T1 T3
(2) A (24)
(23) (3) (21)
(6)
A
(20)
(5)
T5 T4 (16)
(7) (17)
(4)
(8)
(10)
(9)
(15)
T1 (18)
T3
(19)
(11)
T3
(14)
(12)
(13)
T4
T1
T2 T2
T2
EN1499
EX(TURBO)-2
GENERAL DESCRIPTION
EXHAUST
(1) Gasket (12) Front exhaust pipe lower insulator (25) Exhaust temperature sensor
(2) Upper exhaust manifold cover (RH) (LH)
(3) Exhaust manifold (RH) (13) Front exhaust pipe lower cover Tightening torque: N·m (kgf-m, ft-lb)
(4) Lower exhaust manifold cover (RH) (14) Front exhaust pipe lower clamp T1: 19 (1.9, 13.7)
(5) Front exhaust pipe upper clamp (15) Gasket T2: 25 (2.5, 18.1)
(6) Front exhaust pipe upper cover (16) Gasket T3: 35 (3.6, 26.0)
(7) Front exhaust pipe upper insulator (17) Upper exhaust manifold cover (LH) T4: 40 (4, 28.9)
(RH) (18) Exhaust manifold (LH) T5: <Ref. to FU(TURBO)-45,
(8) Front exhaust pipe upper insulator (19) Lower exhaust manifold cover (LH) INSTALLATION, Front Oxygen
(LH) (20) Gasket (A/F) Sensor.>
(9) Gasket (21) Turbocharger joint pipe T6: <Ref. to FU(TURBO)-48,
(10) Front exhaust pipe (22) Gasket INSTALLATION, Exhaust Tem-
(11) Front exhaust pipe lower insulator (23) Front oxygen (A/F) sensor perature Sensor.>
(RH) (24) Precatalytic converter
EX(TURBO)-3
GENERAL DESCRIPTION
EXHAUST
2. CENTER AND REAR EXHAUST PIPE, AND MUFFLER
(26)
(25)
(24)
(20)
(22) (23)
(19)
(21)
(15)
(25)
T5
(14)
(17)
(18)
(12) T6
A
(16) T4
(10)
T4
(8)
A
(1) T4 (27)
(3) (7)
T2
(13)
(4)
T4 T3
(9)
(2)
T4
T1 (11)
(5)
T1 T4
T1
(6)
EN1500
(1) Gasket (13) Rear catalytic converter (24) Muffler

(2) Front catalytic converter (14) Gasket (25) Cushion
(3) Upper center pipe cover (Front) (15) Rear exhaust pipe (26) Muffler cutter
(4) Center exhaust pipe (Front) (16) Lower rear exhaust pipe cover (27) Center exhaust pipe (Rear)
(5) Lower center pipe cover (Front) (Front)
(6) Bracket (17) Chamber Tightening torque: N·m (kgf-m, ft-lb)
(7) Gasket (18) Cushion T1: 13 (1.3, 9.6)
(8) Upper center pipe cover (Rear) (19) Spring T2: 18 (1.8, 13.0)
(9) Lower center pipe cover (Rear) (20) Bolt T3: 30 (3.1, 22.4)
(10) Upper rear catalytic converter (21) Upper rear exhaust pipe cover T4: 35 (3.6, 26.0)
cover (Front) T5: 48 (4.9, 35.4)
(11) Lower rear catalytic converter (22) Upper rear exhaust pipe cover T6: <Ref. to FU(TURBO)-46,
cover (Rear) INSTALLATION, Rear Oxygen
(12) Rear oxygen sensor (23) Gasket Sensor.>
EX(TURBO)-4
GENERAL DESCRIPTION
EXHAUST
B: CAUTION
tion.
points.
cable from battery.
EX(TURBO)-5
FRONT EXHAUST PIPE
EXHAUST
2. Front Exhaust Pipe 10) Separate the front exhaust pipe from exhaust
manifolds.
A: REMOVAL
G2M0854
G6M0095
B: INSTALLATION
NOTE:
2) Remove the front oxygen (A/F) sensor. <Ref. to Replace the gaskets with new ones.
FU(TURBO)-44, REMOVAL, Front Oxygen (A/F)
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 ft-lb)
covers (LH).
G2M0854
G2M0852
2) Install the front exhaust pipe covers.
6) Remove the bolts and nuts which hold front ex-
haust pipe assembly to turbocharger joint pipe. Tightening torque:
7) While holding the front exhaust pipe assembly 25 N·m (2.5 kgf-m, 18.1 ft-lb)
with one hand, remove the nuts which hold front ex- 3) Install the upper exhaust manifold cover (RH).
haust pipe assembly to cylinder head exhaust port. Tightening torque:
19 N·m (1.9 kgf-m, 13.7 ft-lb)
4) Install the front exhaust pipe assembly.
Tightening torque:
35 N·m (3.6 kgf-m, 26.0 ft-lb)
G2M0853
8) Remove the front exhaust pipe assembly.

9) Remove the covers from exhaust manifold and
front exhaust pipe.
EX(TURBO)-6
FRONT EXHAUST PIPE
EXHAUST
5) Connect the exhaust manifold (RH) to turbo-

charger joint pipe.
Tightening torque:
35 N·m (3.6 kgf-m, 26.0 ft-lb)
G2M0853
6) Install the upper and lower exhaust manifold

covers (LH).
Tightening torque:
19 N·m (1.9 kgf-m, 13.7 ft-lb)
7) Install the lower exhaust manifold cover (RH).
Tightening torque:
19 N·m (1.9 kgf-m, 13.7 ft-lb)
G2M0852
8) Install the front oxygen (A/F) sensor. <Ref. to

FU(TURBO)-45, INSTALLATION, Front Oxygen
(A/F) Sensor.>
G6M0095
EX(TURBO)-7
CENTER EXHAUST PIPE
EXHAUST
3. Center Exhaust Pipe 9) Lower the vehicle.

10) Remove the turbocharger upper cover.
A: REMOVAL
4) Remove the intercooler bracket.
H2M1733
11) Remove the bolts which install lower upper side

of turbocharger upper cover, and remove it.
EN0910

7) Remove the universal joint bolts and then re-
move the universal joint (RHD model only).
CAUTION:
Scribe alignment marks on the universal joint H2M1931
so that it can be reassembled at the original
serration. 12) Separate the center exhaust pipe from turbo-
charger.
H2M1950
H2M1745
8) Remove the bolts which install lower side of tur-
bocharger upper cover. 13) Lift-up the vehicle.
14) Disconnect the connector from rear oxygen
CAUTION:
sensor.
Be careful, the turbocharger and exhaust pipe
are hot.
EN0834
H2M1929
EX(TURBO)-8
CENTER EXHAUST PIPE
EXHAUST
15) Vertically draw out the clip from crossmember. 20) Remove the center exhaust pipe.
S2M2254 H2M1762
16) Separate the center exhaust pipe from rear ex- B: INSTALLATION
haust pipe.
NOTE:
1) Install the center exhaust pipe and temporarily
tighten the bolt which holds center exhaust pipe to
hanger bracket.
2) Temporarily tighten the bolt which holds center
pipe to transmission.
3) Connect the center exhaust pipe to turbocharg-
er.
Tightening torque:
G2M0855 35 N·m (3.6 kgf-m, 26.0 ft-lb)
17) Remove the bolt which holds center exhaust
pipe bracket to transmission.
H2M1745
4) Install the center exhaust pipe to rear exhaust

H2M1746
pipe.
18) Remove the intercooler bracket.
Tightening torque:
19) 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.
G2M0855
S2M1723
EX(TURBO)-9
CENTER EXHAUST PIPE
EXHAUST
5) Connect the connector to rear oxygen sensor. 9) Tighten the bolts which hold intercooler bracket.
Tightening torque:
35 N·m (3.6 kgf-m, 26.0 ft-lb)
11) Place the turbocharger lower cover, and tighten
the bolts which install upper side of lower cover.
Tightening torque:
7.4 N·m (0.75 kgf-m, 5.4 ft-lb)
EN0834
6) Secure the clip on crossmember.
H2M1931
12) Place the turbocharger upper cover, and tight-

en the bolts which install upper side of upper cover.
S2M2254 Tightening torque:
7.4 N·m (0.75 kgf-m, 5.4 ft-lb)
7) Tighten the bolt which holds center exhaust pipe
bracket to transmission.
Tightening torque:
30 N·m (3.1 kgf-m, 22.4 ft-lb)
H2M1930

14) Tighten the bolts which install under side of tur-
bocharger upper cover.
H2M1746
Tightening torque:
8) Tighten the bolt which holds center exhaust pipe 7.4 N·m (0.75 kgf-m, 5.4 ft-lb)
to hanger bracket.
Tightening torque:
35 N·m (3.6 kgf-m, 26.0 ft-lb)
H2M1929
S2M1723
EX(TURBO)-10
CENTER EXHAUST PIPE
EXHAUST
15) Install the universal joint (RHD model only).

(1) Align the bolt hole on long yoke side of uni-
versal joint with the cutout at serrated section of
shaft end, and insert the universal joint.
(2) Align the bolt hole on short yoke side of uni-
versal joint with the cutout at serrated section of
gearbox assembly. Lower the universal joint
completely.
(3) Temporarily tighten the bolt on short yoke
side. Raise the universal joint to make sure the
bolt is properly passing through the cutout at
serrated section.
(4) Tighten the bolt on long yoke side, then that
on the short yoke side.
Tightening torque:
24 N·m (2.4 kgf-m, 17.4 ft-lb)
CAUTION:
• Make sure that the universal joint bolts are
tightened through notches in shaft serration.
• Excessively large tightening torque of uni-
versal joint bolts may lead to heavy steering
wheel operation.
Standard clearance between gearbox to DOJ:
Over 15 mm (0.59 in)
H2M1950

18) Install the intercooler bracket.
EN0910

20) Align the center of roll connector. <Ref. to AB-
11, ROLL CONNECTOR, INSPECTION, Inspec-
tion Locations After a Collision.>
EX(TURBO)-11
JOINT PIPE
EXHAUST
4. Joint Pipe 6) Remove the lower exhaust manifold cover (RH).
A: REMOVAL
G2M0852
7) Remove the nuts which hold front exhaust man-

ifold to joint pipe.
G6M0095
2) Remove the solenoid valve cover.
EN0917

EN0828
3) Disconnect the exhaust temperature sensor con- 9) Remove the turbocharger. <Ref. to IN(TURBO)-
nector. 12, REMOVAL, Turbocharger.>
10) Take off the joint pipe in the upward direction.
B: INSTALLATION
Tightening torque:
T: 35 N·m (3.6 kgf-m, 26.0 ft-lb)
EN0896
4) Remove the front oxygen (A/F) sensor. <Ref. to

FU(TURBO)-44, REMOVAL, Front Oxygen (A/F)
Sensor.>
H2M1747A
EX(TURBO)-12
REAR EXHAUST PIPE
EXHAUST
5. Rear Exhaust Pipe B: INSTALLATION

A: REMOVAL NOTE:
Tightening torque:
48 N·m (4.9 kgf-m, 35.4 ft-lb)
G6M0095

haust pipe. S2M0559
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)
S2M0558

S2M0558
CAUTION:
Be careful not to pull down the rear exhaust 3) Lower the vehicle.
pipe. 4) Connect the battery ground cable to battery.
S2M0559 G6M0095
5) Remove the rear exhaust pipe. C: INSPECTION

nections and welds.
cracked.
EX(TURBO)-13
MUFFLER
EXHAUST
A: REMOVAL
NOTE:
1) Separate the muffler from rear exhaust pipe.
CAUTION:
48 N·m (4.9 kgf-m, 35.4 ft-lb)
S2M0559
S2M0559
2) Remove the rubber cushions, and detach the
muffler. C: INSPECTION
CAUTION:
nections and welds.
Be careful not to drop the muffler during remov-
al. 2) Make sure there are no holes or rusting.
NOTE: cracked.
To facilitate removal, apply a coat of SUBARU
CRC to the mating area of rubber cushions in ad-
vance.
EN0897
EX(TURBO)-14
IGNITION
IG(TURBO)
Page
2. Spark Plug...................................................................................................4
GENERAL DESCRIPTION
IGNITION
A: SPECIFICATIONS
Item Designation
Ignition coil Model FK0140
and ignitor
assembly Manufacturer DIAMOND
Type and manufacturer NGK: PFR6G
Spark plug Thread size mm 14, P = 1.25
Spark gap mm (in) 0.7 — 0.8 (0.028 — 0.031)
IG(TURBO)-2
GENERAL DESCRIPTION
IGNITION
B: COMPONENT
T2
T1
(2)
(1)
(1) T1
(2)
T2
EN0853
(1) Spark plug Tightening torque: N·m (kgf-m, ft-lb)

T2: 16 (1.6, 11.7)

IG(TURBO)-3
SPARK PLUG
IGNITION
2. Spark Plug 5) Remove the spark plugs with the spark plug
sockets.
A: REMOVAL
CAUTION:
Spark plug:
NGK: PFR6G
1. RH SIDE
EN0856
2. LH SIDE
1) Disconnect the battery cables, and then remove
the battery and battery carrier.
G6M0095
2) Remove the air cleaner lower case. <Ref. to

IN(TURBO)-7, REMOVAL, Air Cleaner.>
3) Disconnect the connector from ignition coil.
G6M0095
2) Disconnect the washer motor connector.
EN0854
4) Remove the ignition coil.

B6M0562

suitable cap.
EN0855
IG(TURBO)-4
SPARK PLUG
IGNITION
4) Remove the two bolts which hold washer tank, B: INSTALLATION

then take the tank away from working area.
1. RH SIDE
21 N·m (2.1 kgf-m, 15.2 ft-lb)
Tightening torque (Ignition coil):
16 N·m (1.6 kgf-m, 11.7 ft-lb)
CAUTION:
B2M2023
5) Disconnect the connector from ignition coil. should be reduced by approx. 1/3 of the speci-
2. LH SIDE
21 N·m (2.1 kgf-m, 15.2 ft-lb)
Tightening torque (Ignition coil):
16 N·m (1.6 kgf-m, 11.7 ft-lb)
EN0857
CAUTION:
6) Remove the ignition coil. new spark plugs without oil on their threads.
EN0858
7) Remove the spark plugs with the spark plug

sockets.
EN0859
IG(TURBO)-5
SPARK PLUG
IGNITION
C: INSPECTION 3) Oil fouled:

Check the electrodes and inner and outer porcelain Wet black deposits show excessive oil entrance
of plugs, noting the type of deposits and the degree into combustion chamber through worn rings and
of electrode erosion. pistons or excessive clearance between valve
guides and stems. If the same condition remains
after repair, use a hotter plug.
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 indicates
(E) Damaged gasket engine overheating. Moreover, the appearance re-
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 indicates correct spark plug heat range. colder heat range.
G6M0087 G6M0090
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.
G6M0088
IG(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, recondition the firing
surface of electrodes with file. Then correct the
spark plug gap using a gap gauge.
Spark plug gap: L
0.7 — 0.8 mm (0.028 — 0.031 in)
S6M0412B
NOTE:
Replace with a new spark plug if this area (A) is
worn to “ball” shape.
IG(TURBO)-7
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(TURBO)-4, REMOVAL, Spark
Plug.>
B: INSTALLATION
Tightening torque:
16 N·m (1.6 kgf-m, 11.7 ft-lb)
IG(TURBO)-8
EN(TURBO)
Page
4. Electrical Components Location..................................................................8
6. Engine Condition Data ..............................................................................26
8. Data Link Connector .................................................................................31
9. OBD-II General Scan Tool ........................................................................32
11. Read Diagnostic Trouble Code .................................................................41
12. Inspection Mode........................................................................................42

A: PROCEDURE
1. ENGINE
Step Check Yes No

occurred using the interview check list. <Ref. Engine Start Fail-
to EN(TURBO)-3, CHECK, Check List for ure”. <Ref. to
Interview.> EN(TURBO)-58,
Engine Starting
Failure.>
2 CHECK ILLUMINATION OF CHECK ENGINE Does the CHECK ENGINE Go to step 3. Inspection using
MALFUNCTION INDICATOR LAMP (MIL). malfunction indicator lamp illu- “General Diagnos-
minate? tics Table”. <Ref.
to EN(TURBO)-
350, General
Diagnostic Table.>
3 CHECK INDICATION OF DIAGNOSTIC Does the Subaru Select Moni- Record the DTC Repair the related
TROUBLE CODE (DTC) ON DISPLAY. tor or OBD-II general scan tool code. Repair the parts.
1)Turn the ignition switch to OFF. indicate DTC? trouble cause. NOTE:
2)Connect the Subaru Select Monitor or OBD- <Ref. to If a DTC is not
II general scan tool to data link connector. EN(TURBO)-75, shown on display
3)Turn the ignition switch to ON and the List of Diagnostic although MIL illu-
Subaru Select Monitor or OBD-II general scan Trouble Code minates, perform
tool switch to ON. (DTC).> Go to diagnostics of MIL
4)Read the DTC on Subaru Select Monitor or step 4. (CHECK ENGINE
OBD-II general scan tool. malfunction indica-
tor lamp) circuit or
combination
meter. <Ref. to
EN(TURBO)-48,
Engine Malfunc-
tion Indicator Lamp
(MIL).>
4 PERFORM THE DIAGNOSIS. Does the Subaru Select Moni- Inspect using Complete the
1)Perform the clear memory mode. <Ref. to tor or OBD-II general scan tool “Diagnostics Pro- diagnosis.
EN(TURBO)-45, Clear Memory Mode.> indicate DTC? cedure with Diag-
2)Perform the inspection mode. <Ref. to nostic Trouble
EN(TURBO)-42, Inspection Mode.> Code (DTC)”.
<Ref. to
EN(TURBO)-82,
Diagnostic Proce-
dure with Diagnos-
tic Trouble Code
(DTC).>
EN(TURBO)-2

A: CHECK
1. CHECK LIST NO. 1
NOTE:
Vin No. miles
Weather ❏ Fine
❏ Cloudy
❏ Rainy
❏ Snowy
❏ Various/Others:
Outdoor temperature °C (°F)
❏ Hot
❏ Warm
❏ Cool
❏ Cold
Place ❏ Highway
❏ Suburbs
❏ Inner city
❏ Uphill
❏ Downhill
❏ Rough road
❏ Others:
❏ Warming-up
❏ Any temperature
❏ Others:
Engine speed rpm
Vehicle speed MPH
❏ At starting
❏ While idling
❏ At racing
❏ While cruising
EN(TURBO)-3
2. CHECK LIST NO. 2

NOTE:
b) Fuel level
• What:
• What:
• What:
• Where:
• From where:
• What kind:
• From where:
• What kind:
❏ Rough idling
❏ Back fire
❏ After fire
❏ No shift
EN(TURBO)-4
GENERAL DESCRIPTION
1) Airbag system wiring harness is routed near the
engine control module (ECM), main relay and fuel
pump relay.
CAUTION:
H2M1154A
2) Never connect the battery in reverse polarity. 9) Use the engine grounding terminal or engine
• The ECM will be destroyed instantly. proper as the grounding point to the body, when
• The fuel injector and other part will be damaged measuring voltage and resistance in the engine
in just a few minutes more. compartment.
3) Do not disconnect the battery cables while the
engine is running.
switch to OFF.
EN0945
control modules at the harness side connector, use 10) Use the TCM mounting stud bolts at the body
a tapered pin with a diameter of less than 0.64 mm head grounding point, when measuring voltage and
(0.025 in). Do not insert the pin more than 5 mm resistance inside the passenger compartment.
(0.20 in) into the part.
6) Before removing the ECM from located position,
CAUTION:
B3M1666E
waterproof. However, it is still necessary to take 11) Every MFI-related part is a precision part. Do
care not to allow water to get into the connectors not drop them.
vehicle on a rainy day.
EN(TURBO)-5
GENERAL DESCRIPTION
12) Observe the following cautions when installing 2. ENGINE GROUNDING

a radio in MFI equipped models.
Make sure the engine grounding terminal is proper-
CAUTION: ly connected to the engine.
• The antenna must be kept as far apart as pos-
(The ECM is located under the steering column,
inside of the instrument panel lower trim panel.)
• The antenna feeder must be placed as far
ness.
• Carefully adjust the antenna for correct
matching.
• When mounting a large power type radio, pay
special attention to the three items above men- EN0945
tioned.
• Incorrect installation of the radio may affect C: NOTE
the operation of the ECM. 1. DESCRIPTION
the fuel pump connector and crank the engine for • The on-board diagnostics (OBD) system detects
more than 5 seconds to release pressure in the fuel and indicates a fault in various inputs and outputs
system. If the engine starts during this operation, of the complex electronic control. CHECK ENGINE
run it until it stops. malfunction indicator lamp (MIL) in the combination
meter indicates occurrence of a fault or trouble.
14) Problems in the electronic-controlled automatic
transmission may be caused by failure of the en- • Further, against such a failure or sensors as may
gine, the electronic control system, the transmis- disable the drive, the fail-safe function is provided
sion proper, or by a combination of these. These to ensure the minimal driveability.
three causes must be distinguished clearly when • The OBD system incorporated with the vehicles
performing diagnostics. within this engine family complies with Section
15) Diagnostics should be conducted by rotating 1968.1, California Code of Regulations (OBD-II
with simple, easy operations and proceeding to regulation). The OBD system monitors the compo-
complicated, difficult operations. The most impor- nents and the system malfunction listed in Engine
tant thing in diagnostics is to understand the cus- Section which affects on emissions.
tomer's complaint, and distinguish between the • When the system decides that a malfunction oc-
three causes. curs, MIL illuminates. At the same time of the MIL il-
16) On ABS vehicle, when performing driving test lumination or blinking, a diagnostic trouble code
in jacked-up or lifted-up position, sometimes the (DTC) and a freeze frame engine conditions are
warning light may be lit, but this is not a malfunction stored into on-board computer.
of the system. The reason for this is the speed dif- • The OBD system stores freeze frame engine
ference between the front and rear wheels. After di- condition data (engine load, engine coolant tem-
agnosis of engine control system, perform the ABS perature, fuel trim, engine speed and vehicle
memory clearance procedure of self-diagnosis sys- speed, etc.) into on-board computer when it detects
tem. a malfunction first.
• If the OBD system detects the various malfunc-
B: INSPECTION tions including the fault of fuel trim or misfire, the
Before performing diagnostics, check the following OBD system first stores freeze frame engine condi-
items which might affect engine problems: tions about the fuel trim or misfire.
• When the malfunction does not occur again for
1. BATTERY three consecutive driving cycles, MIL is turned off,
1) Measure the battery voltage and specific gravity but DTC remains at on-board computer.
of electrolyte. • The OBD-II system is capable of communication
Standard voltage: 12 V with a general scan tool (OBD-II general scan tool)
formed by ISO 9141 CARB.
Specific gravity: Above 1.260 • The OBD-II diagnostics procedure is different
2) Check the condition of the main and other fuses, from the usual diagnostics procedure. When trou-
and harnesses and connectors. Also check for bleshooting OBD-II vehicles, connect Subaru Se-
proper grounding. lect Monitor or the OBD-II general scan tool to the
vehicle.
EN(TURBO)-6
GENERAL DESCRIPTION
2. ENGINE AND EMISSION CONTROL SYS- pulse applied to the fuel injector and this permits
TEM simple, yet highly precise metering of the fuel.
• Further, all the operating conditions of the engine
• The Multipoint Fuel Injection (MFI) system is a
are converted into electric signals, and this results
system that supplies the optimum air-fuel mixture
in additional features of the system, such as large
to the engine for all the various operating condi-
improved adaptability, easier addition of compen-
tions through the use of the latest electronic tech-
sating element, etc.
nology.
The MFI system also has the following features:
With this system fuel, which is pressurized at a con-
• Reduced emission of harmful exhaust gases.
stant pressure, is injected into the intake air pas-
sage of the cylinder head. The injection quantity of • Reduced in fuel consumption.
fuel is controlled by an intermittent injection system • Increased engine output.
where the electro-magnetic injection valve (fuel in- • Superior acceleration and deceleration.
jector) opens only for a short period of time, de- • Superior startability and warm-up perfor-
pending on the quantity of air required for one cycle mance in cold weather since compensation is
of operation. In actual operation, the injection quan- made for coolant and intake air temperature.
tity is determined by the duration of an electric
D: PREPARATION TOOL
(Newly adapted tool) systems.
B2M3876
systems.
out printer)
(Without printer)
(Without printer)
(Without printer)
B2M3877
EN(TURBO)-7

A: LOCATION
1. ENGINE
• Module
LHD model (1)
(3) (2) (4)

EN1423
RHD model (3) (2) (4)
(1)
EN1424
(1) Engine control module (ECM) (3) Test mode connector

(2) CHECK ENGINE malfunction indi- (4) Data link connector
cator lamp (MIL)
EN(TURBO)-8
(2)
B3M1575A EN0718
(3)
(4)
EN0716 EN1425
EN(TURBO)-9
• Sensor
(7) (8) (2) (1) (3)
(6) (4) (8) (5)
EN0946
(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(TURBO)-10
(2)
(1)
EN1008 EN1009
(3)
EN1010 EN1011
EN1012 EN1013
(8)
(7)
EN1014 EN1015
EN(TURBO)-11
(1)
(2)
(3)
(4)
(5) (6)
EN0948
(1) Front oxygen (A/F) sensor (3) Exhaust temperature sensor (5) Rear oxygen sensor
(2) Precatalytic converter (4) Front catalytic converter (6) Rear catalytic converter
(1)
(3)
(2)
EN1016 EN1017
(5)
(4)
EN0949 EN1018
(6)
EN0950
EN(TURBO)-12
LHD model (1)
(2)
EN1019
RHD model (1)
(2)
EN1020
(1) Fuel level sensor (2) Fuel sub level sensor
EN1036 EN1037
EN(TURBO)-13
• Solenoid Valve, Actuator, Emission Control System Parts and Ignition System Parts
(1) (2) (5)
(5) (3) (4)
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(TURBO)-14
(2)
(1)
EN1021 EN1022
(3)
(4)
EN1023 EN1024
(5)
EN0952
EN(TURBO)-15
LHD model (2) (3) (1) (4)
(5) (6) (7) (8) (9)

EN1025
RHD model (1) (4)
(5) (6) (7) (8) (9) (2) (3)

EN1026
(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(TURBO)-16
LHD model
(2) (3)
(1)
EN0953 EN1027
RHD model
(2)
(3)
(4)
EN1028 EN1029
(5)
(6)
(7)
(8)
EN0954 EN1030
EN(TURBO)-17
2. TRANSMISSION
• Module
(1) (2)
EN0751
(1) Transmission control module (2) AT diagnostic indicator light (for

(TCM) (for AT vehicles) AT vehicles)
EN1072
(2)
(1) EN1071 EN1072
EN(TURBO)-18
• Sensor
B2M2258A B2M2259A
B2M2260A B2M2261A
OBD0653B
(1) Vehicle speed sensor 1 (for AT vehicles)

(2) Vehicle speed sensor 2 (for MT vehicles)
(3) Vehicle speed sensor 2 (for AT vehicles)
(4) Torque converter turbine speed sensor (for AT vehicles)
(5) ATF temperature sensor (for AT vehicles)
(6) Brake light switch
EN(TURBO)-19
• Solenoid Valve and Switch (AT Vehicles)
B3M1670C B2M2246B
B2M2263A B2M2264A
(1) Dropping resistor

(2) Inhibitor switch
(5) Line pressure duty solenoid
(6) Lock-up duty solenoid
(7) Transfer duty solenoid
(8) 2-4 brake duty solenoid
(9) Low clutch timing solenoid valve
(10) 2-4 brake timing solenoid valve
• Solenoid Valve and Switch (MT Vehicles)
B2M2265A
(1) Neutral position switch
EN(TURBO)-20
EN(TURBO)-21

To B134 To B135 To B136
7 6 5 4 3 2 1 9 8 7 6 5 4 3 2 1 7 6 5 4 3 2 1
15 14 13 12 11 10 9 8 19 18 17 16 15 14 13 12 11 10 16 15 14 13 12 11 10 9 8
22 21 20 19 18 17 16 28 27 26 25 24 23 22 21 20 24 23 22 21 20 19 18 17
To B137 To B84
9 8 7 6 4 5 3 2 1 6 5 4 3 2 1
21 20 19 18 17 16 15 14 13 12 11 10 12 11 10 9 8 7
31 30 29 28 27 26 25 24 23 22 17 16 15 14 13
EN0955
Con- Signal (V)

Termi-
nal No. Engine ON (Idling)
No. (Engine OFF)
Crank- Signal (+) B135 2 0 −7 — +7 Sensor output waveform
shaft posi- Signal (−) B135 11 0 0 —
tion sensor Shield B135 21 0 0 —
Camshaft Signal (+) B135 1 0 −7 — +7 Sensor output waveform
Signal B135 7 —
Throttle
Power
position B135 9 5 5 —
supply
sensor
GND (sen-
B135 19 0 0 —
sor)
Signal B135 17 0 0 — 0.9 —
Rear oxy-
Shield B135 26 0 0 —
gen sen-
sor GND (sen-
B135 19 0 0 —
sor)
Front oxy- Signal 1 B137 4 0 — 1.0 0 — 1.0 —
gen (A/F)
sensor Signal 2 B137 5 0 — 1.0 0 — 1.0 —
heater
Rear oxygen sensor
B136 13 0 — 1.0 0 — 1.0 —
heater signal
Engine Signal B135 18 1.0 — 1.4 1.0 — 1.4 After warm-up the engine.
coolant
tempera- GND (sen-
ture sen- B135 19 0 0 After warm-up the engine.
sor)
sor
“5” and “0” are repeatedly dis-
Vehicle speed signal B134 1 0 or 5 0 or 5
played when vehicle is driven.
EN(TURBO)-22
Con- Signal (V)

Termi-
No. (Engine OFF)
Mass air Signal B84 13 — 0.3 — 4.5 —
flow sen- Shield B84 8 0 0 —
sor GND B84 7 0 0 —
Intake air temperature
B135 27 — — —
sensor signal
Exhaust Signal B135 16 — — —
gas tem-
perature GND
B135 19 0 0 —
sensor (sensor)
Tumble Signal B84 23 —
generator
Power
valve posi- B135 9 5 5 —
supply
tion sensor
RH GND
B135 19 0 0 —
(sensor)
Tumble Signal B84 13 —
generator
Power
valve posi- B135 9 5 5 —
supply
tion sensor
LH GND
B135 19 0 0 —
(sensor)
Tumble generator valve
B84 4 0 or 5 0 or 5 —
RH (open)
B84 5 0 or 5 0 or 5 —
RH (close)
B84 11 0 or 5 0 or 5 —
LH (open)
B84 10 0 or 5 0 or 5 —
LH (close)
Wastegate control sole-
B137 24 10 — 13 13 — 14 —
noid valve
Starter switch B134 16 0 0 Cranking: 8 — 14
ON: 10 — 13 ON: 13 — 14
OFF: 0 OFF: 0
ON: 12±0.5 Switch is ON when gear is in
Neutral position switch B134 8
OFF: 0 neutral position.
Knock Signal B135 4 2.8 2.8 —
Back-up power supply B137 10 10 — 13 13 — 14 Ignition switch “OFF”: 10 — 13
Control unit power sup- B137 2 10 — 13 13 — 14 —
ply B137 3 10 — 13 13 — 14 —
Sensor power supply B135 9 5 5 —
Line end check 1 B134 10 0 0 —
#1 B136 24 0 13 — 14 Waveform
Ignition #2 B136 23 0 13 — 14 Waveform
control #3 B136 22 0 13 — 14 Waveform
#4 B136 21 0 13 — 14 Waveform
EN(TURBO)-23
Con- Signal (V)

Termi-
No. (Engine OFF)
#1 B137 1 10 — 13 1 — 14 Waveform
Fuel injec- #2 B136 6 10 — 13 1 — 14 Waveform
tor #3 B136 5 10 — 13 1 — 14 Waveform
#4 B136 4 10 — 13 1 — 14 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 16 — — —
ON: 0.5, or less ON: 0.5, or less
OFF: 10 — 13 OFF: 13 — 14
B137 17 —
control OFF: 10 — 13 OFF: 13 — 14
B137 28 With A/C vehicles only
control OFF: 10 — 13 OFF: 13 — 14
Malfunction indicator Light “ON”: 1, or less
B137 15 — —
Engine speed output B136 9 — 0 — 13, or more Waveform
Purge control solenoid ON: 1, or less ON: 1, or less
B137 16 —
valve OFF: 10 — 13 OFF: 13 — 14
Signal B135 8 1.7 — 2.4 1.1 — 1.6
Power
Pressure B135 9 5 5
supply —
sensor
GND (sen-
B135 19 0 0
sor)
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
ON: 0 ON: 0
Rear defogger switch B134 3 —
OFF: 10 — 13 OFF: 13 — 14
Power steering oil pres- ON: 0
B135 24 10 — 13 —
sure switch OFF: 13 — 14
B137 19 2.8 — 3.2 2.8 — 3.2 —
sor signal (+)
B137 29 2.4 — 2.7 2.4 — 2.7 —
sor signal (−)
B136 7 0 0 —
sor shield
SSM/GST communica- Less than 1 ←→ More Less than 1 ←→ More
B134 21 —
tion line than 4 than 4
Torque control 1 signal B134 19 More than 4 More than 4 —
Torque control 2 signal B134 18 More than 4 More than 4 —
Torque control cut sig-
B136 14 8 8 —
nal
AT diagnosis input sig- Less than 1 ←→ More Less than 1 ←→ More
B135 20 Waveform
nal than 4 than 4
AT load signal B135 28 4.3 — 4.4 0.9 — 1.4 —
EN(TURBO)-24
Con- Signal (V)

Termi-
No. (Engine OFF)
B136 17 0 0 —
GND (power supply)
B134 22 0 0 —
B134 7 0 0 —
B134 15 0 0 —
GND (oxygen sensor
B137 9 0 0 —
heater 1)
GND (oxygen sensor
B137 8 0 0 —
heater 2)
EN(TURBO)-25
6. Engine Condition Data

Content Specified data
1.6 — 2.9 (%): Idling
Engine load
6.4 — 12.8 (%): 2,500 rpm racing
Measuring condition:
• After warm-up the engine.
• Gear position is in neutral position.
• A/C is turned to OFF.
• All accessory switches are turned to OFF.
EN(TURBO)-26
EN(TURBO)-27

S2M2131
NOTE:
Con-
nal No. body (ohms)
No.
B54 24 engine OFF)
“P” range
switch More than 8
“P” range (except “N” range)
“N” range
switch More than 8
“N” range (except “P” range)
“R” range
switch More than 8
“R” range
Select lever in “D” range Less than 1
Inhibitor “D” range
switch switch More than 8
“D” range
“3” range
switch More than 8
“3” range
“2” range
switch More than 8
“2” range
“1” range
switch More than 8
“1” range
EN(TURBO)-28
Con-
nal No. body (ohms)
No.
AT OIL TEMP warning light B56 11 —
Throttle fully closed. Approx. 0.5
Throttle fully open. Approx. 4.3
Throttle position sensor power Ignition switch ON (With
B54 2 Approx. 5.0 —
supply engine OFF)
2.9 — 4.0 2.1 — 2.9 k
(68°F)
0.5 — 0.8 275 — 375
(176°F)
Vehicle stopped. 0
km/h (12 MPH)
Vehicle stopped. 0
Front vehicle speed sensor B55 18 Vehicle speed at least 20 450 — 650
km/h (12 MPH)
Engine idling after warm-up.
0
Torque converter turbine (D range)
B55 8 450 — 650
speed sensor Engine idling after warm-up.
(N range)
0
engine OFF)
8 — 11
engine ON)
Less than 1
(SET lamp ON)
More than 6.5
set. (SET lamp OFF)
Torque control signal 1 B56 5 More than 4.8 —
engine ON)
Torque control signal 2 B56 14 More than 4.8 —
engine ON)
Throttle fully closed (with
1.5 — 5.0
engine OFF) after warm-up.
Throttle fully open (with
Less than 0.5
Fuse removed from FWD
Transfer duty solenoid B54 6 switch (with throttle fully 10 — 17
Less than 0.5
open and with select lever in
1st gear).
EN(TURBO)-29
Con-
nal No. body (ohms)
No.
1.5 — 5.0
Less than 0.5
More than 8.5
2-4 brake dropping resistor B54 17 9 — 15
Less than 0.5
B56 19
B54 20
Less than 1 ←
AT diagnosis signal B56 21 Ignition switch ON —
→ More than 4
Data link signal (Subaru 15 — —
B56 —
Select Monitor) 6 — —
EN(TURBO)-30
DATA LINK CONNECTOR
8. Data Link Connector

A: NOTE
1) This connector is used both for the OBD-II general scan tools and Subaru Select Monitor.
2) Terminal No. 4 to No. 6 of the data link connector is used for the Subaru Select Monitor signal.
CAUTION:
Do not connect any scan tools other than the OBD-II general scan tools and Subaru Select Monitor,
because the circuit for Subaru Select Monitor may be damaged.
H2M1280
Terminal No. Contents Terminal No. Contents

1 Power supply 9 Blank
2 Blank 10 K line of ISO 9141 CARB
3 Blank 11 Blank
Subaru Select Monitor signal (ECM to Subaru
4 12 Ground
Select Monitor)*
Subaru Select Monitor signal (Subaru Select
5 13 Ground
Monitor to ECM)*
6 Line end check signal 1 14 Blank
7 Blank 15 Blank
8 Blank 16 Blank
*: Circuit only for Subaru Select Monitor
EN(TURBO)-31
9. OBD-II General Scan Tool 3) Using the OBD-II general scan tool, call up diag-
nostic trouble code(s) (DTC(s)) and freeze frame
A: OPERATION data.
OBD-II general scan tool functions consist of:
1. HOW TO USE OBD-II GENERAL SCAN (1) MODE $01: Current powertrain diagnostic
TOOL data
1) Prepare a general scan tool (OBD-II general (2) MODE $02: Powertrain freeze frame data
scan tool) required by SAE J1978. (3) MODE $03: Emission-related powertrain di-
2) Open the cover and connect the OBD-II general agnostic trouble codes
scan tool to data link connector located in the lower (4) MODE $04: Clear/Reset emission-related
portion of instrument panel (on the driver's side). diagnostic information
Read out the data according to repair procedures.
(For detailed operation procedures, refer to the
OBD-II General Scan Tool Operation Manual.)
NOTE:
For details concerning diagnostic trouble codes
(DTC). <Ref. to EN(TURBO)-75, List of Diagnostic
EN0768
2. MODE $01 (CURRENT POWERTRAIN DIAGNOSTIC DATA)

Refers to data denoting the current operating condition of analog input/output, digital input/output and/or the
powertrain system.
01 Number of emission-related powertrain trouble codes and MIL status ON/OFF
0E Ignition timing advance °
0F Intake air temperature °C
10 Air flow rate from pressure sensor g/sec
11 Throttle valve opening angle %
13 Check whether oxygen sensor is installed. —
Oxygen sensor output voltage and short term fuel trim associated with oxygen sensor—bank
15 V and %
2
24 A/F sensor 1 output voltage and short term fuel trim associated with A/F sensor 1 V and %
1C On-board diagnosis system —
NOTE:
Refer to OBD-II general scan tool manufacturer's instruction manual to access generic OBD-II PIDs (MODE
$01).
EN(TURBO)-32
3. MODE $02 (POWERTRAIN FREEZE FRAME DATA)

Refers to data denoting the operating condition when trouble is sensed by the on-board diagnosis system.
02 Trouble code that caused CARB required freeze frame data storage —
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(TURBO)-41, Read Diagnostic Trouble Code.>
5. MODE $04 (CLEAR/RESET EMISSION-RELATED DIAGNOSTIC INFORMATION)
Refers to the mode used to clear or reset emission-related diagnostic information (OBD-II trouble diagnostic
information).
NOTE:
Refer to OBD-II general scan tool manufacturer's instruction manual to clear or reset emission-related diag-
nostic information (MODE $04).
EN(TURBO)-33
10.Subaru Select Monitor (2) Connect the diagnosis cable to data link
connector.
A: OPERATION CAUTION:
1. HOW TO USE SUBARU SELECT MONI- Do not connect the scan tools except for
TOR Subaru Select Monitor and OBD-II general scan
tool.
5) Turn the ignition switch to ON (engine OFF) and
EN(TURBO)-7, PREPARATION TOOL, General
Description.>
S2M0288A
S2M0285
6) Using the Subaru Select Monitor, call up diag-
nostic trouble code(s) (DTC(s)) and various data,
Monitor.
then record them.
3) Insert the cartridge into Subaru Select Monitor.
<Ref. to EN(TURBO)-7, PREPARATION TOOL, 2. READ DIAGNOSTIC TROUBLE CODE
General Description.> (DTC) FOR ENGINE. (NORMAL MODE)
mation about how to indicate DTC. <Ref. to
EN(TURBO)-41, Read Diagnostic Trouble Code.>
(DTC) FOR ENGINE. (OBD MODE)
mation about how to indicate DTC. <Ref. to
EN(TURBO)-41, Read Diagnostic Trouble Code.>
S2M0286A

connector.
(1) Data link connector located in the lower por-
tion of instrument panel (on the driver's side).
EN0768
EN(TURBO)-34
4. READ CURRENT DATA FOR ENGINE. (NORMAL MODE)

key.
Ignition timing signal Ignition Timing deg
Injection pulse width Fuel Injection #1 Pulse ms
Idle air control signal ISC Valve Duty Ratio %
Alternator duty control signal ALT Duty %
Fuel pump duty control signal Fuel Pump Duty %
A/F sensor current A/F Sensor #1 Current mA
A/F sensor resistance A/F Sensor #1 Resistance Ω
Front oxygen (A/F) sensor output signal A/F Sensor #1 —
Rear oxygen sensor output signal Rear O2 Sensor V
Short term fuel trim A/F Correction #1 %
Knock sensor signal Knocking Correction deg
Atmospheric absolute pressure signal Atmosphere Pressure
psi
Intake manifold relative pressure signal Mani. Relative Pressure
psi
psi
A/F correction (short term fuel trim) by rear oxygen sensor A/F Correction #3 %
Long term whole fuel trim A/F Learning #1 %
Front oxygen (A/F) sensor heater current A/F Heater Current 1 A
Rear oxygen sensor heater voltage Rear O2 Heater Voltage V
Canister purge control solenoid valve duty ratio CPC Valve Duty Ratio %
Primary supercharged pressure control signal Primary Control %
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 generator valve drive signal TGV Drive OPEN or CLOSE
Fuel level signal Fuel Level V
Learned ignition timing Learned Ignition Timing deg
Mass air flow sensor signal Mass Air Flow g/s
Mass air flow sensor signal Air Flow Sensor Voltage V
Ignition switch signal Ignition Switch ON or OFF
Test mode connector signal Test Mode Signal ON or OFF
Neutral position switch signal Neutral Position Switch ON or OFF
Air conditioning switch signal A/C Switch ON or OFF
Air conditioning signal A/C Compressor Signal ON or OFF
EN(TURBO)-35

Radiator main fan relay signal Radiator Fan Relay #1 ON or OFF
Fuel pump relay signal Fuel Pump Relay ON or OFF
Knocking signal Knocking Signal ON or OFF
Radiator sub fan relay signal Radiator Fan Relay #2 ON or OFF
Power steering switch signal P/S Switch ON or OFF
Engine torque control permission signal Torque Permission Signal ON or OFF
Starter switch signal Starter Switch ON or OFF
Idle switch signal Idle Switch 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
NOTE:
EN(TURBO)-36
5. READ CURRENT DATA FOR ENGINE. (OBD MODE)

key.
5) On the «OBD Menu» display screen, select the {Current Data Display & Save} and press [YES] key.
Number of diagnosis code Number of Diagnosis Code —
Malfunction indicator lamp status MI (MIL) Complete or incomplete
Monitoring 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 No support
Test of heated catalyst Heated catalyst No support
Test of evaporative emission purge control system Evaporative purge system No support
Test of secondary air system Secondary air system No support
Test of air conditioning system refrigerant A/C system refrigerant No support
Test of oxygen sensor Oxygen sensor Complete or incomplete
Test of oxygen sensor heater O2 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 %
psi
Ignition timing advance for #1 cylinder Ignition timing adv. #1 °
Intake air amount Mass Air Flow g/s
A/F sensor equipment A/F sensor ON or OFF
Rear oxygen sensor output signal Oxygen Sensor #12 V
Air fuel ratio correction by rear oxygen sensor Short term fuel trim #12 %
On-board diagnostic system OBD System —
NOTE:
EN(TURBO)-37
6. READ FREEZE FRAME DATA FOR ENGINE. (OBD MODE)

key.
5) On the «OBD Menu» display screen, select the {Freeze Frame Data} and press [YES] key.
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
psi
NOTE:
7. READ OXYGEN SENSOR MONITORING TEST RESULTS DATA FOR ENGINE. (OBD
MODE)
key.
5) On the «OBD Menu» display screen, select the {O2 Sensor Monitor} and press [YES] key.
6) On the «O2 Sensor Select» display screen, select the {Bank 1-Sensor1} or {Bank 1-Sensor2} and press
[YES] key.
• Bank 1-Sensor1 indicates the front oxygen or A/F sensor, and Bank 1-Sensor2 indicates the rear oxygen
sensor.
Oxygen sensor for monitoring test <O2 Sensor Monitor (-------)> —
Rich to lean oxygen sensor threshold voltage Rich to lean sensor volt V
Lean to rich oxygen sensor threshold voltage Lean to rich sensor volt V
Low oxygen sensor voltage for switch time calculation Low sensor voltage V
High oxygen sensor voltage for switch time calculation High sensor voltage V
Rich to lean oxygen sensor switch time Rich to lean switch time sec
Lean to rich oxygen sensor switch time Lean to rich switch time sec
Maximum oxygen sensor voltage for test cycle Maximum sensor Voltage V
Minimum oxygen sensor voltage for test cycle Minimum sensor Voltage V
NOTE:
EN(TURBO)-38

key.
5) On the «Data Display Menu» display screen, select the {Data & LED Display} and press [YES] key.
6) Using the scroll key, move the display screen up or down until the desired data is shown.
Contents Display Message LED “ON” requirements
Ignition switch signal Ignition Switch ON or OFF When ignition switch is turned to ON.
Test mode connector signal Test Mode Signal ON or OFF When test mode connector is connected.
Neutral position switch signal Neutral SW ON or OFF When neutral position signal is entered.
Air conditioning switch signal A/C SW ON or OFF When air conditioning switch is turned ON.
Air conditioning relay signal A/C Relay ON or OFF When air conditioning relay is in function.
Radiator main fan relay signal Radiator Fan Relay #1 ON or OFF When radiator main fan relay is in function.
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.
entered.
entered.
Engine torque control permission When engine torque control permission sig-
Torque Control Permit ON or OFF
signal nal is entered.
When rear oxygen sensor mixture ratio is
rich.
Starter switch signal Starter Switch Signal ON or OFF When starter switch signal is entered.
Idle switch signal Idle Switch Signal ON or OFF When idle switch signal is entered.
When crankshaft position sensor signal is
entered.
When camshaft position sensor signal is
entered.
Power steering switch signal P/S SW ON or OFF When power steering switch is entered.
Rear defogger switch signal Rear Defogger SW ON or OFF When rear defogger switch is turned ON.
Blower fan switch signal Blower Fan SW ON or OFF When blower fan switch is turned ON.
Light switch signal Light SW ON or OFF When small light switch is turned ON.
Tumble generator valve actuator
TGV Signal ON or OFF When TGV actuator signal is entered.
signal
Tumble generator valve drive sig-
TGV Drive ON or OFF When TGV moves and valve opens.
nal
NOTE:
EN(TURBO)-39
9. READ CURRENT DATA FOR AT

2) On the «System Selection Menu» display screen, select the {Transmission Control System} and press
[YES] key.
3) Press the [YES] key after displayed the information of transmission type.
4) On the «Transmission Diagnosis» display screen, select the {Current Data Display & Save} and press
[YES] key.
Rear vehicle speed sensor signal Rear Wheel Speed km/h or MPH
Front vehicle speed sensor signal Front Wheel Speed km/h or MPH
Mass air flow sensor signal Air Flow Sensor Voltage V
Torque converter turbine speed signal Turbine Revolution Speed rpm
2-4 brake timing pressure control duty ratio Brake Clutch Duty Ratio %
Stop lamp switch signal Stop Light Switch ON or OFF
Neutral/Parking range signal N/P Range Signal ON or OFF
Automatic transmission diagnosis indicator lamp Diagnosis Lamp ON or OFF
NOTE:
EN(TURBO)-40
READ DIAGNOSTIC TROUBLE CODE
11.Read Diagnostic Trouble 3. OBD-II GENERAL SCAN TOOL

Code Refers to data denoting emission-related power-
train diagnostic trouble codes (DTCs).
A: OPERATION For details concerning diagnostic trouble codes
MODE) Trouble Code (DTC).>
1) On the «Main Menu» display screen, select the NOTE:
{Each System Check} and press [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 (DTCs)
press [YES] key. (MODE $03).
lect the {Diagnostic Code(s) Display} and press
[YES] key.
screen, select the {Current Diagnostic Code(s)} or
{History Diagnostic Code(s)} and press [YES] key.
NOTE:
UAL.
MODE)
press [YES] key.
{Diagnosis Code(s) Display} and press [YES] key.
6) Make sure that a diagnostic trouble code (DTC)
is shown on the display screen.
NOTE:
UAL.
EN(TURBO)-41
INSPECTION MODE
12.Inspection Mode 2. SUBARU SELECT MONITOR

A: OPERATION After performing diagnostics and clearing the mem-
ory, check for any remaining unresolved trouble da-
1. PREPARATION FOR THE INSPECTION ta.
MODE 1) Prepare the Subaru Select Monitor kit. <Ref. to
Raise the vehicle using a garage jack and place on Description.>
WARNING:
brake is applied.
safety stand.
pedal or accelerator pedal during works even S2M0285
Monitor.
• In order to prevent the vehicle from slipping
3) Insert the cartridge into Subaru Select Monitor.
due to vibration, do not place any wooden
<Ref. to EN(TURBO)-7, PREPARATION TOOL,
blocks or similar items between the safety
General Description.>
stands and the vehicle.
S2M0286A

er portion of instrument panel (on the driver's side).
(A)
EN0773
B2M2969A
EN(TURBO)-42
INSPECTION MODE
5) Connect the Subaru Select Monitor to data link 12) Perform subsequent procedures as instructed
connector. on the display screen.
(1) Connect the Subaru Select Monitor to data • If trouble still remains in the memory, corre-
link connector located in the lower portion of the sponding diagnostic trouble code (DTC) appears
instrument panel (on the driver's side). on the display screen.
NOTE:
UAL.
• Release the parking brake.
EN0768
wheels may light either the ABS warning light, but
(2) Connect the diagnosis cable to data link this indicates no malfunctions. When the engine
connector. control diagnosis is finished, perform the ABS
memory clearance procedure of self-diagnosis sys-
CAUTION:
tem.
Do not connect scan tools except for the
Subaru Select Monitor and OBD-II general scan 3. OBD-II GENERAL SCAN TOOL
tool.
After performing diagnostics and clearing the mem-
6) Turn the ignition switch to ON (engine OFF) and ory, check for any remaining unresolved trouble da-
Subaru Select Monitor switch to ON. ta:
er side of instrument panel (on the driver's side).
S2M0288A
(A)
{2. Each System Check} and press [YES] key. EN0773
8) On the «System Selection Menu» display 2) Connect the OBD-II general scan tool to its data
screen, select the {Engine Control System} and link connector in the lower portion of the instrument
press [YES] key. panel (on the driver's side).
lect the {Dealer Check Mode Procedure} and press
[YES] key.
11) When the “Perform Inspection (Dealer Check)
Mode?” is shown on the display screen, press
[YES] key.
EN(TURBO)-43
INSPECTION MODE
CAUTION:
Subaru Select Monitor and OBD-II general scan
tool.
EN0768

NOTE:
Depress the clutch pedal when starting the engine.
4) Using the shift lever, turn the “N” position switch
to ON.
5) Keep engine speed in the 2,500 — 3,000 rpm
range for 40 seconds.
6) Place the shift lever in the “1st” gear and drive
the vehicle at 5 to 10 km/h (3 to 6 MPH).
NOTE:
The speed difference between front and rear
wheels may light the ABS warning light, but this in-
dicates no malfunctions. When the engine control
diagnosis is finished, perform the ABS memory
7) Using the OBD-II general scan tool, check for di-
agnostic trouble code(s) (DTC(s)) and record the
result(s).
NOTE:
• For detailed operation procedures, refer to the
EN(TURBO)-44
CLEAR MEMORY MODE
13.Clear Memory Mode

A: OPERATION
MODE)
press [YES] key.
lect the {Clear Memory} and press [YES] key.
5) When the ‘Done’ and ‘Turn Ignition Switch OFF’
are shown on the display screen, turn the Subaru
Select Monitor and ignition switch to OFF.
NOTE:
UAL.
MODE)
press [YES] key.
{4. Diagnosis Code(s) Cleared} and press [YES]
key.
6) When the ‘Clear Diagnostic Code?’ is shown on
the display screen, press [YES] key.
7) Turn the Subaru Select Monitor and ignition
switch to OFF.
NOTE:
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(TURBO)-45
14.Compulsory Valve Operation (1) Connect the Subaru Select Monitor to data
link connector located in the lower portion of in-
Check Mode strument panel (on the driver's side).
A: OPERATION
Description.>
EN0768

connector.
CAUTION:
S2M0285
2) Connect the diagnosis cable to Subaru Select Subaru Select Monitor and OBD-II general scan
Monitor. tool.
3) Insert the cartridge into Subaru Select Monitor. 6) Turn the ignition switch to ON (engine OFF) and
<Ref. to EN(TURBO)-7, PREPARATION TOOL, Subaru Select Monitor switch to ON.
General Description.>
S2M0288A
S2M0286A
4) Connect the test mode connector (A) at the low- {2. Each System Check} and press [YES] key.
er portion of instrument panel (on the driver's side). 8) On the «System Selection Menu» display
press [YES] key.
lect the {System Operation Check Mode} and press
[YES] key.
11) On the «System Operation Check Mode» dis-
(A) play screen, select the {Actuator ON/OFF Opera-
tion} and press [YES] key.
EN0773 12) Select the desired compulsory actuator on the
5) Connect the Subaru Select Monitor to data link «Actuator ON/OFF Operation» display screen and
connector. press [YES] key.
EN(TURBO)-46
13) Pressing the [NO] key completes the compulsory operation check mode. The display will then return to
the «Actuator ON/OFF Operation» screen.
Contents Display
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
NOTE:
• The following parts will be displayed but not functional because they are not installed on the vehicle.
Display
EGR Solenoid Valve
ASV Solenoid Valve
PCV Solenoid Valve
Vent Control Solenoid Valve
FICD Solenoid
AAI Solenoid Valve
Fuel Tank Sensor Control Valve
EN(TURBO)-47

A: PROCEDURE
1. Activation of check engine malfunction indicator lamp (MIL). <Ref. to EN(TURBO)-49, ACTIVATION OF CHECK ENGINE
MALFUNCTION INDICATOR LAMP (MIL), Engine Malfunction Indicator Lamp (MIL).>
↓
2. Check that the engine malfunction indicator lamp (MIL) does not come on. <Ref. to EN(TURBO)-50, CHECK ENGINE MAL-
FUNCTION INDICATOR LAMP (MIL) DOES NOT COME ON., Engine Malfunction Indicator Lamp (MIL).>
↓
3. Check that the engine malfunction indicator lamp (MIL) does not go off. <Ref. to EN(TURBO)-52, CHECK ENGINE MAL-
FUNCTION INDICATOR LAMP (MIL) DOES NOT GO OFF., Engine Malfunction Indicator Lamp (MIL).>
↓
4. Check that the engine malfunction indicator lamp (MIL) does not blink at a cycle of 3 Hz. <Ref. to EN(TURBO)-53, CHECK
ENGINE MALFUNCTION INDICATOR LAMP (MIL) DOES NOT BLINK AT A CYCLE OF 3 HZ., Engine Malfunction Indicator
Lamp (MIL).>
↓
5. Check that the engine malfunction indicator lamp (MIL) remains blinking at a cycle of 3 Hz. <Ref. to EN(TURBO)-56, CHECK
ENGINE MALFUNCTION INDICATOR LAMP (MIL) REMAINS BLINKING AT A CYCLE OF 3 HZ., Engine Malfunction Indicator
Lamp (MIL).>
EN(TURBO)-48
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 con-
nected, the MIL blinks at a cycle of 3 Hz.
LAMP (MIL)
off), the CHECK ENGINE malfunction indicator
NOTE:
tion meter circuit. <Ref. to EN(TURBO)-50,
CHECK ENGINE MALFUNCTION INDICATOR
LAMP (MIL) DOES NOT COME ON., Engine Mal-
function Indicator Lamp (MIL).> OBD0055A
EN0774
2) After starting the engine, the MIL goes out. If it

does not, either the engine or the emission control
system is malfunctioning.
OBD0053A
3) If the diagnosis system senses a misfire which

could damage the catalyzer, the MIL will blink at a
cycle of 1 Hz.
OBD0054A
EN(TURBO)-49

ON.
• DIAGNOSIS:
• When the ignition switch is turned to ON (engine OFF), MIL does not come on.
• WIRING DIAGRAM:
IGNITION
B72 BATTERY
SWITCH
No.13 SBF-4 SBF-1
4 1
LHD RHD AT
MT
B36 B36 B38

23
22
4
i1 i1 i3
MT
LHD RHD AT
A7
C6
i2 LHD : 16
* RHD
*
: 13
B37
COMBINATION
METER
15
A: i10
B137 ECM
E
C: i12
B72 C: i12 A: i10 B137
1 2
1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9
3 4
7 8 9 10 11 12 13 14 10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31
B36 i2
i3
1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24 12 13 14 15 16 17 18 19 20 21 22 23 24
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22 (LHD)
1 2 3 4 5 6 7 8 9
i1 10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
1 2 3 4 5 6
7 8 9 10 11 12 13 14 (RHD)
EN1426
Step Check Yes No

2 CHECK POOR CONTACT. Does the MIL come on when Repair the poor Go to step 3.
shaking or pulling ECM con- contact in ECM
EN(TURBO)-50
Step Check Yes No

connected? <Ref. to nection of ECM
FU(TURBO)-49, connector.
Engine Control
Module.>
(B137) No. 15 — (i12) No. 6: nector
• Poor contact in
coupling connector
nector. nation meter con-
nector.
NECTOR. necessary.
(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
connector
7 CHECK LAMP BULB. Is the lamp bulb condition OK? Repair the combi- Replace the lamp
Remove the engine malfunction indicator lamp nation meter con- bulb.
bulb. nector.
EN(TURBO)-51

OFF.
• DIAGNOSIS:
• WIRING DIAGRAM:
IGNITION
B72 BATTERY
SWITCH
No.13 SBF-4 SBF-1
4 1
LHD RHD AT
MT
B36 B36 B38

23
22
4
i1 i1 i3
MT
LHD RHD AT
A7
C6
i2 LHD : 16
* RHD
*
: 13
B37
COMBINATION
METER
15
A: i10
B137 ECM
E
C: i12
B72 C: i12 A: i10 B137
1 2
1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9
3 4
7 8 9 10 11 12 13 14 10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31
B36 i2
i3
1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24 12 13 14 15 16 17 18 19 20 21 22 23 24
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22 (LHD)
1 2 3 4 5 6 7 8 9
i1 10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
1 2 3 4 5 6
7 8 9 10 11 12 13 14 (RHD)
EN1426
Step Check Yes No

TION METER AND ECM CONNECTOR. circuit in harness <Ref. to
1)Turn the ignition switch to OFF. between combina- FU(TURBO)-49,
2)Disconnect the connector from ECM. tion meter and Engine Control
3)Turn the ignition switch to ON. ECM connector. Module.>
EN(TURBO)-52

AT A CYCLE OF 3 HZ.
• DIAGNOSIS:
• Test mode connector circuit is open.
EN(TURBO)-53
• WIRING DIAGRAM:
IGNITION
B72 SWITCH BATTERY
No.13 SBF-4 SBF-1
4 1
LHD RHD AT
B36 B36 MT B38

23
22
4
i1 i1 i3
MT
LHD RHD AT
A7
C6
1 1 1 LHD D2 LHD 16
i2
*5
RHD
RHD
COMBINATION B125 B126 B75 B76 B209 F60 :LHD E3
B37 F76
METER
B22 :RHD
A: i10
B15
C:
A5
i12
A : B134
ECM
B : B137 E E
B75 B76 B72 F60 : LHD C: i12 B209
B125 B126 1 2 B22 : RHD A1 A2 A3 A4 A5

1 2 3 4 5 6 B1 B2 B4 B5
3 4
1 1 1 2 3 4 7 8 9 10 11 12 13 14 C1 C2 C3 C4 C5
2 2 5 6 7 8 D1 D2 D4 D5
9 10 11 12 E1 E5
13 14 15 16
F1 F5
A: i10 G1G2 G4 G5
H1 H2 H3 H4 H5
1 2 3 4 5 6 7 8 9 10 I1 I2 I4 I5
B : B137 J1 J2 J3 J4 J5
A : B134
1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9
8 9 10 11 12 13 14 15 10 11 12 13 14 15 16 17 18 19 20 21
i2 16 17 18 19 20 21 22 22 23 24 25 26 27 28 29 30 31
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
(LHD)
B36 i3
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21 1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9 10
22 23 24 25 26 27 28 29 30 31 32 12 13 14 15 16 17 18 19 20 21 22 23 24 11 12 13 14 15 16 17 18 19 20 21 22
(RHD)
EN1427
EN(TURBO)-54
Step Check Yes No

FUNCTION INDICATOR LAMP (MIL). cuit. <Ref. to
1)Turn the ignition switch to OFF. EN(TURBO)-50,
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).>
2 CHECK HARNESS BETWEEN COMBINA- Does the MIL come on? Repair the ground Go to step 3.
TION METER AND ECM CONNECTOR. short circuit in har-
2)Disconnect the connector from ECM. combination meter
3)Turn the ignition switch to ON. and ECM connec-
tor.
test mode connec-
tor and chassis
ground
connector.
TEST MODE CONNECTOR. Ω? circuit 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.
Check poor contact in ECM connector. connector? contact in ECM <Ref. to
connector. FU(TURBO)-49,
Engine Control
Module.>
EN(TURBO)-55

• DIAGNOSIS:
• MIL blinks at a cycle of 3 Hz when ignition switch is turned to ON.
• WIRING DIAGRAM:
IGNITION
B72 SWITCH BATTERY
No.13 SBF-4 SBF-1
4 1
LHD RHD AT
MT
B36 B36 B38

23
22
4
i1 i1 i3
MT
LHD RHD AT
A7
C6
1 1 1 LHD D2 LHD 16
i2
*5
RHD
RHD
COMBINATION B125 B126 B75 B76 B209 F60 :LHD E3

B37 F76
METER
B22 :RHD
A: i10
B15
C:
A5
i12
A : B134
ECM
B : B137 E E
B75 B76 B72 F60 : LHD C: i12 B209
B125 B126 1 2 B22 : RHD A1 A2 A3 A4 A5

1 2 3 4 5 6 B1 B2 B4 B5
3 4
1 1 1 2 3 4 7 8 9 10 11 12 13 14 C1 C2 C3 C4 C5
2 2 5 6 7 8 D1 D2 D4 D5
9 10 11 12 E1 E5
13 14 15 16
F1 F5
A: i10 G1G2 G4 G5
H1 H2 H3 H4 H5
1 2 3 4 5 6 7 8 9 10 I1 I2 I4 I5
B : B137 J1 J2 J3 J4 J5
A : B134
1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9
8 9 10 11 12 13 14 15 10 11 12 13 14 15 16 17 18 19 20 21
i2 16 17 18 19 20 21 22 22 23 24 25 26 27 28 29 30 31
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
(LHD)
B36 i3
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21 1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9 10
22 23 24 25 26 27 28 29 30 31 32 12 13 14 15 16 17 18 19 20 21 22 23 24 11 12 13 14 15 16 17 18 19 20 21 22
(RHD)
EN1427
EN(TURBO)-56
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.
MIL blinks at a cy-
cle of 3 Hz when
test mode connec-
tor is connected.
NECTOR AND ENGINE GROUNDING TER- Ω? circuit in harness <Ref. to
MINAL. between ECM and FU(TURBO)-49,
1)Turn the ignition switch to OFF. test mode connec- Engine Control
2)Disconnect the connector from ECM. tor. Module.>
EN(TURBO)-57

A: PROCEDURE
1. Inspection of starter motor circuit. <Ref. to EN(TURBO)-60, STARTER MOTOR CIRCUIT, Diagnostics for Engine Starting
Failure.>
↓
2. Inspection of ECM power supply and ground line. <Ref. to EN(TURBO)-62, CONTROL MODULE POWER SUPPLY AND
GROUND LINE, Diagnostics for Engine Starting Failure.>
↓
3. Inspection of ignition control system. <Ref. to EN(TURBO)-66, IGNITION CONTROL SYSTEM, Diagnostics for Engine Start-
ing Failure.>
↓
4. Inspection of fuel pump circuit. <Ref. to EN(TURBO)-70, FUEL PUMP CIRCUIT, Diagnostics for Engine Starting Failure.>
↓
5. Inspection of fuel injector circuit. <Ref. to EN(TURBO)-72, FUEL INJECTOR CIRCUIT, Diagnostics for Engine Starting Fail-
ure.>
EN(TURBO)-58
EN(TURBO)-59

CAUTION:
After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to EN(TURBO)-45,
Clear Memory Mode.> and INSPECTION MODE <Ref. to EN(TURBO)-42, Inspection Mode.> .
• WIRING DIAGRAM:
BATTERY
SBF-4 SBF-1
1
IGNITION
SWITCH
B72
3
P R N D 3 2 1
AT 12 12
11 7
MT
B12 T3 T7
MT
AT
B134 ECM 16
B14
STARTER
MOTOR
E E
B72 B134 B12 T7
1 2 1 2 3 4 5 6 7 1 2 3 4 1 2 3 4 5 6
3 4 8 9 10 11 12 13 14 15 5 6 7 8 7 8 9 10 11 12
16 17 18 19 20 21 22 9 10 11 12
EN1428
Step Check Yes No

(DTC). <Ref. to EN(TURBO)-75, LIST, Repair the trouble
<Ref. to EN(TURBO)-41, OPERATION, Read List of Diagnostic Trouble cause. <Ref. to
Diagnostic Trouble Code.> Code (DTC).> EN(TURBO)-82,
Diagnostic Proce-
dure with Diagnos-
tic Trouble Code
(DTC).>
EN(TURBO)-60
Step Check Yes No

TOR.
ground.
1)Turn the ignition switch to OFF. SC-5, Starter.> cable.
2)Disconnect the terminal from starter motor.
ground.
motor and ECM.
1)Ignition the switch to OFF. between ignition
switch.
8 CHECK HARNESS BETWEEN BATTERY Is the voltage more than 10 V? Repair the open Go to step 9.
AND IGNITION SWITCH CONNECTOR. circuit between
1)Connect the connector to ignition switch. ignition switch and
2)Turn the ignition switch to START. starter motor cir-
3)Measure the voltage between ignition switch cuit.
and chassis ground.
9 CHECK POOR CONTACT. Is there poor contact in ignition Repair the poor Replace the igni-
Check poor contact in ignition switch connec- switch connector? contact in ignition tion switch.
EN(TURBO)-61

CAUTION:
Clear Memory Mode.> and INSPECTION MODE. <Ref. to EN(TURBO)-42, Inspection Mode.>
• WIRING DIAGRAM:
• LHD model
MAIN RELAY

6 2
SBF-5
5 8
3
B61 F44
2 B72 IGNITION BATTERY
1 SWITCH
No.11 SBF-4 SBF-1
B47 4 1
D10
A14
D2
D3
A2
A : B134
C : B136
ECM
D : B137
E: B84
C17
C18
A22
A15
D8
D9
C8
E1
A7
B209
C3
D2
A3
F1
J3
F76
F60
13
14
16
15
3
E3
E E E
B72 B47 F60 A : B134 C : B136
1 2 1 2 1 2 3 4 1 2 3 4 5 6 7 1 2 3 4 5 6 7
3 4 3 4 5 6 7 8 8 9 10 11 12 13 14 15 8 9 10 11 12 13 14 15 16
5 6 9 10 11 12 16 17 18 19 20 21 22 17 18 19 20 21 22 23 24
13 14 15 16
B209 D : B137 E: B84
A1 A2 A3 A4 A5 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6
B1 B2 B4 B5 10 11 12 13 14 15 16 17 18 19 20 21 7 8 9 10 11 12
C1 C2 C3 C4 C5 22 23 24 25 26 27 28 29 30 31 13 14 15 16 17
D1 D2 D4 D5
E1 E5
F1 F5
G1G2 G4 G5
H1 H2 H3 H4 H5
I1 I2 I4 I5
J1 J2 J3 J4 J5
EN1429
EN1429
EN(TURBO)-62
• RHD model
MAIN RELAY
4 DATA LINK CONNECTOR

6
SBF-5
5
3
2 B72 IGNITION
1 SWITCH BATTERY
No.11 SBF-4 SBF-1
B47 4 1
D10
A14
D2
D3
A2
A: B134
C : B136
ECM
D : B137
E: B84
C17
C18
A22
A15
D8
D9
C8
E1
A7
B22
13
14
16
15
3
E3
E E E
B72 B47 B22 A : B134 C : B136 D : B137
1 2 1 2 1 2 3 4 1 2 3 4 5 6 7 1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9
3 4 3 4 5 6 7 8 8 9 10 11 12 13 14 15 8 9 10 11 12 13 14 15 16 10 11 12 13 14 15 16 17 18 19 20 21
5 6 9 10 11 12 16 17 18 19 20 21 22 17 18 19 20 21 22 23 24 22 23 24 25 26 27 28 29 30 31
13 14 15 16
E: B84
1 2 3 4 5 6
7 8 9 10 11 12
13 14 15 16 17
EN0960
Step Check Yes No

No. 1 and No. 2.
terminals.
Terminals
No. 3 — No. 5:
No. 4 — No. 6:
EN(TURBO)-63
Step Check Yes No

Connector & terminal connector, then
(B134) No. 2 — Chassis ground: replace ECM.
1)Connect the connector to ECM. <Ref. to
2)Turn the ignition switch to ON. FU(TURBO)-49,
3)Measure the voltage between ECM connec- Engine Control
tor and chassis ground. Module.>
nector.
EN(TURBO)-64
Step Check Yes No

2)Turn the ignition switch to ON. <Ref. to cuit in harness
3)Measure the voltage between ECM connec- EN(TURBO)-66, between ECM
tor and chassis ground. IGNITION CON- connector and
Connector & terminal TROL SYSTEM, main relay con-
(B137) No. 2 (+) — Chassis ground (–): Diagnostics for nector.
(B137) No. 3 (+) — Chassis ground (–): Engine Starting
Failure.>
EN(TURBO)-65

CAUTION:
• WIRING DIAGRAM:
• LHD model
B136 ECM
24
23
22
21
SBF-1 SBF-4 No.11
4 1
IGNITION
SWITCH B72
B209
H3
D5
D4
E1
E5
F76
F60
4
8
E3
E31 E32 E33 E34

3
E
E
IGNITION COIL IGNITION COIL IGNITION COIL IGNITION COIL

No.1 No.2 No.3 No.4
E31 F60 B72 B136 B209

E32 1 2 3 A1 A2 A3 A4 A5
4 1 2 1 2 3 4 5 6 7
5 6 7 8 3 4 8 9 10 11 12 13 14 15 16 B1 B2 B4 B5
E33
9 10 11 12 17 18 19 20 21 22 23 24 C1 C2 C3 C4 C5
E34 13 14 15 16 D1 D2 D4 D5
E1 E5
1
2 F1 F5
3 G1G2 G4 G5
H1 H2 H3 H4 H5
I1 I2 I4 I5
J1 J2 J3 J4 J5
EN1430
EN(TURBO)-66
• RHD model
B136 ECM
24
23
22
21
SBF-1 SBF-4 No.11
4 1
IGNITION
SWITCH B72
B22
8
E3
E31 E32 E33 E34

3
2
E
E
IGNITION COIL IGNITION COIL IGNITION COIL IGNITION COIL

No.1 No.2 No.3 No.4
E31 B22 B136 B72

E32 1 2 3 4 1 2 3 4 5 6 7 1 2
E33 5 6 7 8 8 9 10 11 12 13 14 15 16 3 4
9 10 11 12 17 18 19 20 21 22 23 24
E34 13 14 15 16
1
2
3
EN1431
Step Check Yes No

1 CHECK SPARK PLUG CONDITION. Is the spark plug’s status OK? Go to step 2. Replace the spark
1)Remove the spark plug. <Ref. to plug.
IG(TURBO)-5, INSTALLATION, Spark Plug.>
2)Check the spark plug condition. <Ref. to
IG(TURBO)-6, INSPECTION, Spark Plug.>
1)Connect the spark plug to ignition coil. inder? pump system.
2)Release the fuel pressure. <Ref. to <Ref. to
FU(TURBO)-53, RELEASING OF FUEL EN(TURBO)-70,
PRESSURE, OPERATION, Fuel.> FUEL PUMP CIR-
3)Contact the spark plug's thread portion on CUIT, Diagnostics
engine. for Engine Start-
4)While opening the throttle valve fully, crank ing Failure.>
inder.
EN(TURBO)-67
Step Check Yes No

ignition coil & ignitor assembly connector and harness between
engine ground. ignition coil & igni-
Connector & terminal tor assembly, and
(E31) No. 3 (+) — Engine ground (−): ignition switch
(E33) No. 3 (+) — Engine ground (−): • Poor contact in
(E34) No. 3 (+) — Engine ground (−): coupling connec-
tors
(E32) No. 2 — Engine ground: ignition coil & igni-
(E33) No. 2 — Engine ground: tor assembly con-
(E34) No. 2 — Engine ground: nector and engine
grounding terminal
NECTOR. tor.
3)Disconnect the connector from ignition coil & the following:
ignitor assembly. • Open circuit in
ECM and ignition coil & ignitor assembly con- ECM and ignition
nector. coil & ignitor
(B136) No. 21 — (E34) No. 1: tor
(B136) No. 23 — (E32) No. 1: coupling connector
(B136) No. 24 — (E31) No. 1:
7 CHECK POOR CONTACT. Is there poor contact in ECM Repair the poor Replace the igni-
Check poor contact in ECM connector. connector? contact in ECM tion coil and ignitor
connector. assembly.
EN(TURBO)-68
EN(TURBO)-69

CAUTION:
• WIRING DIAGRAM:
RHD
RHD
BATTERY
SBF-5
4 2 LHD 8 LHD
B97 B61 F44

FUEL PUMP
*3
RELAY
B46
R1
10
FUEL PUMP
CONTROLLER
R122
5
9
8
7
6
LHD : 20
R15 R3 *1 RHD : 15
*21
*
1
3
R57 B99 LHD : 19

*2 RHD : 14
A13
C16
2
1
*3 LHD : 7
RHD : 5
FUEL ECM
PUMP
A: B134
E E
R58 M
C: B136
F44 B97 B46 R122 B99 R58
1 2 3 4 1 2 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 1 2 3
5 6 7 8 3 4 5 6 7 8 9 10 12 13 14 15 16 17 18 19 20 21 22 23 24 4 5 6
A : B134 C : B136
1 2 3 4 5 6 7 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 8 9 10 11 12 13 14 15 16
16 17 18 19 20 21 22 17 18 19 20 21 22 23 24
EN0991
EN(TURBO)-70
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 the fuel pump is in operation for <Ref. to cause. <Ref. to
2 seconds when turning ignition switch to ON. EN(TURBO)-72, EN(TURBO)-82,
NOTE: FUEL INJECTOR Diagnostic Proce-
Fuel pump operation can also be executed us- CIRCUIT, Diag- dure with Diagnos-
ing the Subaru Select Monitor (Function mode: nostics for Engine tic Trouble Code
FD01). Starting Failure.> (DTC).>
For the procedure, refer to “Compulsory Valve
Operation Check Mode”. <Ref. to
EN(TURBO)-46, Compulsory Valve Operation
Check Mode.>
EN(TURBO)-71

CAUTION:
• Check or repair only faulty parts.
• After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to EN(TURBO)-
45, Clear Memory Mode.> and INSPECTION MODE. <Ref. to EN(TURBO)-42, Inspection Mode.>
• WIRING DIAGRAM:
• LHD model
MAIN RELAY
6 BATTERY
4 B61 F44
SBF-5
5 8
3
2
1
B47 C: B136 D: B137 ECM

D1
C6
C5
C4
B61
B209
1
J5
J4
I5
I4
F44
F76
F60
12
11
10
1
9
E3
E5 E16 E6 E17
2
1
2
1
2
1
2
1
#1 #2 #3 #4
E
FUEL INJECTORS
E5 E6 F44 C : B136 D : B137 F60 B209
E16 E17 A1 A2 A3 A4 A5
1 2 3 4 1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9 1 2 3 4 B1 B2 B4 B5
1 2 5 6 7 8 8 9 10 11 12 13 14 15 16 10 11 12 13 14 15 16 17 18 19 20 21 5 6 7 8 C1 C2 C3 C4 C5
17 18 19 20 21 22 23 24 22 23 24 25 26 27 28 29 30 31 9 10 11 12 D1 D2 D4 D5
13 14 15 16 E1 E5
B47 F1 F5
G1G2 G4 G5
1 2 H1 H2 H3 H4 H5
3 4 I1 I2 I4 I5
5 6 J1 J2 J3 J4 J5
EN1432
EN(TURBO)-72
• RHD model
MAIN RELAY
6 BATTERY
4
SBF-5
5
3
2
1
B47
C: B136 D: B137 ECM
D1
C6
C5
C4
B22
12
11
10
1
9
E3
E5 E16 E6 E17
2
1
2
1
2
1
2
1
#1 #2 #3 #4
E
FUEL INJECTORS
E5 E6 C : B136 D : B137 B22 B47
E16 E17 1 2
1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9 1 2 3 4
8 9 10 11 12 13 14 15 16 10 11 12 13 14 15 16 17 18 19 20 21 5 6 7 8 3 4
1 2 17 18 19 20 21 22 23 24 22 23 24 25 26 27 28 29 30 31 9 10 11 12 5 6
13 14 15 16
EN0965
Step Check Yes No

While cranking the engine, check that each ME(TURBO)-27,
fuel injector emits “operating” sound. Use a INSPECTION,
sound scope or attach a screwdriver to injector Fuel Pressure.>
for this check.
EN(TURBO)-73
Step Check Yes No

• Poor contact in
coupling connector
• Poor contact in
fuel injector con-
nector
FUEL INJECTOR CONNECTOR. Ω? ness and connec-
(B137) No. 1 — (E5) No. 1: • Open circuit in
(B136) No. 6 — (E16) No. 1: harness between
(B136) No. 5 — (E6) No. 1: ECM and fuel
(B136) No. 4 — (E6) No. 1: injector connector
• Poor contact in
coupling connector
injector terminals.
Terminals
No. 1 — No. 2:
EN(TURBO)-350,
INSPECTION,
General Diagnos-
tic Table.>
EN(TURBO)-74

A: LIST
DTC
Item Index
No.
P0031 Front oxygen (A/F) sensor heater cir- <Ref. to EN(TURBO)-82, DTC P0031 — FRONT OXYGEN (A/F) SENSOR
cuit low input HEATER CIRCUIT LOW INPUT —, Diagnostic Procedure with Diagnostic
P0032 Front oxygen (A/F) sensor heater cir- <Ref. to EN(TURBO)-86, DTC P0032 — FRONT OXYGEN (A/F) SENSOR
cuit high input HEATER CIRCUIT HIGH INPUT —, Diagnostic Procedure with Diagnostic
P0037 Rear oxygen sensor heater circuit <Ref. to EN(TURBO)-88, DTC P0037 — REAR OXYGEN SENSOR
malfunction HEATER CIRCUIT MALFUNCTION —, Diagnostic Procedure with Diagnos-
P0038 Rear oxygen sensor heater circuit <Ref. to EN(TURBO)-92, DTC P0038 — REAR OXYGEN SENSOR
high input HEATER CIRCUIT HIGH INPUT —, Diagnostic Procedure with Diagnostic
P0101 Mass air flow sensor circuit range/ <Ref. to EN(TURBO)-94, DTC P0101 — MASS AIR FLOW SENSOR CIR-
performance problem (high input) CUIT RANGE/PERFORMANCE PROBLEM (HIGH INPUT) —, Diagnostic
P0102 Mass air flow sensor circuit low input <Ref. to EN(TURBO)-96, DTC P0102 — MASS AIR FLOW SENSOR CIR-
CUIT LOW INPUT —, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P0103 Mass air flow sensor circuit high <Ref. to EN(TURBO)-100, DTC P0103 — MASS AIR FLOW SENSOR CIR-
input CUIT HIGH INPUT —, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P0106 Pressure sensor circuit range/perfor- <Ref. to EN(TURBO)-102, DTC P0106 — PRESSURE SENSOR CIRCUIT
mance problem (low input) RANGE/PERFORMANCE PROBLEM (LOW INPUT) —, Diagnostic Proce-
P0107 Pressure sensor circuit low input <Ref. to EN(TURBO)-105, DTC P0107 — PRESSURE SENSOR CIRCUIT
LOW INPUT —, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P0108 Pressure sensor circuit high input <Ref. to EN(TURBO)-109, DTC P0108 — PRESSURE SENSOR CIRCUIT
HIGH INPUT —, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P0111 Intake air temperature sensor circuit <Ref. to EN(TURBO)-114, DTC P0111 — INTAKE AIR TEMPERATURE
range/performance problem SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM —, Diagnostic
low input SENSOR CIRCUIT LOW INPUT —, Diagnostic Procedure with Diagnostic
high input SENSOR CIRCUIT HIGH INPUT —, Diagnostic Procedure with Diagnostic
P0117 Engine coolant temperature sensor <Ref. to EN(TURBO)-122, DTC P0117 — ENGINE COOLANT TEMPERA-
circuit low input TURE SENSOR CIRCUIT LOW INPUT —, Diagnostic Procedure with Diag-
P0118 Engine coolant temperature sensor <Ref. to EN(TURBO)-124, DTC P0118 — ENGINE COOLANT TEMPERA-
circuit high input TURE SENSOR CIRCUIT HIGH INPUT —, Diagnostic Procedure with Diag-
P0121 Throttle position sensor circuit range/ <Ref. to EN(TURBO)-127, DTC P0121 — THROTTLE POSITION SENSOR
performance problem (high input) CIRCUIT RANGE/PERFORMANCE PROBLEM (HIGH INPUT) —, Diagnos-
P0122 Throttle position sensor circuit low <Ref. to EN(TURBO)-129, DTC P0122 — THROTTLE POSITION SENSOR
input CIRCUIT LOW INPUT —, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
EN(TURBO)-75
DTC
Item Index
No.
P0123 Throttle position sensor circuit high <Ref. to EN(TURBO)-133, DTC P0123 — THROTTLE POSITION SENSOR
input CIRCUIT HIGH INPUT —, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P0125 Insufficient coolant temperature for <Ref. to EN(TURBO)-136, DTC P0125 — INSUFFICIENT COOLANT TEM-
closed loop fuel control PERATURE FOR CLOSED LOOP FUEL CONTROL —, Diagnostic Proce-
P0131 Front oxygen (A/F) sensor circuit <Ref. to EN(TURBO)-138, DTC P0131 — FRONT OXYGEN (A/F) SENSOR
range/performance problem (low CIRCUIT RANGE/PERFORMANCE PROBLEM (LOW INPUT) —, Diagnos-
input) tic Procedure with Diagnostic Trouble Code (DTC).>
range/performance problem (high CIRCUIT RANGE/PERFORMANCE PROBLEM (HIGH INPUT) —, Diagnos-
input) tic Procedure with Diagnostic Trouble Code (DTC).>
slow response CIRCUIT SLOW RESPONSE —, Diagnostic Procedure with Diagnostic
P0136 Rear oxygen sensor circuit malfunc- <Ref. to EN(TURBO)-144, DTC P0136 — REAR OXYGEN SENSOR CIR-
tion [MT vehicles] CUIT MALFUNCTION [MT VEHICLES] —, Diagnostic Procedure with Diag-
P0137 Rear oxygen sensor circuit low input <Ref. to EN(TURBO)-148, DTC P0137 — REAR OXYGEN SENSOR CIR-
[AT vehicles] CUIT LOW INPUT [AT VEHICLES] —, Diagnostic Procedure with Diagnostic
P0138 Rear oxygen sensor circuit high input <Ref. to EN(TURBO)-152, DTC P0138 — REAR OXYGEN SENSOR CIR-
[AT vehicles] CUIT HIGH INPUT [AT VEHICLES] —, Diagnostic Procedure with Diagnos-
P0139 Rear oxygen sensor circuit slow <Ref. to EN(TURBO)-156, DTC P0139 — REAR OXYGEN SENSOR CIR-
response CUIT SLOW RESPONSE —, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P0171 Fuel trim malfunction (A/F too lean) <Ref. to EN(TURBO)-158, DTC P0171 — FUEL TRIM MALFUNCTION (A/F
TOO LEAN) —, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0172 Fuel trim malfunction (A/F too rich) <Ref. to EN(TURBO)-159, DTC P0172 — FUEL TRIM MALFUNCTION (A/F
TOO RICH) —, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0244 Wastegate control solenoid valve <Ref. to EN(TURBO)-162, DTC P0244 — WASTEGATE CONTROL SOLE-
malfunction (high input) [MT vehi- NOID VALVE MALFUNCTION (HIGH INPUT) [MT VEHICLES] —, Diagnos-
cles] tic Procedure with Diagnostic Trouble Code (DTC).>
malfunction (fail-safe) [AT vehicles] NOID VALVE MALFUNCTION (FAIL-SAFE) [AT VEHICLES] —, Diagnostic
P0245 Wastegate control solenoid valve cir- <Ref. to EN(TURBO)-166, DTC P0245 — WASTEGATE CONTROL SOLE-
cuit low input NOID VALVE CIRCUIT LOW INPUT —, Diagnostic Procedure with Diagnos-
P0246 Wastegate control solenoid valve cir- <Ref. to EN(TURBO)-170, DTC P0246 — WASTEGATE CONTROL SOLE-
cuit high input NOID VALVE CIRCUIT HIGH INPUT —, Diagnostic Procedure with Diag-
P0301 Cylinder 1 misfire detected <Ref. to EN(TURBO)-172, DTC P0301 — CYLINDER 1 MISFIRE
DETECTED —, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
(DTC).>
(DTC).>
(DTC).>
EN(TURBO)-76
DTC
Item Index
No.
P0327 Knock sensor circuit low input <Ref. to EN(TURBO)-182, DTC P0327 — KNOCK SENSOR CIRCUIT LOW
P0328 Knock sensor circuit high input <Ref. to EN(TURBO)-184, DTC P0328 — KNOCK SENSOR CIRCUIT HIGH
P0335 Crankshaft position sensor circuit <Ref. to EN(TURBO)-186, DTC P0335 — CRANKSHAFT POSITION SEN-
malfunction SOR CIRCUIT MALFUNCTION —, Diagnostic Procedure with Diagnostic
P0336 Crankshaft position sensor circuit <Ref. to EN(TURBO)-188, DTC P0336 — Crankshaft Position Sensor Circuit
range/performance problem Range/Performance Problem —, Diagnostic Procedure with Diagnostic
P0340 Camshaft position sensor circuit mal- <Ref. to EN(TURBO)-190, DTC P0340 — CAMSHAFT POSITION SENSOR
function CIRCUIT MALFUNCTION —, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P0341 Camshaft position sensor circuit <Ref. to EN(TURBO)-192, DTC P0341 — CAMSHAFT POSITION SENSOR
P0420 Catalyst system efficiency below <Ref. to EN(TURBO)-196, DTC P0420 — CATALYST SYSTEM EFFI-
threshold CIENCY BELOW THRESHOLD —, Diagnostic Procedure with Diagnostic
P0444 Evaporative emission control system <Ref. to EN(TURBO)-198, DTC P0444 — EVAPORATIVE EMISSION CON-
purge control valve circuit low input TROL SYSTEM PURGE CONTROL VALVE CIRCUIT LOW INPUT [MT
[MT vehicles] VEHICLES] —, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
purge control valve circuit high input TROL SYSTEM PURGE CONTROL VALVE CIRCUIT HIGH INPUT [MT
[MT vehicles] VEHICLES] —, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
purge control valve circuit low input TROL SYSTEM PURGE CONTROL VALVE CIRCUIT LOW INPUT [AT
[AT vehicles] VEHICLES] —, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
purge control valve circuit high input TROL SYSTEM PURGE CONTROL VALVE CIRCUIT HIGH INPUT [AT
[AT vehicles] VEHICLES] —, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0461 Fuel level sensor circuit range/perfor- <Ref. to EN(TURBO)-210, DTC P0461 — FUEL LEVEL SENSOR CIRCUIT
mance problem RANGE/PERFORMANCE PROBLEM —, Diagnostic Procedure with Diag-
P0462 Fuel level sensor circuit low input <Ref. to EN(TURBO)-212, DTC P0462 — FUEL LEVEL SENSOR CIRCUIT
(DTC).>
P0463 Fuel level sensor circuit high input <Ref. to EN(TURBO)-216, DTC P0463 — FUEL LEVEL SENSOR CIRCUIT
(DTC).>
P0464 Fuel level sensor intermittent input <Ref. to EN(TURBO)-220, DTC P0464 — FUEL LEVEL SENSOR INTER-
MITTENT INPUT—, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P0480 Cooling fan relay 1 circuit low input <Ref. to EN(TURBO)-223, DTC P0480 — COOLING FAN RELAY 1 CIR-
(DTC).>
P0483 Cooling fan function problem <Ref. to EN(TURBO)-227, DTC P0483 — COOLING FAN FUNCTION
PROBLEM —, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0500 Vehicle speed sensor malfunction <Ref. to EN(TURBO)-230, DTC P0500 — VEHICLE SPEED SENSOR MAL-
FUNCTION —, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0506 Idle control system RPM lower than <Ref. to EN(TURBO)-232, DTC P0506 — IDLE CONTROL SYSTEM RPM
expected LOWER THAN EXPECTED —, Diagnostic Procedure with Diagnostic Trou-
ble Code (DTC).>
P0507 Idle control system RPM higher than <Ref. to EN(TURBO)-234, DTC P0507 — IDLE CONTROL SYSTEM RPM
expected HIGHER THAN EXPECTED —, Diagnostic Procedure with Diagnostic Trou-
ble Code (DTC).>
EN(TURBO)-77
DTC
Item Index
No.
P0508 Idle control system circuit low input <Ref. to EN(TURBO)-236, DTC P0508 — IDLE CONTROL SYSTEM CIR-
(DTC).>
P0509 Idle control system circuit high input <Ref. to EN(TURBO)-238, DTC P0509 — IDLE CONTROL SYSTEM CIR-
CUIT HIGH INPUT —, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P0512 Starter switch circuit high input <Ref. to EN(TURBO)-240, DTC P0512 — STARTER SWITCH CIRCUIT
(DTC).>
P0513 Incorrect immobilizer key <Ref. to IM-22, DTC P0153 INCORRECT IMMOBILIZER KEY (USE OF
UNREGISTERED KEY), Diagnostics Chart with Diagnostic Trouble Code
(DTC).>
P0545 Exhaust gas temperature sensor cir- <Ref. to EN(TURBO)-242, DTC P0545 — EXHAUST GAS TEMPERATURE
cuit low input SENSOR CIRCUIT LOW INPUT —, Diagnostic Procedure with Diagnostic
P0546 Exhaust gas temperature sensor cir- <Ref. to EN(TURBO)-244, DTC P0546 — EXHAUST GAS TEMPERATURE
cuit high input SENSOR CIRCUIT HIGH INPUT —, Diagnostic Procedure with Diagnostic
P0604 Internal control module memory <Ref. to EN(TURBO)-247, DTC P0604 — INTERNAL CONTROL MODULE
check sum error MEMORY CHECK SUM ERROR —, Diagnostic Procedure with Diagnostic
P0703 Brake switch input malfunction <Ref. to EN(TURBO)-250, DTC P0703 — BRAKE SWITCH INPUT MAL-
FUNCTION —, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0705 Transmission range sensor circuit <Ref. to AT-119, CHECK INHIBITOR SWITCH., Diagnostic Procedure for
malfunction No-diagnostic Trouble Code (DTC).>
P0710 Transmission fluid temperature sen- <Ref. to AT-46, DTC 27 ATF TEMPERATURE SENSOR, Diagnostic Proce-
sor circuit malfunction dure with Diagnostic Trouble Code (DTC).>
P0715 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).>
P0720 Output speed sensor (vehicle speed <Ref. to AT-57, DTC 33 FRONT VEHICLE SPEED SENSOR, Diagnostic
sensor 2) circuit malfunction Procedure with Diagnostic Trouble Code (DTC).>
P0725 Engine speed input circuit malfunc- <Ref. to AT-42, DTC 11 ENGINE SPEED SIGNAL, Diagnostic Procedure
tion with Diagnostic Trouble Code (DTC).>
P0731 Gear 1 incorrect ratio <Ref. to EN(TURBO)-252, DTC P0731 — GEAR 1 INCORRECT RATIO —,
P0741 Torque converter clutch system mal- <Ref. to EN(TURBO)-254, DTC P0741 — TORQUE CONVERTER CLUTCH
function SYSTEM MALFUNCTION —, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P0743 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).>
P0748 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).>
P0753 Shift solenoid A (Shift solenoid 1) <Ref. to AT-70, DTC 71 SHIFT SOLENOID 1, Diagnostic Procedure with
P0758 Shift solenoid B (Shift solenoid 2) <Ref. to AT-74, DTC 72 SHIFT SOLENOID 2, Diagnostic Procedure with
P0778 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
EN(TURBO)-78
DTC
Item Index
No.
P0785 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
P0851 Neutral position switch circuit high <Ref. to EN(TURBO)-256, DTC P0851 — NEUTRAL POSITION SWITCH
input [AT vehicles] CIRCUIT HIGH INPUT [AT VEHICLES] —, Diagnostic Procedure with Diag-
P0852 Neutral position switch circuit low <Ref. to EN(TURBO)-260, DTC P0852 — NEUTRAL POSITION SWITCH
input [AT vehicles] CIRCUIT LOW INPUT [AT VEHICLES] —, Diagnostic Procedure with Diag-
P0864 Automatic transmission diagnosis <Ref. to EN(TURBO)-262, DTC P0864 — AUTOMATIC TRANSMISSION
input signal circuit malfunction DIAGNOSIS INPUT SIGNAL CIRCUIT MALFUNCTION —, Diagnostic Pro-
cedure with Diagnostic Trouble Code (DTC).>
P1086 Tumble generator valve #2 (LH) posi- <Ref. to EN(TURBO)-264, DTC P1086 — TUMBLE GENERATOR VALVE
tion sensor circuit low input #2 (LH) POSITION SENSOR CIRCUIT LOW INPUT —, Diagnostic Proce-
P1087 Tumble generator valve #2 (LH) posi- <Ref. to EN(TURBO)-268, DTC P1087 — TUMBLE GENERATOR VALVE
tion sensor circuit high input #2 (LH) POSITION SENSOR CIRCUIT HIGH INPUT —, Diagnostic Proce-
P1088 Tumble generator valve #1 (RH) <Ref. to EN(TURBO)-271, DTC P1088 — TUMBLE GENERATOR VALVE
position sensor circuit low input #1 (RH) POSITION SENSOR CIRCUIT LOW INPUT —, Diagnostic Proce-
P1089 Tumble generator valve #1 (RH) <Ref. to EN(TURBO)-275, DTC P1089 — TUMBLE GENERATOR VALVE
position sensor circuit high input #1 (RH) POSITION SENSOR CIRCUIT HIGH INPUT —, Diagnostic Proce-
P1090 Tumble generator valve system <Ref. to EN(TURBO)-278, DTC P1090 — TUMBLE GENERATOR VALVE
#1 (RH) malfunction (stuck open) SYSTEM #1 (RH) MALFUNCTION (STUCK OPEN) —, Diagnostic Proce-
#1 (RH) malfunction (stuck close) SYSTEM #1 (RH) MALFUNCTION (STUCK CLOSE) —, Diagnostic Proce-
#2 (LH) malfunction (stuck open) SYSTEM #2 (LH) MALFUNCTION (STUCK OPEN) —, Diagnostic Proce-
#2 (LH) malfunction (stuck close) SYSTEM #2 (LH) MALFUNCTION (STUCK CLOSE) —, Diagnostic Proce-
P1094 Tumble generator valve circuit #1 <Ref. to EN(TURBO)-280, DTC P1094 — TUMBLE GENERATOR VALVE
(open circuit) CIRCUIT #1 (OPEN CIRCUIT) —, Diagnostic Procedure with Diagnostic
(overcurrent) CIRCUIT #1 (OVERCURRENT) —, Diagnostic Procedure with Diagnostic
(open circuit) CIRCUIT #2 (OPEN CIRCUIT) —, Diagnostic Procedure with Diagnostic
(overcurrent) CIRCUIT #2 (OVERCURRENT) —, Diagnostic Procedure with Diagnostic
P1110 Atmospheric pressure sensor circuit <Ref. to EN(TURBO)-288, DTC P1110 — ATMOSPHERIC PRESSURE
low input SENSOR CIRCUIT LOW INPUT —, Diagnostic Procedure with Diagnostic
high input SENSOR CIRCUIT HIGH INPUT —, Diagnostic Procedure with Diagnostic
range/performance problem SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM —, Diagnostic
EN(TURBO)-79
DTC
Item Index
No.
malfunction (open circuit) [MT vehi- CIRCUIT MALFUNCTION (OPEN CIRCUIT) [MT VEHICLES] —, Diagnostic
cles] Procedure with Diagnostic Trouble Code (DTC).>
malfunction (short circuit) [MT vehi- CIRCUIT MALFUNCTION (SHORT CIRCUIT) [MT VEHICLES] —, Diagnos-
cles] tic Procedure with Diagnostic Trouble Code (DTC).>
P1134 Front oxygen (A/F) sensor micro- <Ref. to EN(TURBO)-294, DTC P1134 — FRONT OXYGEN (A/F) SENSOR
computer problem MICRO-COMPUTER PROBLEM —, Diagnostic Procedure with Diagnostic
P1139 Front oxygen (A/F) sensor #1 heater <Ref. to EN(TURBO)-296, DTC P1139 — FRONT OXYGEN (A/F) SENSOR
circuit range/performance problem #1 HEATER CIRCUIT RANGE/PERFORMANCE PROBLEM —, Diagnostic
P1141 Mass air flow sensor circuit range/ <Ref. to EN(TURBO)-298, DTC P1141 — MASS AIR FLOW SENSOR CIR-
performance problem (low input) CUIT RANGE/PERFORMANCE PROBLEM (LOW INPUT) —, Diagnostic
P1142 Throttle position sensor circuit range/ <Ref. to EN(TURBO)-300, DTC P1142 — THROTTLE POSITION SENSOR
performance problem (low input) CIRCUIT RANGE/PERFORMANCE PROBLEM (LOW INPUT) —, Diagnos-
P1146 Pressure sensor circuit range/perfor- <Ref. to EN(TURBO)-302, DTC P1146 — PRESSURE SENSOR CIRCUIT
mance problem (high input) RANGE/PERFORMANCE PROBLEM (HIGH INPUT) —, Diagnostic Proce-
range/performance problem (low CIRCUIT RANGE/PERFORMANCE PROBLEM (LOW INPUT) [AT VEHI-
input) [AT vehicles] CLES] —, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
range/performance problem (high CIRCUIT RANGE/PERFORMANCE PROBLEM (HIGH INPUT) [AT VEHI-
input) [AT vehicles] CLES] —, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P1230 Fuel pump controller malfunction <Ref. to EN(TURBO)-310, DTC P1230 — FUEL PUMP CONTROLLER
MALFUNCTION —, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
range/performance problem (low NOID VALVE RANGE/PERFORMANCE PROBLEM (LOW INPUT) [MT
input) [MT vehicles] VEHICLES] —, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
malfunction (fail-safe) [MT vehicles] NOID VALVE MALFUNCTION (FAIL-SAFE) [MT VEHICLES] —, Diagnostic
P1301 Fire due to increased exhaust tem- <Ref. to EN(TURBO)-318, DTC P1301 — FIRE DUE TO INCREASED
perature EXHAUST TEMPERATURE —, Diagnostic Procedure with Diagnostic Trou-
ble Code (DTC).>
P1312 Exhaust gas temperature circuit mal- <Ref. to EN(TURBO)-320, DTC P1312 — EXHAUST GAS TEMPERATURE
function CIRCUIT MALFUNCTION —, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P1480 Cooling fan relay 1 circuit high input <Ref. to EN(TURBO)-323, DTC P1480 — COOLING FAN RELAY 1 CIR-
CUIT HIGH INPUT —, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P1507 Idle control system malfunction (fail- <Ref. to EN(TURBO)-326, DTC P1507 — IDLE CONTROL SYSTEM MAL-
safe) FUNCTION (FAIL-SAFE) —, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P1518 Starter switch circuit low input <Ref. to EN(TURBO)-328, DTC P1518 — STARTER SWITCH CIRCUIT
(DTC).>
P1544 High exhaust temperature detected <Ref. to EN(TURBO)-330, DTC P1544 — HIGH EXHAUST TEMPERA-
TURE DETECTED —, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
P1560 Back-up voltage circuit malfunction <Ref. to EN(TURBO)-332, DTC P1560 — BACK-UP VOLTAGE CIRCUIT
MALFUNCTION —, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
EN(TURBO)-80
DTC
Item Index
No.
P1570 Antenna <Ref. to IM-24, DTC P1570 ANTENNA, Diagnostics Chart with Diagnostic
P1571 Reference code incompatibility <Ref. to IM-17, DTC P1571 Reference Code Incompatibility, Diagnostics
P1572 IMM circuit failure except antenna <Ref. to IM-18, DTC P1572 IMM CIRCUIT FAILURE (EXCEPT ANTENNA
circuit CIRCUIT), Diagnostics Chart with Diagnostic Trouble Code (DTC).>
P1574 Key communication failure <Ref. to IM-21, DTC P1574 KEY COMMUNICATION FAILURE, Diagnostics
P1576 EGI control module EEPROM <Ref. to IM-22, DTC P1576 EGI CONTROL MODULE EEPROM, Diagnos-
P1577 IMM control module EEPROM <Ref. to IM-22, DTC P1577 IMM CONTROL MODULE EEPROM, Diagnos-
input signal circuit low input DIAGNOSIS INPUT SIGNAL CIRCUIT LOW INPUT —, Diagnostic Proce-
input signal circuit high input DIAGNOSIS INPUT SIGNAL CIRCUIT HIGH INPUT —, Diagnostic Proce-
P1698 Engine torque control cut signal cir- <Ref. to EN(TURBO)-340, DTC P1698 — ENGINE TORQUE CONTROL
cuit low input CUT SIGNAL CIRCUIT LOW INPUT —, Diagnostic Procedure with Diagnos-
P1699 Engine torque control cut signal cir- <Ref. to EN(TURBO)-342, DTC P1699 — ENGINE TORQUE CONTROL
cuit high input CUT SIGNAL CIRCUIT HIGH INPUT —, Diagnostic Procedure with Diag-
P1700 Throttle position sensor circuit mal- <Ref. to AT-50, DTC 31 THROTTLE POSITION SENSOR, Diagnostic Pro-
function for automatic transmission cedure with Diagnostic Trouble Code (DTC).>
P1701 Cruise control set signal circuit mal- <Ref. to EN(TURBO)-344, DTC P1701 — CRUISE CONTROL SET SIGNAL
function for automatic transmission CIRCUIT MALFUNCTION FOR AUTOMATIC TRANSMISSION —, Diagnos-
P1703 Low clutch timing control solenoid <Ref. to AT-78, DTC 73 LOW CLUTCH TIMING SOLENOID, Diagnostic
valve circuit malfunction Procedure with Diagnostic Trouble Code (DTC).>
P1711 Engine torque control signal 1 circuit <Ref. to EN(TURBO)-346, DTC P1711 — ENGINE TORQUE CONTROL
malfunction SIGNAL 1 CIRCUIT MALFUNCTION —, Diagnostic Procedure with Diag-
P1712 Engine torque control signal 2 circuit <Ref. to EN(TURBO)-348, DTC P1712 — ENGINE TORQUE CONTROL
malfunction SIGNAL 2 CIRCUIT MALFUNCTION —, Diagnostic Procedure with Diag-
EN(TURBO)-81

A: DTC P0031 — FRONT OXYGEN (A/F) SENSOR HEATER CIRCUIT LOW IN-
PUT —
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(TURBO)-45, OP-
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(TURBO)-42, Inspection Mode.> .
• WIRING DIAGRAM:
B18
1 2
RHD
RHD
MAIN RELAY BATTERY

3 4
SBF-5
6 LHD 2 LHD
4
B61 F44 B47
5
3 1 2
3 4
2 5 6
2
1
FRONT OXYGEN
B47 (A/F) SENSOR
B18 F44
1 2 3 4
1
5 6 7 8
F60 : LHD
B22 : RHD
1 2 3 4
5 6 7 8
19
29
18
9 10 11 12
4
5
13 14 15 16
B137 ECM
B137
8
9
RHD 1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
LHD
22 23 24 25 26 27 28 29 30 31
B209
A3
F76 B209
LHD
A1 A2 A3 A4 A5
E B1 B2 B4 B5
RHD C1 C2 C3 C4 C5
D1 D2 D4 D5
F60 : LHD B22 : RHD E1 E5
3
E3 F1 F5
G1G2 G4 G5
H1 H2 H3 H4 H5
E I1 I2 I4 I5
J3 J4 J5
J1 J2
EN1433
Step Check Yes No

P0037 at the same time?
EN(TURBO)-82
Step Check Yes No

2 CHECK POWER SUPPLY TO FRONT OXY- Is the voltage more than 10 V? Go to step 3. Repair the power
GEN (A/F) SENSOR. supply line.
2)Disconnect the connector from front oxygen In this case, repair
(A/F) sensor. the following:
4)Measure the voltage between front oxygen harness between
(A/F) sensor connector and engine ground. main relay and
Connector & terminal front oxygen (A/F)
• Poor contact in
front oxygen (A/F)
sensor connector
• Poor contact in
main relay con-
nector
Measure the resistance of harness between Ω? ness and connec-
ECM connector and chassis ground. tor.
(B137) No. 8 — Chassis ground: In this case, repair
• Open circuit in
harness between
ECM and engine
ground cable
• Poor contact in
ECM connector
• Poor contact in
coupling connector
4 CHECK CURRENT DATA. Is the value more than 0.2 A? Repair the poor Go to step 5.
1)Start the engine. contact in connec-
2)Read the data of front oxygen (A/F) sensor tor.
heater current using Subaru Select Monitor or NOTE:
OBD-II general scan tool. In this case, repair
•Subaru Select Monitor • Poor contact in
For detailed operation procedure, refer to the front oxygen (A/F)
“READ CURRENT DATA FOR ENGINE”. sensor connector
<Ref. to EN(TURBO)-34, Subaru Select Moni- • Poor contact in
tor.> ECM connector
•OBD-II scan tool
and chassis ground.
EN(TURBO)-83
Step Check Yes No

9 CHECK FRONT OXYGEN (A/F) SENSOR. Is the resistance less than 10 Repair the har- Replace the front
1)Turn the ignition switch to OFF. Ω? ness and connec- oxygen (A/F) sen-
2)Measure the resistance between front oxy- tor. sor. <Ref. to
gen (A/F) sensor connector terminals. NOTE: FU(TURBO)-44,
Terminals In this case, repair Front Oxygen (A/
No. 2 — No. 1: the following: F) Sensor.>
• Open or ground
ness between
front oxygen (A/F)
sensor and ECM
connector
• Poor contact in
front oxygen (A/F)
sensor connector
• Poor contact in
ECM connector
EN(TURBO)-84
EN(TURBO)-85
B: DTC P0032 — FRONT OXYGEN (A/F) SENSOR HEATER CIRCUIT HIGH IN-
PUT —
CAUTION:
• WIRING DIAGRAM:
B18
1 2
RHD
RHD
MAIN RELAY BATTERY

3 4
SBF-5
6 LHD 2 LHD
4
B61 F44 B47
5
3 1 2
3 4
2 5 6
2
1
FRONT OXYGEN
B47 (A/F) SENSOR
B18 F44
1 2 3 4
1
5 6 7 8
F60 : LHD
B22 : RHD
1 2 3 4
5 6 7 8
19
29
18
9 10 11 12
4
5
13 14 15 16
B137 ECM
B137
8
9
RHD 1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
LHD
22 23 24 25 26 27 28 29 30 31
B209
A3
F76 B209
LHD
A1 A2 A3 A4 A5
E B1 B2 B4 B5
RHD C1 C2 C3 C4 C5
D1 D2 D4 D5
3
E3 F1 F5
G1G2 G4 G5
H1 H2 H3 H4 H5
E I1 I2 I4 I5
J3 J4 J5
J1 J2
EN1433
Step Check Yes No

EN(TURBO)-86
Step Check Yes No

2 CHECK FRONT OXYGEN (A/F) SENSOR Is the value more than 2.3 A? Replace the ECM. END
HEATER CURRENT. <Ref. to
1)Turn the ignition switch to OFF. FU(TURBO)-49,
2)Repair the battery short circuit in harness Engine Control
between ECM and front oxygen (A/F) sensor Module.>
connector.
heater current using Subaru Select Monitor or
the OBD-II general scan tool.
NOTE:
<Ref. to EN(TURBO)-34, Subaru Select Moni-
tor.>
3 CHECK OUTPUT SIGNAL FROM ECM. Does the voltage change more Repair the battery END
Measure the voltage between ECM connector than 8 V by shaking harness short circuit in har-
and chassis ground. and connector of ECM while ness between
Connector & terminal monitoring the value with volt- ECM and front
(B137) No. 5 (+) — Chassis ground (−): sor connector.
EN(TURBO)-87
C: DTC P0037 — REAR OXYGEN SENSOR HEATER CIRCUIT MALFUNCTION

—
CAUTION:
• WIRING DIAGRAM:
RHD
RHD
MAIN RELAY BATTERY B19 F44 B47
1 2 1 2 3 4 1 2
6 LHD 2 LHD 3 4 5 6 7 8 3 4
4 5 6
(LHD)
B61 F44
5
*3
3 2 1
REAR 4 3
2 OXYGEN SENSOR B83
1 (RHD)
LHD : 2
B19
*1 RHD : 4 1 2 3
B47
* 45
*6
F60 : LHD 4 5 6
*
2 LHD : 6
* RHD : 1 B22 : RHD
(LHD)
1 2 3 4 1 2 3 4 5 6
LHD : 2
*3 RHD : 1
5 6 7
11
8
12
(RHD)
9 10
13 14 15 16
LHD LHD : 1
*4 RHD : 2
RHD
B135
5 LHD : 3
B260
* 12 * RHD : 4 1 2 3 4 5 6 7 8 9
* 10 11 12 13 14 15 16 17 18 19
1
B259 LHD : 4 20 21 22 23 24 25 26 27 28
B83 *6 RHD : 3
RHD
B136
LHD 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24
RHD B137
C13
B17
B26
B19
LHD
1 2 3 4 5 6 7 8 9
B : B135 10 11 12 13 14 15 16 17 18 19 20 21
B209
22 23 24 25 26 27 28 29 30 31
A3
C : B136 ECM
F76
D : B137 B209 B259
E
LHD
A1 A2 A3 A4 A5 1 2
D8
D9
B1 B2 B4 B5
RHD
C1 C2 C3 C4 C5
D1 D2 D4 D5
F60 : LHD B22 : RHD
E1 E5
3
E3
F1 F5
G1G2 G4 G5
H1 H2 H3 H4 H5
E I1 I2 I4 I5
J1 J2 J3 J4 J5
EN1434
EN(TURBO)-88
Step Check Yes No

ECM connector and chassis ground. In this case, repair
ECM and engine
ground cable
• Poor contact in
ECM connector
• Poor contact in
coupling connector
2 CHECK CURRENT DATA. Is the value more than 0.2 A? Repair the con- Go to step 3.
1)Start the engine. nector.
2)Read the data of rear oxygen sensor heater NOTE:
current using Subaru Select Monitor or OBD-II In this case, repair
general scan tool. the following:
•Subaru Select Monitor rear oxygen sen-
For detailed operation procedure, refer to the sor connector
<Ref. to EN(TURBO)-34, Subaru Select Moni- rear oxygen sen-
tor.> sor connecting
•OBD-II scan tool harness connector
OBD-II General Scan Tool Instruction Manual. ECM connector
5 CHECK OUTPUT SIGNAL FROM ECM. Is the voltage less than 1.0 V? Replace the ECM. Repair the battery
1)Disconnect the connector from rear oxygen <Ref. to short circuit in har-
sensor. FU(TURBO)-49, 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
(B136) No. 13 (+) — Chassis ground (−): repair, replace the
ECM. <Ref. to
FU(TURBO)-49,
Engine Control
Module.>
EN(TURBO)-89
Step Check Yes No

6 CHECK POWER SUPPLY TO REAR OXY- Is the voltage more than 10 V? Go to step 7. Repair the power
GEN SENSOR. supply line.
2)Disconnect the connector from rear oxygen In this case, repair
sensor. the following:
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
LHD model: • Poor contact in
(B19) No. 2 (+) — Chassis ground (−): rear oxygen sen-
RHD model: sor connector
(B19) No. 1 (+) — Chassis ground (−): • Poor contact in
coupling connector
7 CHECK REAR OXYGEN SENSOR. Is the resistance less than 30 Repair the har- Replace the rear
1)Turn the ignition switch to OFF. Ω? ness and connec- oxygen sensor.
2)Measure the resistance between rear oxy- tor. <Ref. to
gen sensor connector terminals. NOTE: FU(TURBO)-46,
Terminals In this case, repair Rear Oxygen Sen-
No. 1 — No. 2: the following: sor.>
• 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 connector
EN(TURBO)-90
EN(TURBO)-91
D: DTC P0038 — REAR OXYGEN SENSOR HEATER CIRCUIT HIGH INPUT —

CAUTION:
• WIRING DIAGRAM:
RHD
RHD
1 2 1 2 3 4 1 2
6 LHD 2 LHD 3 4 5 6 7 8 3 4
4 5 6
(LHD)
B61 F44
5
*3
3 2 1
REAR 4 3
2 OXYGEN SENSOR B83
1 (RHD)
LHD : 2
B19
*1 RHD : 4 1 2 3
B47
* 45
*6
F60 : LHD 4 5 6
*
LHD : 6
*2 RHD : 1 B22 : RHD
(LHD)
1 2 3 4 1 2 3 4 5 6
LHD : 2
*3 RHD : 1
5 6 7
11
8
12
(RHD)
9 10
13 14 15 16
LHD LHD : 1
*4 RHD : 2
RHD
B135
5 LHD : 3
B260
* 12 * RHD : 4 1 2 3 4 5 6 7 8 9
* 10 11 12 13 14 15 16 17 18 19
1
B259 LHD : 4 20 21 22 23 24 25 26 27 28
B83 *6 RHD : 3
RHD
B136
LHD 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24
RHD B137
C13
B17
B26
B19
LHD
1 2 3 4 5 6 7 8 9
B : B135 10 11 12 13 14 15 16 17 18 19 20 21
B209
22 23 24 25 26 27 28 29 30 31
A3
C : B136 ECM
F76
D : B137 B209 B259
E
LHD
A1 A2 A3 A4 A5 1 2
D8
D9
B1 B2 B4 B5
RHD
C1 C2 C3 C4 C5
D1 D2 D4 D5
F60 : LHD B22 : RHD
E1 E5
3
E3
F1 F5
G1G2 G4 G5
H1 H2 H3 H4 H5
E I1 I2 I4 I5
J1 J2 J3 J4 J5
EN1434
Step Check Yes No

and chassis ground.
EN(TURBO)-92
Step Check Yes No

2 CHECK CURRENT DATA. Is the value more than 7 A? Replace the ECM. END
1)Turn the ignition switch to OFF. <Ref. to
2)Repair the battery short circuit in harness FU(TURBO)-49,
between ECM and rear oxygen sensor con- Engine Control
nector. Module.>
4)Read the data of rear oxygen sensor heater
current using Subaru Select Monitor or the
NOTE:
tor.>
3 CHECK POOR CONTACT. Is there poor contact in ECM Repair the poor END
connector.
EN(TURBO)-93
E: DTC P0101 — MASS AIR FLOW SENSOR CIRCUIT RANGE/PERFORMANCE

• Engine stalls.
CAUTION:
• WIRING DIAGRAM:
MAIN RELAY
RHD
RHD
6 BATTERY
4
SBF-5
5 LHD 8 LHD
3
B61 F44
2
1
1
B47
MASS AIR FLOW AND

INTAKE AIR TEMPERATURE
B3
5
* 12
*
B83
E13
B19
B27
E8
E7
LHD : 3
*1 RHD : 2
LHD : 6 B: B135 E
*2 RHD : 1 ECM
E: B84
B3 B47 E: B84 B : B135 B83
1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 1 2 3
1 2
1 2 3 4 5 7 8 9 10 11 12 10 11 12 13 14 15 16 17 18 19 4 5 6
3 4
5 6 13 14 15 16 17 20 21 22 23 24 25 26 27 28 (LHD)
F44 1 2 3 4 5 6
(RHD)
1 2 3 4
5 6 7 8
EN0970
EN(TURBO)-94
Step Check Yes No

1 CHECK ANY OTHER DIAGNOSTIC TROU- Is any other DTC displayed? Inspect the rele- Replace the mass
BLE CODE (DTC) ON DISPLAY. vant DTC using air flow and intake
“List of Diagnostic air temperature
Trouble Code sensor. <Ref. to
(DTC)”. <Ref. to FU(TURBO)-34,
EN(TURBO)-75, Mass Air Flow and
List of Diagnostic Intake Air Temper-
Trouble Code ature Sensor.>
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0101.
EN(TURBO)-95
F: DTC P0102 — MASS AIR FLOW SENSOR CIRCUIT LOW INPUT —

• Engine stalls.
• WIRING DIAGRAM:
MAIN RELAY
RHD
RHD
6 BATTERY
4
SBF-5
5 LHD 8 LHD
3
B61 F44
2
1
1
B47
MASS AIR FLOW AND

B3
5
* 12
*
B83
E13
B19
B27
E8
E7
LHD : 3
*1 RHD : 2
LHD : 6 B: B135 E
*2 RHD : 1 ECM
E: B84
B3 B47 E: B84 B : B135 B83
1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 1 2 3
1 2
1 2 3 4 5 7 8 9 10 11 12 10 11 12 13 14 15 16 17 18 19 4 5 6
3 4
5 6 13 14 15 16 17 20 21 22 23 24 25 26 27 28 (LHD)
F44 1 2 3 4 5 6
(RHD)
1 2 3 4
5 6 7 8
EN0970
EN(TURBO)-96
Step Check Yes No

1 CONNECT SUBARU SELECT MONITOR OR Is the value equal to or more Even if MIL lights Go to step 2.
THE OBD-II GENERAL SCAN TOOL, AND than 1.3 g/sec (0.172 lb/min) or up, the circuit has
READ DATA. 0.3 V and equal to or less than returned to a nor-
1)Turn the ignition switch to OFF. 240 g/sec (32 lb/min) or 4.58 mal condition at
2)Connect the Subaru Select Monitor or OBD- V? this time. A tempo-
II general scan tool to data link connector. rary poor contact
3)Turn the ignition switch to ON and Subaru of the connector or
Select Monitor or the OBD-II general scan tool harness may be
switch to ON. the cause. Repair
4)Start the engine. the harness or
5)Read the data of mass air flow sensor signal connector in the
using Subaru Select Monitor or OBD-II general mass air flow sen-
scan tool. sor.
NOTE: NOTE:
•Subaru Select Monitor In this case, repair
For detailed operation procedure, refer to the the following:
“READ CURRENT DATA FOR ENGINE”. • Open or ground
<Ref. to EN(TURBO)-34, Subaru Select Moni- short circuit in har-
tor.> ness between
•OBD-II general scan tool mass air flow sen-
For detailed operation procedures, refer to the sor and ECM con-
OBD-II General Scan Tool Instruction Manual. nector
• Poor contact in
mass air flow sen-
sor or ECM con-
nector
and chassis ground while engine is idling.
3 CHECK INPUT SIGNAL FOR ECM (USING Does the voltage change more Repair the poor Contact with your
SUBARU SELECT MONITOR). than 0.2 V by shaking harness contact in ECM Subaru distributor
Measure the voltage between ECM connector and connector of ECM while connector. service.
and chassis ground while engine is idling. monitoring the value with NOTE:
Subaru Select Monitor? Inspection by DTM
is required, be-
cause probable
cause is deteriora-
tion of multiple
parts.
4 CHECK POWER SUPPLY TO MASS AIR Is the voltage more than 10 V? Go to step 5. Repair the open
FLOW SENSOR. circuit between
1)Turn the ignition switch to OFF. mass air flow sen-
2)Disconnect the connector from mass air flow sor and main
sensor. relay.
4)Measure the voltage between mass air flow
sensor connector and chassis ground.
EN(TURBO)-97
Step Check Yes No

5 CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1Ω? Go to step 6. Repair the open
MASS AIR FLOW SENSOR CONNECTOR. circuit between
1)Turn the ignition switch to OFF. ECM and mass air
2)Disconnect the connector from ECM. flow sensor con-
3)Measure the resistance of harness between nector.
ECM and mass air flow sensor connector.
(B84) No. 13 — (B3) No. 3:
(B135) No. 27 — (B3) No. 4:
(B135) No. 19 — (B3) No. 5:
6 CHECK HARNESS BETWEEN ECM AND Is the resistance more than Go to step 7. Repair the ground
MASS AIR FLOW SENSOR CONNECTOR 1MΩ? short circuit
Measure the resistance of harness between between ECM and
ECM and chassis ground. mass air flow sen-
7 CHECK POOR CONTACT Is there poor contact in mass Repair the poor Replace the mass
Check poor contact in mass air flow sensor air flow sensor connector? contact in mass air air flow and intake
connector. flow sensor con- air temperature
nector. sensor. <Ref. to
FU(TURBO)-34,
Mass Air Flow and
Intake Air Temper-
ature Sensor.>
EN(TURBO)-98
EN(TURBO)-99
G: DTC P0103 — MASS AIR FLOW SENSOR CIRCUIT HIGH INPUT —

• Engine stalls.
CAUTION:
• WIRING DIAGRAM:
MAIN RELAY
RHD
RHD
6 BATTERY
4
SBF-5
5 LHD 8 LHD
3
B61 F44
2
1
1
B47
MASS AIR FLOW AND

B3
5
* 12
*
B83
E13
B19
B27
E8
E7
LHD : 3
*1 RHD : 2
LHD : 6 B: B135 E
*2 RHD : 1 ECM
E: B84
B3 B47 E: B84 B : B135 B83
1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 1 2 3
1 2
1 2 3 4 5 7 8 9 10 11 12 10 11 12 13 14 15 16 17 18 19 4 5 6
3 4
5 6 13 14 15 16 17 20 21 22 23 24 25 26 27 28 (LHD)
F44 1 2 3 4 5 6
(RHD)
1 2 3 4
5 6 7 8
EN0970
EN(TURBO)-100
Step Check Yes No

1 CONNECT SUBARU SELECT MONITOR OR Is the value equal to or more Even if MIL lights Go to step 2.
THE OBD-II GENERAL SCAN TOOL, AND than 1.3 g/sec (0.172 lb/min) or up, the circuit has
READ DATA. 0.3 V and equal to or less than returned to a nor-
1)Turn the ignition switch to OFF. 240 g/sec (32 lb/min) or 4.58 mal condition at
2)Connect the Subaru Select Monitor or OBD- V? this time.
II general scan tool to data link connector.
Select Monitor or OBD-II general scan tool
switch to ON.
4)Start the engine.
5)Read the data of mass air flow sensor signal
scan tool.
NOTE:
tor.>
2 CHECK HARNESS BETWEEN ECM AND Is the value more than 240 Repair the battery Replace the mass
MASS AIR FLOW SENSOR CONNECTOR. g/sec (32 lb/min) or 4.58 V in short circuit in har- air flow sensor.
1)Turn the ignition switch to OFF and Subaru function mode F06? ness between
Select Monitor or the OBD-II 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.
switch to ON.
4)Read the data of mass air flow sensor signal
scan tool.
NOTE:
tor.>
EN(TURBO)-101
H: DTC P0106 — PRESSURE SENSOR CIRCUIT RANGE/PERFORMANCE

CAUTION:
• LHD model:
THROTTLE BODY
PRESSURE SENSOR
1
2
3
E21
E2
18
20
16
F61
F76
A1
G2
F5
B209
1
6
B83
19
9
8
B135 ECM
E21 B83 F61 B135 B209
1 2 3 A1 A2 A3 A4 A5
1 2 3 1 2 3 4 1 2 3 4 5 6 7 8 9
4 5 6 B1 B2 B4 B5
5 6 7 8 10 11 12 13 14 15 16 17 18 19
C1 C2 C3 C4 C5
9 10 11 12 20 21 22 23 24 25 26 27 28 D4 D5
D1 D2
13 14 15 16 E1 E5
17 18 19 20
F1 F5
G1G2 G4 G5
H1 H2 H3 H4 H5
I1 I2 I4 I5
J1 J2 J3 J4 J5
EN1435
EN(TURBO)-102
• RHD model:
THROTTLE BODY
PRESSURE SENSOR
2
3
1
E21
E2
18
20
16
B21
3
1
B83
19
9
8
B135 ECM
E21 B83 B21 B135
1 2 3 1 2 3 4 5 6 1 2 3 4 1 2 3 4 5 6 7 8 9
5 6 7 8 10 11 12 13 14 15 16 17 18 19
9 10 11 12 20 21 22 23 24 25 26 27 28
13 14 15 16
17 18 19 20
EN0968
EN(TURBO)-103
Step Check Yes No

1 CHECK IDLE SWITCH SIGNAL. Does the LED of {Idle Switch Go to step 2. Check the throttle
1)Turn the ignition switch to ON. Signal} come on? position sensor cir-
2)Operate the LED operation mode for engine cuit. <Ref. to
using Subaru Select Monitor. EN(TURBO)-127,
NOTE: DTC P0121 —
•Subaru Select Monitor THROTTLE POSI-
For detailed operation procedure, refer to the TION SENSOR
“LED OPERATION MODE FOR ENGINE”. CIRCUIT RANGE/
<Ref. to EN(TURBO)-34, Subaru Select Moni- PERFORMANCE
tor.> PROBLEM (HIGH
INPUT) —, Diag-
nostic Procedure
with Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0106.
BLE CODE (DTC) ON DISPLAY. vant DTC. “List of
Diagnostic Trou-
ble Code (DTC)”.
<Ref. to
EN(TURBO)-75,
List of Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0106.
3 CHECK CONDITION OF INTAKE MANIFOLD Is the pressure sensor installa- Go to step 4. Tighten the pres-
PRESSURE SENSOR. tion bolt tightened securely? sure sensor instal-
lation bolt
securely.
4 CHECK CONDITION OF THROTTLE BODY. Is the throttle body installation Replace the pres- Tighten the throttle
bolt tightened securely? sure sensor. <Ref. body installation
to FU(TURBO)-35, bolt securely.
Pressure Sensor.>
EN(TURBO)-104
I: DTC P0107 — PRESSURE SENSOR CIRCUIT LOW INPUT —

CAUTION:
• WIRING DIAGRAM:
• LHD model
THROTTLE BODY
PRESSURE SENSOR
1
2
3
E21
E2
18
20
16
F61
F76
A1
G2
F5
B209
1
6
B83
19
9
8
B135 ECM
E21 B83 F61 B135 B209
1 2 3 A1 A2 A3 A4 A5
1 2 3 1 2 3 4 1 2 3 4 5 6 7 8 9
4 5 6 B1 B2 B4 B5
5 6 7 8 10 11 12 13 14 15 16 17 18 19
C1 C2 C3 C4 C5
9 10 11 12 20 21 22 23 24 25 26 27 28 D4 D5
D1 D2
13 14 15 16 E1 E5
17 18 19 20
F1 F5
G1G2 G4 G5
H1 H2 H3 H4 H5
I1 I2 I4 I5
J1 J2 J3 J4 J5
EN1435
EN(TURBO)-105
• RHD model
THROTTLE BODY
PRESSURE SENSOR
2
3
1
E21
E2
18
20
16
B21
3
1
B83
19
9
8
B135 ECM
E21 B83 B21 B135
1 2 3 1 2 3 4 5 6 1 2 3 4 1 2 3 4 5 6 7 8 9
5 6 7 8 10 11 12 13 14 15 16 17 18 19
9 10 11 12 20 21 22 23 24 25 26 27 28
13 14 15 16
17 18 19 20
EN0968
Step Check Yes No

1 CHECK CURRENT DATA. Is the value less than −7.2 kPa Go to step 3. Go to step 2.
1)Start the engine. (−54 mmHg, −2.1 inHg)?
NOTE:
tor.>
EN(TURBO)-106
Step Check Yes No

sor connector. pressure sensor returned to a nor-
connector. mal condition at
this time.
and chassis ground.
is required, be-
cause probable
cause is deteriora-
tion of multiple
parts.
5 CHECK INPUT SIGNAL FOR ECM. Is the voltage less than 0.7 V? Go to step 6. Contact with your
Measure the voltage between ECM and chas- Subaru distributor
sis ground. service.
(B135) No. 8 (+) — Chassis ground (−): Inspection by DTM
is required, be-
cause probable
cause is deteriora-
tion of multiple
parts.
6 CHECK HARNESS BETWEEN ECM AND Is the voltage more than 4.5 V? Go to step 7. Repair the open
PRESSURE SENSOR CONNECTOR. circuit in harness
2)Disconnect the connector from pressure intake manifold
sensor. pressure sensor
2)Disconnect the connector from ECM. intake manifold
3)Measure the resistance of harness between pressure sensor
ECM and intake manifold pressure sensor con- connector.
nector.
(B135) No. 19 — (E21) No. 2:
PRESSURE SENSOR CONNECTOR. MΩ? short circuit in har-
intake manifold pressure sensor connector and ECM and intake
engine ground. manifold pressure
EN(TURBO)-107
Step Check Yes No

9 CHECK POOR CONTACT. Is there poor contact in pres- Repair the poor Replace the pres-
Check poor contact in pressure sensor con- sure sensor connector? contact in pressure sensor. <Ref.
nector. sure sensor con- to FU(TURBO)-35,
nector. Pressure Sensor.>
EN(TURBO)-108
J: DTC P0108 — PRESSURE SENSOR CIRCUIT HIGH INPUT —

CAUTION:
• WIRING DIAGRAM:
• LHD model
THROTTLE BODY
PRESSURE SENSOR
1
2
3
E21
E2
18
20
16
F61
F76
A1
G2
F5
B209
1
6
B83
19
9
8
B135 ECM
E21 B83 F61 B135 B209
1 2 3 A1 A2 A3 A4 A5
1 2 3 1 2 3 4 1 2 3 4 5 6 7 8 9
4 5 6 B1 B2 B4 B5
5 6 7 8 10 11 12 13 14 15 16 17 18 19
C1 C2 C3 C4 C5
9 10 11 12 20 21 22 23 24 25 26 27 28 D4 D5
D1 D2
13 14 15 16 E1 E5
17 18 19 20
F1 F5
G1G2 G4 G5
H1 H2 H3 H4 H5
I1 I2 I4 I5
J1 J2 J3 J4 J5
EN1435
EN(TURBO)-109
• RHD model
THROTTLE BODY
PRESSURE SENSOR
2
3
1
E21
E2
18
20
16
B21
3
1
B83
19
9
8
B135 ECM
E21 B83 B21 B135
1 2 3 1 2 3 4 5 6 1 2 3 4 1 2 3 4 5 6 7 8 9
5 6 7 8 10 11 12 13 14 15 16 17 18 19
9 10 11 12 20 21 22 23 24 25 26 27 28
13 14 15 16
17 18 19 20
EN0968
Step Check Yes No

1 CHECK CURRENT DATA. Is the value more than 282 kPa Go to step 9. Go to step 2.
1)Start the engine. (2121 mmHg, 83.50 inHg)?
NOTE:
tor.>
EN(TURBO)-110
Step Check Yes No

and chassis ground.
is required, be-
cause probable
cause is deteriora-
tion of multiple
parts.
4 CHECK INPUT SIGNAL FOR ECM. Is the voltage less than 0.7 V? Go to step 5. Contact with your
Measure the voltage between ECM connector Subaru distributor
and chassis ground. service.
(B135) No. 8 (+) — Chassis ground (−): Inspection by DTM
is required, be-
cause probable
cause is deteriora-
tion of multiple
parts.
5 CHECK HARNESS BETWEEN ECM AND Is the voltage more than 4.5 V? Go to step 6. Repair the open
PRESSURE SENSOR CONNECTOR. circuit in harness
2)Disconnect the connector from pressure pressure sensor
sensor. connector.
2)Disconnect the connector from ECM. pressure sensor
ECM and pressure sensor connector.
(B135) No. 8 — (E21) No. 1:
TAKE MANIFOLD PRESSURE SENSOR Ω? circuit in harness
CONNECTOR. between ECM and
Measure the resistance of harness between pressure sensor
ECM and pressure sensor connector. connector.
(B135) No. 19 — (E21) No. 2:
8 CHECK POOR CONTACT. Is there poor contact in pres- Repair the poor Replace the intake
Check poor contact in pressure sensor con- sure sensor connector? contact in pres- manifold pressure
nector. sure sensor con- sensor. <Ref. to
nector. FU(TURBO)-35,
Pressure Sensor.>
EN(TURBO)-111
Step Check Yes No

9 CHECK HARNESS BETWEEN ECM AND Is the value more than 282 kPa Repair the battery Replace the pres-
PRESSURE SENSOR CONNECTOR. (2121 mmHg, 83.50 inHg)? short circuit in har- sure sensor. <Ref.
1)Turn the ignition switch to OFF and Subaru ness between to FU(TURBO)-35,
Select Monitor or the OBD-II general scan tool ECM and pressure Pressure Sensor.>
switch to OFF. sensor connector.
2)Disconnect the connector from pressure
sensor.
switch to ON.
NOTE:
tor.>
EN(TURBO)-112
EN(TURBO)-113
K: DTC P0111 — INTAKE AIR TEMPERATURE SENSOR CIRCUIT RANGE/PER-

CAUTION:
• WIRING DIAGRAM:
MAIN RELAY
RHD
RHD
6 BATTERY
4
SBF-5
5 LHD 8 LHD
3
B61 F44
2
1
1
B47
MASS AIR FLOW AND

B3
5
* 12
*
B83
E13
B19
B27
E8
E7
LHD : 3
*1 RHD : 2
LHD : 6 B: B135 E
*2 RHD : 1 ECM
E: B84
B3 B47 E: B84 B : B135 B83
1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 1 2 3
1 2
1 2 3 4 5 7 8 9 10 11 12 10 11 12 13 14 15 16 17 18 19 4 5 6
3 4
5 6 13 14 15 16 17 20 21 22 23 24 25 26 27 28 (LHD)
F44 1 2 3 4 5 6
(RHD)
1 2 3 4
5 6 7 8
EN0970
EN(TURBO)-114
Step Check Yes No

Trouble Code
(DTC)”. <Ref. to
EN(TURBO)-75,
List of Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0111.
2 CHECK ENGINE COOLANT TEMPERA- Is the engine coolant tempera- Replace the mass Inspect the DTC
TURE. ture between 75°C (167°F) air flow and intake P0125 using “List
1)Start the engine and warm it up completely. and 95°C (203°F)? air temperature of Diagnostic
2)Measure the engine coolant temperature sensor. <Ref. to Trouble Code
using Subaru Select Monitor or OBD-II general FU(TURBO)-34, (DTC)”. <Ref. to
scan tool. Mass Air Flow and EN(TURBO)-75,
NOTE: Intake Air Temper- List of Diagnostic
•Subaru Select Monitor ature Sensor.> Trouble Code
For detailed operation procedure, refer to the (DTC).>
tor.>
EN(TURBO)-115
L: DTC P0112 — INTAKE AIR TEMPERATURE SENSOR CIRCUIT LOW INPUT

—
CAUTION:
• WIRING DIAGRAM:
MAIN RELAY
RHD
RHD
6 BATTERY
4
SBF-5
5 LHD 8 LHD
3
B61 F44
2
1
1
B47
MASS AIR FLOW AND

B3
5
* 12
*
B83
E13
B19
B27
E8
E7
LHD : 3
*1 RHD : 2
LHD : 6 B: B135 E
*2 RHD : 1 ECM
E: B84
B3 B47 E: B84 B : B135 B83
1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 1 2 3
1 2
1 2 3 4 5 7 8 9 10 11 12 10 11 12 13 14 15 16 17 18 19 4 5 6
3 4
5 6 13 14 15 16 17 20 21 22 23 24 25 26 27 28 (LHD)
F44 1 2 3 4 5 6
(RHD)
1 2 3 4
5 6 7 8
EN0970
EN(TURBO)-116
Step Check Yes No

sor signal using Subaru Select Monitor or the In this case, repair
NOTE: • Poor contact
•Subaru Select Monitor mass air flow and
For detailed operation procedure, refer to the intake air tempera-
“READ CURRENT DATA FOR ENGINE”. ture sensor
tor.> ECM
•OBD-II general scan tool • Poor contact in
For detailed operation procedure, refer to the joint connector
2 CHECK HARNESS BETWEEN MASS AIR Is the value less than −36°C Replace the mass Repair the ground
FLOW AND INTAKE AIR TEMPERATURE (−97°F)? air flow and intake short circuit in har-
SENSOR AND ECM CONNECTOR. air temperature ness between
1)Turn the ignition switch to OFF. sensor. <Ref. to mass air flow and
2)Disconnect the connector from mass air flow FU(TURBO)-34, intake air tempera-
and intake air temperature sensor. Mass Air Flow and ture sensor and
3)Turn the ignition switch to ON. Intake Air Temper- ECM connector.
4)Read the data of intake air temperature sen- ature Sensor.>
sor signal using Subaru Select Monitor or the
NOTE:
tor.>
EN(TURBO)-117
M: DTC P0113 — INTAKE AIR TEMPERATURE SENSOR CIRCUIT HIGH INPUT

—
CAUTION:
• WIRING DIAGRAM:
MAIN RELAY
RHD
RHD
6 BATTERY
4
SBF-5
5 LHD 8 LHD
3
B61 F44
2
1
1
B47
MASS AIR FLOW AND

B3
5
* 12
*
B83
E13
B19
B27
E8
E7
LHD : 3
*1 RHD : 2
LHD : 6 B: B135 E
*2 RHD : 1 ECM
E: B84
B3 B47 E: B84 B : B135 B83
1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 1 2 3
1 2
1 2 3 4 5 7 8 9 10 11 12 10 11 12 13 14 15 16 17 18 19 4 5 6
3 4
5 6 13 14 15 16 17 20 21 22 23 24 25 26 27 28 (LHD)
F44 1 2 3 4 5 6
(RHD)
1 2 3 4
5 6 7 8
EN0970
EN(TURBO)-118
Step Check Yes No

sor signal using Subaru Select Monitor or the In this case, repair
•Subaru Select Monitor mass air flow and
For detailed operation procedure, refer to the intake air tempera-
“READ CURRENT DATA FOR ENGINE”. ture sensor
tor.> ECM
For detailed operation procedure, refer to the joint connector
2 CHECK HARNESS BETWEEN MASS AIR Is the voltage more than 10 V? Repair the 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.
and intake air temperature sensor connector
and engine ground.
1)Turn the 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.
4 CHECK HARNESS BETWEEN MASS AIR Is the voltage more than 3 V? Go to step 5. Repair the har-
FLOW AND INTAKE AIR TEMPERATURE ness and connec-
SENSOR AND ECM CONNECTOR. tor.
Measure the voltage between mass air flow NOTE:
and intake air temperature sensor and pres- In this case, repair
sure sensor connector and engine ground. the following:
(B3) No. 2 (+) — Engine ground (−): harness between
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(TURBO)-119
Step Check Yes No

5 CHECK HARNESS BETWEEN MASS AIR Is the resistance less than 5 Replace the mass Repair the har-
FLOW AND INTAKE AIR TEMPERATURE Ω? air flow and intake ness and connec-
SENSOR AND ECM CONNECTOR. air temperature tor.
1)Turn the ignition switch to OFF. sensor. <Ref. to NOTE:
2)Measure the resistance of harness between FU(TURBO)-34, In this case, repair
mass air flow and intake air temperature sen- Mass Air Flow and the following:
sor and engine ground. Intake Air Temper- • Open circuit in
Connector & terminal ature Sensor.> ness between
(B3) No. 5 — Engine ground: 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(TURBO)-120
EN(TURBO)-121
N: DTC P0117 — ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT LOW

INPUT —
• Hard to start
CAUTION:
• WIRING DIAGRAM:
E8 F61 : LHD
B21 : RHD
1 2
ENGINE
COOLANT 3
TEMPERATURE 1 2 3 4
SENSOR 5 6 7 8
9 10 11 12
13 14 15 16
1
2
17 18 19 20
E8
E2 B83
18
17
F61 : LHD B21 : RHD 1 2 3

4 5 6
RHD RHD (LHD)
LHD
LHD
1 2 3 4 5 6
(RHD)
F76
G2
G1
B209
B135
1 2 3 4 5 6 7 8 9
LHD
LHD
10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 28
RHD RHD
B209
* 21 A1 A2 A3 A4 A5
* B1 B2 B4 B5
B83 C1 C2 C3 C4 C5
D1 D2 D4 D5
E1 E5
LHD : 6
*1 RHD : 1 F1 F5
19
18
G1G2 G4 G5
2 LHD : 1
* RHD : 3
H1 H2
I1 I2
H3 H4 H5
I4 I5
J1 J2 J3 J4 J5
B135 ECM
EN1436
EN(TURBO)-122
Step Check Yes No

tor.> ECM
For detailed operation procedures, refer to the coupling connector
joint connector
2 CHECK HARNESS BETWEEN ENGINE Is the value less than −40°C Replace the Repair the ground
COOLANT TEMPERATURE SENSOR AND (−40°F)? engine coolant short circuit in har-
ECM CONNECTOR. temperature sen- ness between
1)Turn the ignition switch to OFF. sor. <Ref. to engine coolant
2)Disconnect the connector from engine cool- FU(TURBO)-29, temperature sen-
ant temperature sensor. Engine Coolant sor and ECM con-
3)Turn the ignition switch to ON. Temperature Sen- nector.
4)Read the data of engine coolant temperature sor.>
NOTE:
tor.>
EN(TURBO)-123
O: DTC P0118 — ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT HIGH

INPUT —
• Hard to start
CAUTION:
• WIRING DIAGRAM:
E8 F61 : LHD
B21 : RHD
1 2
ENGINE
COOLANT 3
TEMPERATURE 1 2 3 4
SENSOR 5 6 7 8
9 10 11 12
13 14 15 16
1
2
17 18 19 20
E8
E2 B83
18
17
F61 : LHD B21 : RHD 1 2 3

4 5 6
RHD RHD (LHD)
LHD
LHD
1 2 3 4 5 6
(RHD)
F76
G2
G1
B209
B135
1 2 3 4 5 6 7 8 9
LHD
LHD
10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 28
RHD RHD
B209
* 21 A1 A2 A3 A4 A5
* B1 B2 B4 B5
B83 C1 C2 C3 C4 C5
D1 D2 D4 D5
E1 E5
LHD : 6
*1 RHD : 1 F1 F5
19
18
G1G2 G4 G5
2 LHD : 1
* RHD : 3
H1 H2
I1 I2
H3 H4 H5
I4 I5
J1 J2 J3 J4 J5
B135 ECM
EN1436
EN(TURBO)-124
Step Check Yes No

tor.> ECM
For detailed operation procedures, refer to the coupling connector
joint connector
2)Disconnect the connector from engine cool- coolant tempera-
ant temperature sensor. ture sensor con-
3)Measure the voltage between engine coolant nector.
ground.
ground. nector.
ECM CONNECTOR. tor.
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
coupling connector
• Poor contact in
joint connector
EN(TURBO)-125
Step Check Yes No

5 CHECK HARNESS BETWEEN ENGINE Is the resistance less than 5 Replace the Repair the har-
COOLANT TEMPERATURE SENSOR AND Ω? engine coolant ness and connec-
ECM CONNECTOR. temperature sen- tor.
1)Turn the ignition switch to OFF. sor. <Ref. to NOTE:
engine coolant temperature sensor connector Engine Coolant the following:
and engine ground. Temperature Sen- • Open circuit in
Connector & terminal sor.> harness between
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(TURBO)-126
P: DTC P0121 — THROTTLE POSITION SENSOR CIRCUIT RANGE/PERFOR-

• Engine stalls.
• Fuel is cut.
CAUTION:
• WIRING DIAGRAM:
• LHD model
THROTTLE
POSITION
E13 F61
SENSOR
1 2 3 1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
17 18 19 20
1
3
2
E13
B83
1 2 3
E2
4 5 6
20
19
18
F61
F76
A1
G2
i2
B135
B209
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19
1 20 21 22 23 24 25 26 27 28
6
B83
B209
A1 A2 A3 A4 A5
B1 B2 B4 B5
C1 C2 C3 C4 C5
D1 D2 D4 D5
E1 E5
19
7
9
F1 F5
G1G2 G4 G5
H1 H2 H3 H4 H5
I1 I2 I4 I5
B135 ECM J1 J2 J3 J4 J5
EN1437
EN(TURBO)-127
• RHD model
THROTTLE
POSITION
SENSOR
E13
1 2 3
1
3
2
E13
B21
1 2 3 4
5 6 7 8
E2 9 10 11 12
13 14 15 16
20
19
18
B21 17 18 19 20
B83
3
1 1 2 3 4 5 6
B83
B135
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19
19
23 24 25 26 27 28
7
20 21 22
9
B135 ECM
EN0972
Step Check Yes No

“List of Diagnostic <Ref. to
Trouble Code FU(TURBO)-33,
(DTC)”. <Ref. to Throttle Position
EN(TURBO)-75, Sensor.>
List of Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0121.
EN(TURBO)-128
Q: DTC P0122 — THROTTLE POSITION SENSOR CIRCUIT LOW INPUT —

• Engine stalls.
CAUTION:
• WIRING DIAGRAM:
• LHD model
THROTTLE
POSITION
E13 F61
SENSOR
1 2 3 1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
17 18 19 20
1
3
2
E13
B83
1 2 3
E2
4 5 6
20
19
18
F61
F76
A1
G2
i2
B135
B209
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19
1 20 21 22 23 24 25 26 27 28
6
B83
B209
A1 A2 A3 A4 A5
B1 B2 B4 B5
C1 C2 C3 C4 C5
D1 D2 D4 D5
E1 E5
19
7
9
F1 F5
G1G2 G4 G5
H1 H2 H3 H4 H5
I1 I2 I4 I5
B135 ECM J1 J2 J3 J4 J5
EN1437
EN(TURBO)-129
• RHD model
THROTTLE
POSITION
SENSOR
E13
1 2 3
1
3
2
E13
B21
1 2 3 4
5 6 7 8
E2 9 10 11 12
13 14 15 16
20
19
18
B21 17 18 19 20
B83
3
1 1 2 3 4 5 6
B83
B135
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19
19
23 24 25 26 27 28
7
20 21 22
9
B135 ECM
EN0972
EN(TURBO)-130
Step Check Yes No

<Ref. to EN(TURBO)-34, Subaru Select Moni- In this case, repair
tor.> the following:
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 connector
closed.
is required, be-
cause probable
cause is deteriora-
tion of multiple
parts.
and chassis ground.
and chassis ground. monitoring the value with
Subaru Select Monitor?
EN(TURBO)-131
Step Check Yes No

THROTTLE POSITION SENSOR CONNEC- ness and connec-
TOR. tor.
tion sensor connector and engine ground. throttle position
• Poor contact in
throttle position
sensor connector
• Poor contact in
ECM connector
• Poor contact in
coupling connector
• Poor contact in
joint connector
THROTTLE POSITION SENSOR CONNEC- Ω? ness and connec-
TOR. tor.
(B135) No. 7 — (E13) No. 3: throttle position
sensor and ECM
connector
• Poor contact in
ECM connector
• Poor contact in
throttle position
sensor connector
• Poor contact in
coupling connector
TOR. ness between
Measure the resistance of harness between throttle position
throttle position sensor connector and engine sensor and ECM
ground. connector.
connector. position sensor <Ref. to
Throttle Position
Sensor.>
EN(TURBO)-132
R: DTC P0123 — THROTTLE POSITION SENSOR CIRCUIT HIGH INPUT —

• Engine stalls.
CAUTION:
• WIRING DIAGRAM:
• LHD model
THROTTLE
POSITION
E13 F61
SENSOR
1 2 3 1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
17 18 19 20
1
3
2
E13
B83
1 2 3
E2
4 5 6
20
19
18
F61
F76
A1
G2
i2
B135
B209
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19
1 20 21 22 23 24 25 26 27 28
6
B83
B209
A1 A2 A3 A4 A5
B1 B2 B4 B5
C1 C2 C3 C4 C5
D1 D2 D4 D5
E1 E5
19
7
9
F1 F5
G1G2 G4 G5
H1 H2 H3 H4 H5
I1 I2 I4 I5
B135 ECM J1 J2 J3 J4 J5
EN1437
EN(TURBO)-133
• RHD model
THROTTLE
POSITION
SENSOR
E13
1 2 3
1
3
2
E13
B21
1 2 3 4
5 6 7 8
E2 9 10 11 12
13 14 15 16
20
19
18
B21 17 18 19 20
B83
3
1 1 2 3 4 5 6
B83
B135
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19
19
23 24 25 26 27 28
7
20 21 22
9
B135 ECM
EN0972
EN(TURBO)-134
Step Check Yes No

• Poor contact in
ECM connector
• Poor contact in
coupling connector
2 CHECK HARNESS BETWEEN THROTTLE Is the resistance less than 5 Go to step 3. Repair the har-
TOR. tor.
ground. throttle position
• Poor contact in
coupling connector
• Poor contact in
joint connector
3 CHECK HARNESS BETWEEN THROTTLE Is the voltage more than 4.9 V? Repair the battery Replace the throt-
POSITION SENSOR AND ECM CONNEC- short circuit in har- tle position sensor.
TOR. ness between <Ref. to
1)Turn the ignition switch to ON. throttle position FU(TURBO)-33,
2)Measure the voltage between throttle posi- sensor and ECM Throttle Position
tion sensor connector and engine ground. connector. After Sensor.>
(E13) No. 3 (+) — Engine ground (−): ECM. <Ref. to
FU(TURBO)-49,
Engine Control
Module.>
EN(TURBO)-135
S: DTC P0125 — INSUFFICIENT COOLANT TEMPERATURE FOR CLOSED

LOOP FUEL CONTROL —
• Engine will not return to idling.
CAUTION:
• WIRING DIAGRAM:
E8 F61 : LHD
B21 : RHD
1 2
ENGINE
COOLANT 3
TEMPERATURE 1 2 3 4
SENSOR 5 6 7 8
9 10 11 12
13 14 15 16
1
2
17 18 19 20
E8
E2 B83
18
17
F61 : LHD B21 : RHD 1 2 3

4 5 6
RHD RHD (LHD)
LHD
LHD
1 2 3 4 5 6
(RHD)
F76
G2
G1
B209
B135
1 2 3 4 5 6 7 8 9
LHD
LHD
10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 28
RHD RHD
B209
2
* 1
A1 A2 A3 A4 A5
* B1 B2 B4 B5
B83 C1 C2 C3 C4 C5
D1 D2 D4 D5
E1 E5
LHD : 6
*1 RHD : 1 F1 F5
19
18
G1G2 G4 G5
2 LHD : 1
* RHD : 3
H1 H2
I1 I2
H3 H4 H5
I4 I5
J1 J2 J3 J4 J5
B135 ECM
EN1436
EN(TURBO)-136
Step Check Yes No

Trouble Code
(DTC)”. <Ref. to
EN(TURBO)-75,
List of Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0125.
2 CHECK ENGINE COOLING SYSTEM. Is there a fault in engine cool- Replace the ther- Replace the
NOTE: ing system? mostat. <Ref. to engine coolant
Check the following items. CO-37, Thermo- temperature sen-
•Thermostat open stuck stat.> sor. <Ref. to
•Coolant level FU(TURBO)-29,
•Coolant freeze Engine Coolant
•Tire diameter Temperature Sen-
sor.>
EN(TURBO)-137
T: DTC P0131 — FRONT OXYGEN (A/F) SENSOR CIRCUIT RANGE/PERFOR-

NOTE:
For the diagnostic procedure, refer to DTC P0132. <Ref. to EN(TURBO)-140, DTC P0132 — FRONT OXY-
GEN (A/F) SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM (HIGH INPUT) —, Diagnostic Proce-
EN(TURBO)-138
EN(TURBO)-139
U: DTC P0132 — FRONT OXYGEN (A/F) SENSOR CIRCUIT RANGE/PERFOR-

CAUTION:
• WIRING DIAGRAM:
B18
1 2
RHD
RHD
MAIN RELAY BATTERY

3 4
SBF-5
6 LHD 2 LHD
4
B61 F44 B47
5
3 1 2
3 4
2 5 6
2
1
FRONT OXYGEN
B47 (A/F) SENSOR
B18 F44
1 2 3 4
1
5 6 7 8
F60 : LHD
B22 : RHD
1 2 3 4
5 6 7 8
19
29
18
9 10 11 12
4
5
13 14 15 16
B137 ECM
B137
8
9
RHD 1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
LHD
22 23 24 25 26 27 28 29 30 31
B209
A3
F76 B209
LHD
A1 A2 A3 A4 A5
E B1 B2 B4 B5
RHD C1 C2 C3 C4 C5
D1 D2 D4 D5
3
E3 F1 F5
G1G2 G4 G5
H1 H2 H3 H4 H5
E I1 I2 I4 I5
J3 J4 J5
J1 J2
EN1433
EN(TURBO)-140
Step Check Yes No

Trouble Code
(DTC)”.<Ref. to
EN(TURBO)-75,
List of Diagnostic
Trouble Code
(DTC).>
2 CHECK FRONT (A/F) OXYGEN SENSOR DA- Is the value equal to or more Go to step 3. Go to step 4.
70°C (158°F).
general scan tool.
NOTE:
tor.>
3 CHECK REAR OXYGEN SENSOR SIGNAL. Does the LED of {Rear O2 Repair the poor Check the rear
1)Race the engine at speeds from idling to Rich Signal} blink? contact in front oxygen sensor cir-
5,000 rpm for a total of 5 cycles. oxygen (A/F) sen- cuit. <Ref. to
NOTE: sor and rear oxy- FU(TURBO)-46,
To increase the engine speed to 5,000 rpm, gen sensor Rear Oxygen Sen-
slowly depress accelerator pedal, taking ap- connector. sor.>
prox. 5 seconds, and quickly release accelera-
tor pedal to decrease engine speed.
2)Operate the LED operation mode for engine.
NOTE:
“LED OPERATION MODE FOR ENGINE”.
tor.>
NOTE: sor. <Ref. to
Check the following items. FU(TURBO)-44,
•Loose installation of portions Front Oxygen (A/
•Damage (crack, hole etc.) of parts F) Sensor.>
EN(TURBO)-141
V: DTC P0133 — FRONT OXYGEN (A/F) SENSOR CIRCUIT SLOW RESPONSE

—
CAUTION:
• WIRING DIAGRAM:
B18
1 2
RHD
RHD
MAIN RELAY BATTERY

3 4
SBF-5
6 LHD 2 LHD
4
B61 F44 B47
5
3 1 2
3 4
2 5 6
2
1
FRONT OXYGEN
B47 (A/F) SENSOR
B18 F44
1 2 3 4
1
5 6 7 8
F60 : LHD
B22 : RHD
1 2 3 4
5 6 7 8
19
29
18
9 10 11 12
4
5
13 14 15 16
B137 ECM
B137
8
9
RHD 1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
LHD
22 23 24 25 26 27 28 29 30 31
B209
A3
F76 B209
LHD
A1 A2 A3 A4 A5
E B1 B2 B4 B5
RHD C1 C2 C3 C4 C5
D1 D2 D4 D5
3
E3 F1 F5
G1G2 G4 G5
H1 H2 H3 H4 H5
E I1 I2 I4 I5
J3 J4 J5
J1 J2
EN1433
EN(TURBO)-142
Step Check Yes No

Trouble Code
(DTC)”. <Ref. to
EN(TURBO)-75,
List of Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0133.
2 CHECK EXHAUST SYSTEM. Is there a fault in exhaust sys- Repair the exhaust Replace the front
NOTE: tem? system. oxygen (A/F) sen-
Check the following items. sor. <Ref. to
•Loose installation of front portion of exhaust FU(TURBO)-44,
pipe onto cylinder heads Front Oxygen (A/
•Loose connection between front exhaust pipe F) Sensor.>
and front catalytic converter
•Damage of exhaust pipe resulting in a hole
EN(TURBO)-143
W: DTC P0136 — REAR OXYGEN SENSOR CIRCUIT MALFUNCTION [MT VEHI-

CLES] —
CAUTION:
• WIRING DIAGRAM:
RHD
RHD
1 2 1 2 3 4 1 2
6 LHD 2 LHD 3 4 5 6 7 8 3 4
4 5 6
(LHD)
B61 F44
5
*3
3 2 1
REAR 4 3
2 OXYGEN SENSOR B83
1 (RHD)
LHD : 2
B19
*1 RHD : 4 1 2 3
B47
* 45
*6
F60 : LHD 4 5 6
*
2 LHD : 6
* RHD : 1 B22 : RHD
(LHD)
1 2 3 4 1 2 3 4 5 6
LHD : 2
*3 RHD : 1
5 6 7
11
8
12
(RHD)
9 10
13 14 15 16
LHD LHD : 1
*4 RHD : 2
RHD
B135
5 LHD : 3
B260
* 12 * RHD : 4 1 2 3 4 5 6 7 8 9
* 10 11 12 13 14 15 16 17 18 19
1
B259 LHD : 4 20 21 22 23 24 25 26 27 28
B83 *6 RHD : 3
RHD
B136
LHD 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24
RHD B137
C13
B17
B26
B19
LHD
1 2 3 4 5 6 7 8 9
B : B135 10 11 12 13 14 15 16 17 18 19 20 21
B209
22 23 24 25 26 27 28 29 30 31
A3
C : B136 ECM
F76
D : B137 B209 B259
E
LHD
A1 A2 A3 A4 A5 1 2
D8
D9
B1 B2 B4 B5
RHD
C1 C2 C3 C4 C5
D1 D2 D4 D5
F60 : LHD B22 : RHD
E1 E5
3
E3
F1 F5
G1G2 G4 G5
H1 H2 H3 H4 H5
E I1 I2 I4 I5
J1 J2 J3 J4 J5
EN1434
Step Check Yes No

EN(TURBO)-144
Step Check Yes No

Inspect the DTC P0131 or P0132 using “List of NOTE:
Diagnostic Trouble Code (DTC)”. <Ref. to In this case, it is
EN(TURBO)-75, List of Diagnostic Trouble not necessary to
Code (DTC).> inspect DTC
P0136.
2 minutes.
scan tool.
NOTE:
PLAY FOR ENGINE”. <Ref. to EN(TURBO)-
34, Subaru Select Monitor.>
using Subaru Select Monitor or OBD-II general <Ref. to
scan tool. FU(TURBO)-46,
Rear Oxygen Sen-
sor.>
(B135) No. 26 — (B19) No. 4:
1)Turn the ignition switch to OFF. <Ref. to tor.
2)Disconnect the connector from rear oxygen FU(TURBO)-46, NOTE:
sensor. Rear Oxygen Sen- In this case, repair
3)Turn the ignition switch to ON. sor.> the following:
• Poor contact in
rear oxygen sen-
sor connector
• Poor contact in
ECM connector
EN(TURBO)-145
Step Check Yes No

NOTE: <Ref. to
•Loose installation of portions Rear Oxygen Sen-
•Damage (crack, hole etc.) of parts sor.>
EN(TURBO)-146
EN(TURBO)-147
X: DTC P0137 — REAR OXYGEN SENSOR CIRCUIT LOW INPUT [AT VEHI-
CLES] —
CAUTION:
• WIRING DIAGRAM:
RHD
RHD
1 2 1 2 3 4 1 2
6 LHD 2 LHD 3 4 5 6 7 8 3 4
4 5 6
(LHD)
B61 F44
5
*3
3 2 1
REAR 4 3
2 OXYGEN SENSOR B83
1 (RHD)
LHD : 2
B19
*1 RHD : 4 1 2 3
B47
* 45
*6
F60 : LHD 4 5 6
*
2 LHD : 6
* RHD : 1 B22 : RHD
(LHD)
1 2 3 4 1 2 3 4 5 6
LHD : 2
*3 RHD : 1
5 6 7
11
8
12
(RHD)
9 10
13 14 15 16
LHD LHD : 1
*4 RHD : 2
RHD
B135
5 LHD : 3
B260
* 12 * RHD : 4 1 2 3 4 5 6 7 8 9
* 10 11 12 13 14 15 16 17 18 19
1
B259 LHD : 4 20 21 22 23 24 25 26 27 28
B83 *6 RHD : 3
RHD
B136
LHD 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24
RHD B137
C13
B17
B26
B19
LHD
1 2 3 4 5 6 7 8 9
B : B135 10 11 12 13 14 15 16 17 18 19 20 21
B209
22 23 24 25 26 27 28 29 30 31
A3
C : B136 ECM
F76
D : B137 B209 B259
E
LHD
A1 A2 A3 A4 A5 1 2
D8
D9
B1 B2 B4 B5
RHD
C1 C2 C3 C4 C5
D1 D2 D4 D5
F60 : LHD B22 : RHD
E1 E5
3
E3
F1 F5
G1G2 G4 G5
H1 H2 H3 H4 H5
E I1 I2 I4 I5
J1 J2 J3 J4 J5
EN1434
Step Check Yes No

EN(TURBO)-148
Step Check Yes No

P0137.
2 minutes.
scan tool.
NOTE:
Rear Oxygen Sen-
sor.>
(B135) No. 26 — (B19) No. 4:
• Poor contact in
rear oxygen sen-
sor connector
• Poor contact in
ECM connector
EN(TURBO)-149
Step Check Yes No

NOTE: <Ref. to
EN(TURBO)-150
EN(TURBO)-151
Y: DTC P0138 — REAR OXYGEN SENSOR CIRCUIT HIGH INPUT [AT VEHI-
CLES] —
CAUTION:
• WIRING DIAGRAM:
RHD
RHD
1 2 1 2 3 4 1 2
6 LHD 2 LHD 3 4 5 6 7 8 3 4
4 5 6
(LHD)
B61 F44
5
*3
3 2 1
REAR 4 3
2 OXYGEN SENSOR B83
1 (RHD)
LHD : 2
B19
*1 RHD : 4 1 2 3
B47
* 45
*6
F60 : LHD 4 5 6
*
2 LHD : 6
* RHD : 1 B22 : RHD
(LHD)
1 2 3 4 1 2 3 4 5 6
LHD : 2
*3 RHD : 1
5 6 7
11
8
12
(RHD)
9 10
13 14 15 16
LHD LHD : 1
*4 RHD : 2
RHD
B135
5 LHD : 3
B260
* 12 * RHD : 4 1 2 3 4 5 6 7 8 9
* 10 11 12 13 14 15 16 17 18 19
1
B259 LHD : 4 20 21 22 23 24 25 26 27 28
B83 *6 RHD : 3
RHD
B136
LHD 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24
RHD B137
C13
B17
B26
B19
LHD
1 2 3 4 5 6 7 8 9
B : B135 10 11 12 13 14 15 16 17 18 19 20 21
B209
22 23 24 25 26 27 28 29 30 31
A3
C : B136 ECM
F76
D : B137 B209 B259
E
LHD
A1 A2 A3 A4 A5 1 2
D8
D9
B1 B2 B4 B5
RHD
C1 C2 C3 C4 C5
D1 D2 D4 D5
F60 : LHD B22 : RHD
E1 E5
3
E3
F1 F5
G1G2 G4 G5
H1 H2 H3 H4 H5
E I1 I2 I4 I5
J1 J2 J3 J4 J5
EN1434
Step Check Yes No

EN(TURBO)-152
Step Check Yes No

P0138.
2 minutes.
scan tool.
NOTE:
Rear Oxygen Sen-
sor.>
(B135) No. 26 — (B19) No. 4:
• Poor contact in
rear oxygen sen-
sor connector
• Poor contact in
ECM connector
EN(TURBO)-153
Step Check Yes No

NOTE: <Ref. to
EN(TURBO)-154
EN(TURBO)-155
Z: DTC P0139 — REAR OXYGEN SENSOR CIRCUIT SLOW RESPONSE —

CAUTION:
• WIRING DIAGRAM:
RHD
RHD
1 2 1 2 3 4 1 2
6 LHD 2 LHD 3 4 5 6 7 8 3 4
4 5 6
(LHD)
B61 F44
5
*3
3 2 1
REAR 4 3
2 OXYGEN SENSOR B83
1 (RHD)
LHD : 2
B19
*1 RHD : 4 1 2 3
B47
* 45
*6
F60 : LHD 4 5 6
*
LHD : 6
*2 RHD : 1 B22 : RHD
(LHD)
1 2 3 4 1 2 3 4 5 6
LHD : 2
*3 RHD : 1
5 6 7
11
8
12
(RHD)
9 10
13 14 15 16
LHD LHD : 1
*4 RHD : 2
RHD
B135
5 LHD : 3
B260
* 12 * RHD : 4 1 2 3 4 5 6 7 8 9
* 10 11 12 13 14 15 16 17 18 19
1
B259 LHD : 4 20 21 22 23 24 25 26 27 28
B83 *6 RHD : 3
RHD
B136
LHD 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24
RHD B137
C13
B17
B26
B19
LHD
1 2 3 4 5 6 7 8 9
B : B135 10 11 12 13 14 15 16 17 18 19 20 21
B209
22 23 24 25 26 27 28 29 30 31
A3
C : B136 ECM
F76
D : B137 B209 B259
E
LHD
A1 A2 A3 A4 A5 1 2
D8
D9
B1 B2 B4 B5
RHD
C1 C2 C3 C4 C5
D1 D2 D4 D5
F60 : LHD B22 : RHD
E1 E5
3
E3
F1 F5
G1G2 G4 G5
H1 H2 H3 H4 H5
E I1 I2 I4 I5
J1 J2 J3 J4 J5
EN1434
EN(TURBO)-156
Step Check Yes No

1 CHECK ANY OTHER DIAGNOSTIC TROU- In any other DTC displayed? Inspect the rele- Replace the rear
BLE CODE (DTC) ON DISPLAY. vant DTC using oxygen sensor.
(DTC)”. <Ref. to Rear Oxygen Sen-
EN(TURBO)-75, sor.>
List of Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0139.
EN(TURBO)-157
AA:DTC P0171 — FUEL TRIM MALFUNCTION (A/F TOO LEAN) —

NOTE:
For the diagnostic procedure, refer to DTC P0172. <Ref. to EN(TURBO)-159, DTC P0172 — FUEL TRIM
MALFUNCTION (A/F TOO RICH) —, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
EN(TURBO)-158
AB:DTC P0172 — FUEL TRIM MALFUNCTION (A/F TOO RICH) —

• Engine stalls.
CAUTION:
Step Check Yes No

1 CHECK EXHAUST SYSTEM. Are there holes or loose bolts Repair the exhaust Go to step 2.
on exhaust system? system.
intake system?
Warning: 284 — 314 kPa (2.9 — 3.2 ing items.
•Place “NO FIRE” signs near the working kg/cm2, 41 — 46 psi)? Fuel pressure too
area. high:
•Be careful not to spill fuel on the floor. • Clogged fuel
1)Release the 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 5 • 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)Install 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 the fuel pressure does not increase, squeeze
fuel return hose 2 to 3 times, then measure fuel
pressure again.
EN(TURBO)-159
Step Check Yes No

After connecting the pressure regulator vac- 206 — 235 kPa (2.1 — 2.4 ing items.
uum hose, measure fuel pressure. kg/cm2, 30 — 34 psi)? Fuel pressure too
Warning: high:
Before removing the fuel pressure gauge, • Faulty pres-
release fuel pressure. sure regulator
NOTE: • Clogged fuel
•If the fuel pressure does not increase, return line or
squeeze fuel return hose 2 to 3 times, then bent hose
measure fuel pressure again. Fuel pressure too
•If out of specification as measured at this low:
step, check or replace the pressure regulator • Faulty pres-
and pressure regulator vacuum hose. sure regulator
• Improper fuel
pump discharge
• Clogged fuel
supply line
5 CHECK ENGINE COOLANT TEMPERATURE Is the temperature greater than Go to step 6. Replace the
SENSOR. 60°C (140°F)? engine coolant
1)Start the engine and warm-up completely. temperature sen-
2)Read the data of engine coolant temperature sor. <Ref. to
sensor signal using Subaru Select Monitor or FU(TURBO)-29,
OBD-II general scan tool. Engine Coolant
NOTE: Temperature Sen-
•Subaru Select Monitor sor.>
tor.>
6 CHECK INTAKE MANIFOLD PRESSURE Is the value within the specifi- Go to step 7. Replace the mass
SENSOR. cations? air flow and intake
1)Start the engine and warm-up engine until manifold pressure
coolant temperature is greater than 60°C sensor. <Ref. to
(140°F). FU(TURBO)-34,
2)Place the shift lever in neutral position. Mass Air Flow and
3)Turn the A/C switch to OFF. Intake Air Temper-
4)Turn all accessory switches to OFF. ature Sensor.>
NOTE:
tor.>
Specification:
Ignition ON
73.3 — 106.6 kPa (550 — 800 mmHg,
21.65 — 31.50 inHg)
Idling
24.0 — 41.3 kPa (180 — 310 mmHg, 7.09
— 12.20 inHg)
EN(TURBO)-160
Step Check Yes No

7 CHECK INTAKE AIR TEMPERATURE SEN- Is the value obtained when Contact with your Check the mass
SOR. ambient temperature is sub- Subaru distributor air flow and intake
1)Start the engine and warm-up engine until tracted from intake air temper- service. air temperature
coolant temperature is greater than 60°C ature greater than −10°C NOTE: sensor. <Ref. to
(140°F). (14°F) and less than 50°C Inspection by DTM FU(TURBO)-34,
2)Place the shift lever in neutral position. (122°F)? is required, be- Mass Air Flow and
3)Turn the A/C switch to OFF. cause probable Intake Air Temper-
4)Turn all accessory switches to OFF. cause is deteriora- ature Sensor.>
5)Open the front hood. tion of multiple
6)Measure the ambient temperature. parts.
NOTE:
tor.>
EN(TURBO)-161
AC:DTC P0244 — WASTEGATE CONTROL SOLENOID VALVE MALFUNCTION

(HIGH INPUT) [MT VEHICLES] —
• Engine stalls.
CAUTION:
• WIRING DIAGRAM:
MAIN RELAY
RHD
RHD
6 BATTERY
4
SBF-5 F44
5 LHD 8 LHD
3 1 2 3 4
B61 F44 5 6 7 8
2
1
B47
B47
1 2
3 4
5 6
B137 ECM
B137
1 2 3 4 5 6 7 8 9
24
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31
B127
1 2
B127
2
1
WASTEGATE
E
CONTROL SOLENOID
VALVE
EN0974
EN(TURBO)-162
Step Check Yes No

1 CHECK ANY OTHER DIAGNOSTIC TROU- Is any other DTC displayed? Inspect the rele- Replace the
BLE CODE (DTC) ON DISPLAY. vant DTC using wastegate control
“List of Diagnostic solenoid valve.
Trouble Code <Ref. to
EN(TURBO)-75, Wastegate Con-
List of Diagnostic trol Solenoid
Trouble Code Valve.>
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0244.
EN(TURBO)-163
AD:DTC P0244 — WASTEGATE CONTROL SOLENOID VALVE MALFUNCTION

(FAIL-SAFE) [AT VEHICLES] —
• Engine stalls.
CAUTION:
• WIRING DIAGRAM:
MAIN RELAY
6 BATTERY
4
SBF-5 B47
5
3 1 2
3 4
2 5 6
1
B47
B137
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31
B137 ECM
B127
1 2
24
B127
2
1
WASTEGATE
E
CONTROL SOLENOID
VALVE
EN1438
EN(TURBO)-164
Step Check Yes No

(DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0244.
EN(TURBO)-165
AE:DTC P0245 — WASTEGATE CONTROL SOLENOID VALVE CIRCUIT LOW

INPUT —
CAUTION:
• WIRING DIAGRAM:
MAIN RELAY
RHD
RHD
6 BATTERY
4
SBF-5 F44
5 LHD 8 LHD
3 1 2 3 4
B61 F44 5 6 7 8
2
1
B47
B47
1 2
3 4
5 6
B137 ECM
B137
1 2 3 4 5 6 7 8 9
24
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31
B127
1 2
B127
2
1
WASTEGATE
E
CONTROL SOLENOID
VALVE
EN0974
EN(TURBO)-166
Step Check Yes No

NOTE:
Inspection by DTM
is required, be-
cause probable
cause is deteriora-
tion of multiple
parts.
2 CHECK HARNESS BETWEEN WASTEGATE Is the resistance less than 10 Repair the ground Go to step 3.
CONTROL SOLENOID VALVE AND ECM Ω? short circuit in har-
1)Turn the ignition switch to OFF. ECM and waste-
2)Disconnect the connectors from wastegate gate control sole-
control solenoid valve and ECM. noid valve
wastegate control solenoid valve connector
and engine ground.
3 CHECK HARNESS BETWEEN WASTEGATE Is the resistance less than 1 Go to step 4. Repair the open
CONTROL SOLENOID VALVE AND ECM Ω? circuit 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.
(B137) No. 24 — (B127) No. 1: In this case, repair
the following:
• Open circuit in
harness between
ECM and waste-
gate control sole-
noid valve
connector
4 CHECK WASTEGATE CONTROL SOLE- Is the resistance between 30 Go to step 5. Replace the
NOID VALVE. and 34 Ω? wastegate control
1)Remove the purge control solenoid valve. solenoid valve.
2)Measure the resistance between purge con- <Ref. to
trol solenoid valve terminals. FU(TURBO)-43,
Terminals Wastegate Con-
No. 1 — No. 2: trol Solenoid
Valve.>
5 CHECK POWER SUPPLY TO WASTEGATE Is the voltage more than 10 V? Go to step 6. Repair the open
CONTROL SOLENOID VALVE. circuit in harness
2)Measure the voltage between wastegate relay and waste-
control solenoid valve and engine ground. gate control sole-
Connector & terminal noid valve
(B127) No. 2 (+) — Engine ground (−): connector.
EN(TURBO)-167
Step Check Yes No

6 CHECK POOR CONTACT. Is there poor contact in waste- Repair the poor Contact with your
Check poor contact in wastegate control sole- gate control solenoid valve contact in waste- Subaru distributor
noid valve connector. connector? gate control sole- service.
noid valve NOTE:
connector. Inspection by DTM
is required, be-
cause probable
cause is deteriora-
tion of multiple
parts.
EN(TURBO)-168
EN(TURBO)-169
AF:DTC P0246 — WASTEGATE CONTROL SOLENOID VALVE CIRCUIT HIGH

INPUT —
CAUTION:
• WIRING DIAGRAM:
MAIN RELAY
RHD
RHD
6 BATTERY
4
SBF-5 F44
5 LHD 8 LHD
3 1 2 3 4
B61 F44 5 6 7 8
2
1
B47
B47
1 2
3 4
5 6
B137 ECM
B137
1 2 3 4 5 6 7 8 9
24
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31
B127
1 2
B127
2
1
WASTEGATE
E
CONTROL SOLENOID
VALVE
EN0974
Step Check Yes No

chassis ground.
EN(TURBO)-170
Step Check Yes No

Engine Control
Module.>
3 CHECK HARNESS BETWEEN WASTEGATE Is the voltage more than 10 V? Repair the battery Go to step 4.
CONTROL SOLENOID VALVE AND ECM short circuit in har-
1)Turn the ignition switch to OFF. ECM and waste-
2)Disconnect the connector from wastegate gate control sole-
control solenoid valve. noid valve
chassis ground. ECM. <Ref. to
Connector & terminal FU(TURBO)-49,
(B137) No. 24 (+) — Chassis ground (−): Engine Control
Module.>
4 CHECK WASTEGATE CONTROL SOLE- Is the resistance less than 1 Replace the Go to step 5.
NOID VALVE. Ω? wastegate control
1)Turn the ignition switch to OFF. solenoid valve
2)Measure the resistance between wastegate <Ref. to
control solenoid valve terminals. FU(TURBO)-43,
Terminals Wastegate Con-
No. 1 — No. 2: trol Solenoid
Valve.> and ECM
<Ref. to
FU(TURBO)-49,
Engine Control
Module.>
Engine Control
Module.>
EN(TURBO)-171
AG:DTC P0301 — CYLINDER 1 MISFIRE DETECTED —

NOTE:
For the diagnostic procedure, refer to DTC P0304. <Ref. to EN(TURBO)-173, DTC P0304 — CYLINDER 4
MISFIRE DETECTED —, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
AH:DTC P0302 — CYLINDER 2 MISFIRE DETECTED —
NOTE:
AI: DTC P0303 — CYLINDER 3 MISFIRE DETECTED —
NOTE:
EN(TURBO)-172
AJ:DTC P0304 — CYLINDER 4 MISFIRE DETECTED —

• Immediately at fault recognition (A misfire which could damage catalyst occurs.)
• Engine stalls.
• Rough driving
CAUTION:
• WIRING DIAGRAM:
EN(TURBO)-173
• LHD model
MAIN RELAY
6 BATTERY
4 B61 F44
SBF-5
5 8
3
2
1
B47 C: B136 D: B137 ECM

D1
C6
C5
C4
B61
B209
1
J5
J4
I5
I4
F44
F76
F60
12
11
10
1
9
E3
E5 E16 E6 E17
2
1
2
1
2
1
2
1
#1 #2 #3 #4
E
FUEL INJECTORS
E5 E6 F44 C : B136 D : B137 F60 B209
E16 E17 A1 A2 A3 A4 A5
1 2 3 4 1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9 1 2 3 4 B1 B2 B4 B5
1 2 5 6 7 8 8 9 10 11 12 13 14 15 16 10 11 12 13 14 15 16 17 18 19 20 21 5 6 7 8 C1 C2 C3 C4 C5
17 18 19 20 21 22 23 24 22 23 24 25 26 27 28 29 30 31 9 10 11 12 D1 D2 D4 D5
13 14 15 16 E1 E5
B47 F1 F5
G1G2 G4 G5
1 2 H1 H2 H3 H4 H5
3 4 I1 I2 I4 I5
5 6 J1 J2 J3 J4 J5
EN1432
EN(TURBO)-174
• RHD model
MAIN RELAY
6 BATTERY
4
SBF-5
5
3
2
1
B47
C: B136 D: B137 ECM
D1
C6
C5
C4
B22
12
11
10
1
9
E3
E5 E16 E6 E17
2
1
2
1
2
1
2
1
#1 #2 #3 #4
E
FUEL INJECTORS
E5 E6 C : B136 D : B137 B22 B47
E16 E17 1 2
1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9 1 2 3 4
8 9 10 11 12 13 14 15 16 10 11 12 13 14 15 16 17 18 19 20 21 5 6 7 8 3 4
1 2 17 18 19 20 21 22 23 24 22 23 24 25 26 27 28 29 30 31 9 10 11 12 5 6
13 14 15 16
EN0965
Step Check Yes No

Trouble Code
(DTC)”. <Ref. to
EN(TURBO)-75,
List of Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0301, P0302,
P0303 and P0304.
EN(TURBO)-175
Step Check Yes No

tor and chassis ground on faulty cylinders.
(−):
(−):
(−):
(−):
3 CHECK HARNESS BETWEEN FUEL INJEC- Is the resistance less than 10 Repair the ground Go to step 4.
TOR AND ECM CONNECTOR. Ω? short circuit in har-
1)Turn the ignition switch to OFF. ness between fuel
2)Disconnect the connector from fuel injector injector and ECM
on faulty cylinders. connector.
4)Measure the resistance between ECM con-
nector and engine ground on faulty cylinders.
4 CHECK HARNESS BETWEEN FUEL INJEC- Is the resistance less than 1 Go to step 5. Repair the har-
TOR AND ECM CONNECTOR. Ω? ness and connec-
Measure the resistance of harness connector tor.
between ECM connector and fuel injector on NOTE:
faulty cylinders. In this case, repair
#1 (B137) No. 1 — (E5) No. 1: • Open circuit in
#2 (B136) No. 6 — (E16) No. 1: harness between
#3 (B136) No. 5 — (E6) No. 1: ECM and fuel
#4 (B136) No. 4 — (E17) No. 1: injector connector
• Poor contact in
coupling connector
5 CHECK FUEL INJECTOR. Is the resistance between 5 Go to step 6. Replace the faulty
Measure the resistance between fuel injector and 20 Ω? fuel injector. <Ref.
terminals on faulty cylinder. to FU(TURBO)-37,
Terminals Fuel Injector.>
No. 1 — No. 2:
EN(TURBO)-176
Step Check Yes No

6 CHECK POWER SUPPLY LINE. Is the voltage more than 10 V? Repair the poor Repair the har-
1)Turn the ignition switch to ON. contact in all con- ness and connec-
2)Measure the voltage between fuel injector nectors in fuel tor.
and engine ground on faulty cylinders. injector circuit. NOTE:
#1 (E5) No. 2 (+) — Engine ground (−): the following:
#2 (E16) No. 2 (+) — Engine ground (−): • Open circuit in
#3 (E6) No. 2 (+) — Engine ground (−): harness between
#4 (E17) No. 2 (+) — Engine ground (−): main relay and fuel
injector connector
on faulty cylinders
• Poor contact in
coupling connector
• Poor contact in
main relay con-
nector
• Poor contact in
fuel injector con-
nector on faulty
cylinders
7 CHECK HARNESS BETWEEN FUEL INJEC- Is the voltage more than 10 V? Repair the battery Go to step 8.
TOR AND ECM CONNECTOR. short circuit in har-
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(TURBO)-49,
#1 (B137) No. 1 (+) — Chassis ground Module.>
(−):
(−):
(−):
(−):
8 CHECK FUEL INJECTOR. Is the resistance less than 1 Replace the faulty Go to step 9.
1)Turn the ignition switch to OFF. Ω? fuel injector <Ref.
2)Measure the resistance between fuel injector to FU(TURBO)-37,
terminals on faulty cylinder. Fuel Injector.> and
Terminals ECM <Ref. to
No. 1 — No. 2: FU(TURBO)-49,
Engine Control
Module.>
9 CHECK INSTALLATION OF CAMSHAFT PO- Is the camshaft position sensor Tighten the cam- Go to step 10.
SITION SENSOR/CRANKSHAFT POSITION or crankshaft position sensor shaft position sen-
SENSOR. loosely installed? sor or crankshaft
position sensor.
10 CHECK CRANKSHAFT SPROCKET. Is the crankshaft sprocket Replace the crank- Go to step 11.
Remove the timing belt cover. rusted or does it have broken shaft sprocket.
teeth? <Ref. to
ME(TURBO)-58,
Crankshaft
Sprocket.>
EN(TURBO)-177
Step Check Yes No

11 CHECK INSTALLATION CONDITION OF Is the timing belt dislocated Repair the installa- Go to step 12.
TIMING BELT. from its proper position? tion condition of
Turn the crankshaft using ST, and align align- timing belt. <Ref.
ment mark on crankshaft sprocket with align- to ME(TURBO)-
ment mark on cylinder block. 48, Timing Belt
ST 499987500 CRANKSHAFT SOCKET Assembly.>
12 CHECK FUEL LEVEL. Is the fuel meter indication Go to step 13. Replenish the fuel
higher than the “Lower” level? so fuel meter indi-
cation is higher
than the “Lower”
level. After replen-
ishing fuel; Go to
step 13.
13 CHECK STATUS OF CHECK ENGINE MAL- Is the MIL coming on or blink- Go to step 15. Go to step 14.
FUNCTION INDICATOR LAMP (MIL). ing?
1)Clear the memory using Subaru Select Mon-
itor.
<Ref. to EN(TURBO)-45, Clear Memory
Mode.>
2)Start the engine, and drive the vehicle more
than 10 minutes.
14 CHECK CAUSE OF MISFIRE DIAGNOSED. Was the cause of misfire diag- Finish the diag- Repair the poor
nosed when the engine is run- nostics operation, contact.
ning? if the engine has NOTE:
no abnormality. In this case, repair
Ex. Remove spark • Poor contact in
plug cord, etc. ignitor connector
• 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 connector
15 CHECK AIR INTAKE SYSTEM. Is there a fault in air intake sys- Repair the air Go to step 16.
tem? intake 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(TURBO)-178
Step Check Yes No

16 CHECK MISFIRE SYMPTOM. Does the Subaru Select Moni- Go to step 21. Go to step 17.
1)Turn the ignition switch to ON. tor or OBD-II general scan tool
2)Read the diagnostic trouble code (DTC). indicate only one DTC?
tor.>
OBD-II General Scan Tool Operation Manual.
NOTE:
Perform diagnosis according to the items listed
below.
P0302?
P0304?
P0303?
P0304?
21 ONLY ONE CYLINDER Is there a fault in that cylinder? Repair or replace Go to DTC P0171
the faulty parts. and P0172. <Ref.
NOTE: to EN(TURBO)-
Check the follow- 158, DTC P0171
ing items. — FUEL TRIM
• Spark plug MALFUNCTION
• Spark plug cord (A/F TOO LEAN)
• Fuel injector —, Diagnostic Pro-
• Compression cedure with Diag-
ratio nostic Trouble
Code (DTC).>
22 GROUP OF #1 AND #2 CYLINDERS Are there faults in #1 and #2 Repair or replace Go to DTC P0171
cylinders? the faulty parts. and P0172. <Ref.
NOTE: to EN(TURBO)-
• Check the fol- 158, DTC P0171
lowing items. — FUEL TRIM
• Spark plugs MALFUNCTION
• Fuel injectors (A/F TOO LEAN)
• Ignition coil —, Diagnostic Pro-
• Compres- cedure with Diag-
sion ratio nostic Trouble
• If no abnormal is Code (DTC).>
discovered, check
for “IGNITION
CONTROL SYS-
TEM” of #1 and #2
cylinders side.
<Ref. to
EN(TURBO)-66,
Ignition Control
System.>
EN(TURBO)-179
Step Check Yes No

NOTE: to EN(TURBO)-
• Check the fol- 158, DTC P0171
lowing items. — FUEL TRIM
• Ignition coil —, Diagnostic Pro-
• If no abnormal is cedure with Diag-
discovered, check nostic Trouble
for “16. D: IGNI- Code (DTC).>
TION CONTROL
SYSTEM” of #3
and #4 cylinders
side. <Ref. to
EN(TURBO)-66,
Ignition Control
System.>
NOTE: to EN(TURBO)-
• Skipping timing —, Diagnostic Pro-
belt teeth cedure with Diag-
nostic Trouble
Code (DTC).>
NOTE: to EN(TURBO)-
• Compression —, Diagnostic Pro-
ratio cedure with Diag-
• Skipping timing nostic Trouble
belt teeth Code (DTC).>
26 CYLINDER AT RANDOM Is the engine idle rough? Go to DTC P0171 Repair or replace
and P0172. <Ref. the faulty parts.
to EN(TURBO)- NOTE:
158, DTC P0171 Check the follow-
— FUEL TRIM ing items.
MALFUNCTION • Spark plugs
(A/F TOO LEAN) • Fuel injectors
—, Diagnostic Pro- • Compression
cedure with Diag- ratio
nostic Trouble
Code (DTC).>
EN(TURBO)-180
EN(TURBO)-181
AK:DTC P0327 — KNOCK SENSOR CIRCUIT LOW INPUT —

CAUTION:
• WIRING DIAGRAM:
KNOCK
SENSOR
2
E14
E14
1 2
B20
1 2 3 4
E1 5 6 7
8 9 10
6
B20
B135
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 28
22
4
B135 ECM
E
EN0975
EN(TURBO)-182
Step Check Yes No

1 CHECK HARNESS BETWEEN KNOCK SEN- Is the resistance more than Go to step 2. Repair the har-
SOR AND ECM CONNECTOR. 700 kΩ? ness and connec-
3)Measure the resistance between ECM har- In this case, repair
ness connector and chassis ground. the following:
knock sensor and
ECM connector
• Poor contact in
knock sensor con-
nector
• Poor contact in
coupling connector
2 CHECK KNOCK SENSOR. Is the resistance more than Go to step 3. Repair the har-
1)Disconnect the connector from knock sen- 700 kΩ? ness and connec-
sor. tor.
harness between
knock sensor and
ECM connector
• Poor contact in
knock sensor con-
nector
• Poor contact in
coupling connector
3 CHECK CONDITION OF KNOCK SENSOR Is the knock sensor installa- Replace the knock Tighten the knock
INSTALLATION. tion bolt tightened securely? sensor. <Ref. to sensor installation
FU(TURBO)-32, bolt securely.
Knock Sensor.>
EN(TURBO)-183
AL:DTC P0328 — KNOCK SENSOR CIRCUIT HIGH INPUT —

CAUTION:
• WIRING DIAGRAM:
KNOCK
SENSOR
2
E14
E14
1 2
B20
1 2 3 4
E1 5 6 7
8 9 10
6
B20
B135
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 28
22
4
B135 ECM
E
EN0975
Step Check Yes No

1 CHECK HARNESS BETWEEN KNOCK SEN- Is the resistance less than 400 Go to step 2. Go to step 3.
SOR AND ECM CONNECTOR. kΩ?
Measure the resistance of harness between
EN(TURBO)-184
Step Check Yes No

2 CHECK KNOCK SENSOR. Is the resistance less than 400 Replace the knock Repair the ground
1)Disconnect the connector from knock sen- kΩ? sensor. <Ref. to short circuit in har-
sor. FU(TURBO)-32, ness between
2)Measure the resistance between knock sen- Knock Sensor.> knock sensor con-
sor connector terminal and engine ground. nector and ECM
Terminal connector.
No. 2 — Engine ground: NOTE:
The harness be-
tween both con-
nectors is
shielded. Repair
the short circuit of
harness together
with shield.
3 CHECK INPUT SIGNAL FOR ECM. Is the voltage more than 2 V? Even if MIL lights Repair the poor
1)Connect the connectors to ECM and knock up, the circuit has contact in ECM
sensor. returned to a nor- connector.
2)Turn the ignition switch to ON. mal condition at
3)Measure the voltage between ECM and this time. (How-
chassis ground. ever, the possibil-
Connector & terminal ity of poor contact
(B135) No. 4 (+) — Chassis ground (−): still remains.)
NOTE:
the following:
• Poor contact in
knock sensor con-
nector
• Poor contact in
ECM connector
• Poor contact in
coupling connector
EN(TURBO)-185
AM:DTC P0335 — CRANKSHAFT POSITION SENSOR CIRCUIT MALFUNCTION

—
• Engine stalls.
CAUTION:
• WIRING DIAGRAM:
CRANKSHAFT
POSITION
SENSOR
2
1
E10
E10
1 2
E1 B20
2
1
B20 1 2 3 4
5 6 7
8 9 10
B135
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 28
11
21
2
B135 ECM
E
EN0976
EN(TURBO)-186
Step Check Yes No

1 CHECK HARNESS BETWEEN CRANK- Is the resistance more than Repair the har- Go to step 2.
SHAFT POSITION SENSOR AND ECM CON- 100 kΩ? ness and connec-
NECTOR. tor.
2)Disconnect the connector from crankshaft In this case, repair
engine ground. crankshaft posi-
(E10) No. 1 — Engine ground: ECM connector
• Poor contact in
ECM connector
• Poor contact in
coupling connector
2 CHECK HARNESS BETWEEN CRANK- Is the resistance less than 10 Repair the ground Go to step 3.
SHAFT POSITION SENSOR AND ECM CON- Ω? short circuit in har-
crankshaft position sensor connector and tion sensor and
engine ground. ECM connector.
tween both con-
nectors are
shielded. Repair
in harness togeth-
er with shield.
3 CHECK HARNESS BETWEEN CRANK- Is the resistance less than 5 Go to step 4. Repair the har-
SHAFT POSITION SENSOR AND ECM CON- Ω? ness and connec-
NECTOR. tor.
crankshaft position sensor connector and In this case, repair
crankshaft posi-
tion sensor and
ECM connector
• Poor contact in
ECM connector
• Poor contact in
coupling connector
securely.
5 CHECK CRANKSHAFT POSITION SENSOR. Is the resistance between 1 Repair the poor Replace the crank-
1)Remove the crankshaft position sensor. and 4 kΩ? contact in crankshaft position sen-
2)Measure the resistance between connector shaft position sensor. <Ref. to
terminals of crankshaft position sensor. sor connector. FU(TURBO)-30,
Terminals Crankshaft Posi-
No. 1 — No. 2: tion Sensor.>
EN(TURBO)-187
AN:DTC P0336 — CRANKSHAFT POSITION SENSOR CIRCUIT RANGE/PER-

• Engine stalls.
CAUTION:
• WIRING DIAGRAM:
CRANKSHAFT
POSITION
SENSOR
2
1
E10
E10
1 2
E1 B20
2
1
B20 1 2 3 4
5 6 7
8 9 10
B135
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 28
11
21
2
B135 ECM
E
EN0976
EN(TURBO)-188
Step Check Yes No

Trouble Code
(DTC)”. <Ref. to
EN(TURBO)-75,
List of Diagnostic
Trouble Code
(DTC).>
securely.
3 CHECK CRANKSHAFT SPROCKET. Are the crankshaft sprocket Replace the crank- Go to step 4.
Remove the front belt cover. teeth cracked or damaged? shaft sprocket.
<Ref. to
FU(TURBO)-30,
Crankshaft Posi-
tion Sensor.>
4 CHECK INSTALLATION CONDITION OF Is the timing belt dislocated Repair the installa- Replace the crank-
Turn the crankshaft using ST, and align align- timing belt. <Ref. sor. <Ref. to
ment mark on crankshaft sprocket with align- to ME(TURBO)- FU(TURBO)-30,
ment mark on cylinder block. 48, Timing Belt Crankshaft Posi-
ST 499987500 CRANKSHAFT SOCKET Assembly.> tion Sensor.>
EN(TURBO)-189
AO:DTC P0340 — CAMSHAFT POSITION SENSOR CIRCUIT MALFUNCTION —

• Engine stalls.
CAUTION:
• WIRING DIAGRAM:
CAMSHAFT
POSITION
SENSOR
2
1
E15
E15
1 2
E1 B20
4
3
B20 1 2 3 4
5 6 7
8 9 10
B135
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 28
21
10
1
B135 ECM
E
EN0977
EN(TURBO)-190
Step Check Yes No

TOR. tor.
• Poor contact in
ECM connector
• Poor contact in
coupling connector
TOR. ness between
tween both con-
nectors are
shielded. Repair
the ground short
circuit in harness
together with
shield.
TOR. tor.
camshaft position
sensor and ECM
connector
• Poor contact in
ECM connector
• Poor contact in
coupling connector
securely.
5 CHECK CAMSHAFT POSITION SENSOR. Is the resistance between 1 Repair the poor Replace the cam-
1)Remove the camshaft position sensor. and 4 kΩ? contact in camshaft position sen-
2)Measure the resistance between connector shaft position sensor. <Ref. to
terminals of camshaft position sensor. sor connector. FU(TURBO)-31,
Terminals Camshaft Position
No. 1 — No. 2: Sensor.>
EN(TURBO)-191
AP:DTC P0341 — CAMSHAFT POSITION SENSOR CIRCUIT RANGE/PERFOR-

MANCE PROBLEM —
• Engine stalls.
CAUTION:
• WIRING DIAGRAM:
CAMSHAFT
POSITION
SENSOR
2
1
E15
E15
1 2
E1 B20
4
3
B20 1 2 3 4
5 6 7
8 9 10
B135
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 28
21
10
1
B135 ECM
E
EN0977
EN(TURBO)-192
Step Check Yes No

Trouble Code
(DTC)”. <Ref. to
EN(TURBO)-75,
List of Diagnostic
Trouble Code
(DTC).>
TOR. tor.
• Poor contact in
ECM connector
• Poor contact in
coupling connector
TOR. ness between
tween both con-
nectors are
shielded. Repair
in harness togeth-
er with shield.
TOR. tor.
camshaft position
sensor and ECM
connector
• Poor contact in
ECM connector
• Poor contact in
coupling connector
securely.
EN(TURBO)-193
Step Check Yes No

2)Measure the resistance between connector sor. <Ref. to
terminals of camshaft position sensor. FU(TURBO)-31,
Terminals Camshaft Position
No. 1 — No. 2: Sensor.>
securely.
8 CHECK CAMSHAFT SPROCKET. Are the camshaft sprocket Replace the cam- Go to step 9.
Remove the front belt cover. <Ref. to ME-48, teeth cracked or damaged? shaft sprocket.
Belt Cover.> <Ref. to
ME(TURBO)-57,
Camshaft
Sprocket.>
9 CHECK INSTALLATION CONDITION OF Is the timing belt dislocated Repair the installa- Replace the cam-
Turn the camshaft using ST, and align align- timing belt. <Ref. sor. <Ref. to
ment mark on camshaft sprocket with align- to ME(TURBO)- FU(TURBO)-31,
ment mark on timing belt cover LH. 48, Timing Belt Camshaft Position
ST 499207100 CAMSHAFT SPROCKET Assembly.> Sensor.>
WRENCH
EN(TURBO)-194
EN(TURBO)-195
AQ:DTC P0420 — CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD —

• Engine stalls.
CAUTION:
• WIRING DIAGRAM:
BATTERY
RHD
RHD
MAIN RELAY
6 LHD 2 LHD
4
F61 F44
5
3
*3
2
2
1
REAR OXYGEN FRONT OXYGEN
SENSOR (A/F) SENSOR
B47
B19 B18
*6
*4
*5
4
3
LHD : 2
*1 RHD : 4
LHD : 6
*2 RHD : 1 RHD
LHD
LHD : 2
*3 RHD : 1
B260
LHD : 1
*4
1
RHD : 2
B259
* 12
LHD
* 5 LHD : 3
RHD : 4
*
B83
RHD
6 LHD : 4
* RHD : 3
C13
D19
D29
C23
B19
B17
B26
A22
A23
A: B134 B: B135 C: B136 D: B137 ECM

E
B18 B19 F44 B47 B83 B259 B134 B135
1 2 1 2 1 2 1 2 3 1 2
1 2 3 4 1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9
3 4 3 4 3 4 4 5 6
5 6 7 8 8 9 10 11 12 13 14 15 10 11 12 13 14 15 16 17 18 19
5 6 (LHD)
(LHD) 16 17 18 19 20 21 22 20 21 22 23 24 25 26 27 28
1 2 3 4 5 6 B136 B137
2 1
4 3 (RHD)
(RHD) 1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9
8 9 10 11 12 13 14 15 16 10 11 12 13 14 15 16 17 18 19 20 21
17 18 19 20 21 22 23 24 22 23 24 25 26 27 28 29 30 31
EN1439
EN(TURBO)-196
Step Check Yes No

Trouble Code
(DTC)”. <Ref. to
EN(TURBO)-75,
List of Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0420.
2 CHECK EXHAUST SYSTEM. Is there a fault in exhaust sys- Repair or replace Go to step 3.
Check for gas leaks or air suction caused by tem? the exhaust sys-
loose or dislocated nuts and bolts, and open tem. <Ref. to
hole at exhaust pipes. EX(TURBO)-2,
NOTE: General Descrip-
Check the following positions. tion.>
•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. Is there damage at rear face of Replace the front Go to step 4.
Separate the rear catalytic converter from rear rear catalyst? catalytic con-
exhaust pipe. verter. <Ref. to
EC(TURBO)-3,
Front Catalytic
Converter.> and
rear catalytic con-
verter <Ref. to
EC(TURBO)-4,
Rear Catalytic
Converter.>
4 CHECK FRONT CATALYTIC CONVERTER. Is there damage at rear face or Replace the front Contact with your
Remove the front catalytic converter. front face of front catalyst? catalytic con- Subaru distributor
verter. <Ref. to service.
EC(TURBO)-3, NOTE:
Front Catalytic Inspection by DTM
Converter.> is required, be-
cause probable
cause is deteriora-
tion of multiple
parts.
EN(TURBO)-197
AR:DTC P0444 — EVAPORATIVE EMISSION CONTROL SYSTEM PURGE CON-

TROL VALVE CIRCUIT LOW INPUT [MT VEHICLES] —
CAUTION:
• WIRING DIAGRAM:
MAIN RELAY
F44 B47
RHD
RHD
6 BATTERY
4 1 2 3 4 1 2
SBF-5 5 6 7 8 3 4
5 LHD 8 LHD 5 6
3
B61 F44
2
1
B137
B47
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
B137 ECM 22 23 24 25 26 27 28 29 30 31
16
F60 : LHD
B22 : RHD
1 2 3 4
5 6 7 8
9 10 11 12
RHD RHD 14 15 16
13
LHD
LHD
B61 B209
G4
E4
1
F44 F76
1 2
LHD
LHD
RHD RHD
B209
A1 A2 A3 A4 A5
F60 : LHD B22 : RHD
B1 B2 B4 B5
1
2
E3 C1 C2 C3 C4 C5
D1 D2 D4 D5
E1 E5
E4 F1 F5
G1G2 G4 G5
1
2
H1 H2 H3 H4 H5
E I1 I2 I4 I5
J1 J2 J3 J4 J5
PURGE CONTROL
SOLENOID VALVE
EN1440
EN(TURBO)-198
Step Check Yes No

NOTE:
Inspection by DTM
is required, be-
cause probable
cause is deteriora-
tion of multiple
parts.
engine ground.
the following:
• Open circuit in
harness between
ECM and purge
control solenoid
valve connector
• Poor contact in
coupling connector
2)Measure the resistance between purge con- EC(TURBO)-7,
No. 1 — No. 2:
EN(TURBO)-199
Step Check Yes No

Inspection by DTM
is required, be-
cause probable
cause is deteriora-
tion of multiple
parts.
EN(TURBO)-200
EN(TURBO)-201
AS:DTC P0445 — EVAPORATIVE EMISSION CONTROL SYSTEM PURGE CON-

TROL VALVE CIRCUIT HIGH INPUT [MT VEHICLES] —
CAUTION:
• WIRING DIAGRAM:
MAIN RELAY
F44 B47
RHD
RHD
6 BATTERY
4 1 2 3 4 1 2
SBF-5 5 6 7 8 3 4
5 LHD 8 LHD 5 6
3
B61 F44
2
1
B137
B47
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
B137 ECM 22 23 24 25 26 27 28 29 30 31
16
F60 : LHD
B22 : RHD
1 2 3 4
5 6 7 8
9 10 11 12
RHD RHD 14 15 16
13
LHD
LHD
B61 B209
G4
E4
1
F44 F76
1 2
LHD
LHD
RHD RHD
B209
A1 A2 A3 A4 A5
F60 : LHD B22 : RHD
B1 B2 B4 B5
1
2
E3 C1 C2 C3 C4 C5
D1 D2 D4 D5
E1 E5
E4 F1 F5
G1G2 G4 G5
1
2
H1 H2 H3 H4 H5
E I1 I2 I4 I5
J1 J2 J3 J4 J5
PURGE CONTROL
SOLENOID VALVE
EN1440
EN(TURBO)-202
Step Check Yes No

1 CHECK OUTPUT SIGNAL FROM ECM. Does the voltage change Go to step 2. Even if MIL lights
1)Turn the ignition switch to OFF. between 0 and 10 V? up, the circuit has
chassis ground.
NOTE:
tion Check Mode”. <Ref. to EN(TURBO)-46,
Compulsory Valve Operation Check Mode.>
chassis ground.
Check the poor contact in ECM connector. connector? contact in ECM <Ref. to
Engine Control
Module.>
chassis ground. <Ref. to
Module.>
1)Turn the ignition switch to OFF. valve <Ref. to
No. 1 — No. 2: and ECM <Ref. to
FU(TURBO)-49,
Engine Control
Module.>
Engine Control
Module.>
EN(TURBO)-203
AT:DTC P0458 — EVAPORATIVE EMISSION CONTROL SYSTEM PURGE CON-

TROL VALVE CIRCUIT LOW INPUT [AT VEHICLES] —
CAUTION:
• WIRING DIAGRAM:
MAIN RELAY
B47
6 BATTERY
4 1 2
SBF-5 3 4
5 5 6
3
2
1
B137
B47
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
B137 ECM 22 23 24 25 26 27 28 29 30 31
16
B22
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
E4
1 2
B209
A1 A2 A3 A4 A5
B22
B1 B2 B4 B5
1
2
E3 C1 C2 C3 C4 C5
D1 D2 D4 D5
E1 E5
E4 F1 F5
G1G2 G4 G5
1
2
H1 H2 H3 H4 H5
E I1 I2 I4 I5
J1 J2 J3 J4 J5
PURGE CONTROL
SOLENOID VALVE
EN1441
EN(TURBO)-204
Step Check Yes No

NOTE:
Inspection by DTM
is required, be-
cause probable
cause is deteriora-
tion of multiple
parts.
engine ground.
the following:
• Open circuit in
harness between
ECM and purge
control solenoid
valve connector
• Poor contact in
coupling connector
No. 1 — No. 2:
EN(TURBO)-205
Step Check Yes No

Inspection by DTM
is required, be-
cause probable
cause is deteriora-
tion of multiple
parts.
EN(TURBO)-206
EN(TURBO)-207
AU:DTC P0459 — EVAPORATIVE EMISSION CONTROL SYSTEM PURGE CON-

TROL VALVE CIRCUIT HIGH INPUT [AT VEHICLES] —
CAUTION:
• WIRING DIAGRAM:
MAIN RELAY
B47
6 BATTERY
4 1 2
SBF-5 3 4
5 5 6
3
2
1
B137
B47
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
B137 ECM 22 23 24 25 26 27 28 29 30 31
16
B22
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
E4
1 2
B209
A1 A2 A3 A4 A5
B22
B1 B2 B4 B5
1
2
E3 C1 C2 C3 C4 C5
D1 D2 D4 D5
E1 E5
E4 F1 F5
G1G2 G4 G5
1
2
H1 H2 H3 H4 H5
E I1 I2 I4 I5
J1 J2 J3 J4 J5
PURGE CONTROL
SOLENOID VALVE
EN1441
EN(TURBO)-208
Step Check Yes No

1 CHECK OUTPUT SIGNAL FROM ECM. Does the voltage change Go to step 2. Even if MIL lights
chassis ground.
NOTE:
tion Check Mode”. <Ref. to EN(TURBO)-46,
Compulsory Valve Operation Check Mode.>
chassis ground.
Check the poor contact in ECM connector. connector? contact in ECM <Ref. to
Engine Control
Module.>
chassis ground. <Ref. to
Module.>
1)Turn the ignition switch to OFF. valve <Ref. to
No. 1 — No. 2: and ECM <Ref. to
FU(TURBO)-49,
Engine Control
Module.>
Engine Control
Module.>
EN(TURBO)-209
AV:DTC P0461 — FUEL LEVEL SENSOR CIRCUIT RANGE/PERFORMANCE

PROBLEM —
CAUTION:
• WIRING DIAGRAM:
No.13 SBF-4 SBF-1

4 1
RHD
IGNITION SWITCH
B36 B36 B72

23
i1 i1
RHD
A7
COMBINATION
FUEL METER
GAUGE
A: i10 LHD : 24
*1 RHD : 21
C: i12
A6
C2
LHD : 3
*2 RHD : 2
i2
*1
*2
B37
B135
25 D2 16
ECM
LHD
B209 F76 F60 E3
RHD 16
B22 E3
E B99
11
R3 E E
R15
2
R57
E
R59 R58
1
2
3
5
FUEL SUB FUEL LEVEL

LEVEL SENSOR SENSOR
B72 i1 A: i10 C: i12 B135 R15
1 2 1 2 3 4 5 6 1 2 3 4 5 6
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 1 2
3 4 7 8 9 10 11 12 13 14 7 8 9 10 11 12 13 14
10 11 12 13 14 15 16 17 18 19 3 4 5 6
B209 20 21 22 23 24 25 26 27 28
R59 R58 F60 : LHD A1 A2 A3 A4 A5 B36 B99 i2

B1 B2 B4 B5
1 2 1 2 3 B22 : RHD C1 C2 C3 C4 C5 1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9 10 11
4 5 6 D1 D2 D4 D5
1 2 3 4 12 13 14 15 16 17 18 19 20 21 22 23 24 12 13 14 15 16 17 18 19 20 21 22 23 24
E1 E5
5 6 7 8 (LHD)
9 10 11 12 F1 F5 1 2 3 4 5 6 7 8 9
13 14 15 16 G1G2 G4 G5 10 11 12 13 14 15 16 17 18 19 20 21
H1 H2 H3 H4 H5 22 23 24 25 26 27 28 29 30 31 32
I1 I2 I4 I5 (RHD)
J1 J2 J3 J4 J5
EN1442
EN(TURBO)-210
Step Check Yes No

BLE CODE (DTC) ON DISPLAY. vant DTC using level sensor. <Ref.
“List of Diagnostic to FU(TURBO)-62,
Trouble Code Fuel Level Sen-
(DTC)”. <Ref. to sor.> and fuel sub
EN(TURBO)-75, level sensor <Ref.
List of Diagnostic to FU(TURBO)-63,
Trouble Code Fuel Sub Level
(DTC).> Sensor.>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0461.
EN(TURBO)-211
AW:DTC P0462 — FUEL LEVEL SENSOR CIRCUIT LOW INPUT —

CAUTION:
• WIRING DIAGRAM:
No.13 SBF-4 SBF-1

4 1
RHD
IGNITION SWITCH
B36 B36 B72

23
i1 i1
RHD
A7
COMBINATION
FUEL METER
GAUGE
A: i10 LHD : 24
*1 RHD : 21
C: i12
A6
C2
LHD : 3
*2 RHD : 2
i2
*1
*2
B37
B135
25 D2 16
ECM
LHD
B209 F76 F60 E3
RHD 16
B22 E3
E B99
11
R3 E E
R15
2
R57
E
R59 R58
1
2
3
5
FUEL SUB FUEL LEVEL

LEVEL SENSOR SENSOR
B72 i1 A: i10 C: i12 B135 R15
1 2 1 2 3 4 5 6 1 2 3 4 5 6
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 1 2
3 4 7 8 9 10 11 12 13 14 7 8 9 10 11 12 13 14
10 11 12 13 14 15 16 17 18 19 3 4 5 6
B209 20 21 22 23 24 25 26 27 28
R59 R58 F60 : LHD A1 A2 A3 A4 A5 B36 B99 i2

B1 B2 B4 B5
1 2 1 2 3 B22 : RHD C1 C2 C3 C4 C5 1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9 10 11
4 5 6 D1 D2 D4 D5
1 2 3 4 12 13 14 15 16 17 18 19 20 21 22 23 24 12 13 14 15 16 17 18 19 20 21 22 23 24
E1 E5
5 6 7 8 (LHD)
9 10 11 12 F1 F5 1 2 3 4 5 6 7 8 9
13 14 15 16 G1G2 G4 G5 10 11 12 13 14 15 16 17 18 19 20 21
H1 H2 H3 H4 H5 22 23 24 25 26 27 28 29 30 31 32
I1 I2 I4 I5 (RHD)
J1 J2 J3 J4 J5
EN1442
EN(TURBO)-212
Step Check Yes No

IDI-4, Combina-
tion Meter Sys-
tem.>
2 CHECK INPUT SIGNAL FOR ECM. Is the voltage less than 0.12 Go to step 6. Go to step 3.
1)Turn the ignition switch to ON. (engine OFF) V?
3 CHECK INPUT SIGNAL FOR ECM. (USING Does the value change less Repair the poor Even if MIL lights
SUBARU SELECT MONITOR.) than 0.12 V by shaking har- contact in ECM up, the circuit has
Read the data of fuel level sensor signal using ness and connector of ECM connector. returned to a nor-
Subaru Select Monitor. while monitoring the value with mal condition at
NOTE: Subaru Select Monitor? this time. A tempo-
•Subaru Select Monitor rary poor contact
For detailed operation procedure, refer to the of the connector
“READ CURRENT DATA FOR ENGINE”. may be the cause.
<Ref. to EN(TURBO)-34, Subaru Select Moni- NOTE:
tor.> In this case, repair
the following:
• Poor contact in
combination meter
connector
• Poor contact in
ECM connector
• Poor contact in
coupling connec-
tors
4 CHECK INPUT VOLTAGE OF ECM. Is the voltage more than 0.12 Go to step 4. Go to step 7.
1)Turn the ignition switch to OFF. V?
2)Separate the fuel tank cord connector (R57)
COMBINATION METER. MΩ? short circuit in har-
2)Disconnect the connector from connector ECM and combi-
(i10), (i12) and ECM connector. nation meter con-
3)Measure the resistance between ECM and nector.
chassis ground.
6 CHECK HARNESS BETWEEN ECM AND Is the resistance less than 10 Repair or replace Repair the open
COMBINATION METER. Ω? the combination circuit between
Measure the resistance between ECM and meter. <Ref. to ECM and combi-
combination meter connector. IDI-4, Combina- nation meter con-
Connector & terminal tion Meter Sys- nector.
(B135) No. 25 — (i12) No. 2: tem.> NOTE:
the following:
Poor contact in
coupling connector
EN(TURBO)-213
Step Check Yes No

1)Turn the ignition switch to OFF. MΩ? 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.
9 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 Ω? level sensor.
FU(TURBO)-60, Fuel Pump.>
2)Measure the resistance between fuel level
sensor and terminals with its float set to the full
position.
Terminals
No. 3 — No. 5:
10 CHECK FUEL SUB LEVEL SENSOR. Is the resistance between 0.5 Repair the poor Replace the fuel
1)Remove the fuel sub level sensor. <Ref. to and 2.5 Ω? contact in harness sub level sensor.
FU(TURBO)-63, Fuel Sub Level Sensor.> between ECM and
2)Measure the resistance between fuel sub combination meter
level sensor and terminals with its float set to connector.
the full position.
Terminals
No. 1 — No. 2:
EN(TURBO)-214
EN(TURBO)-215
AX:DTC P0463 — FUEL LEVEL SENSOR CIRCUIT HIGH INPUT —

CAUTION:
• WIRING DIAGRAM:
No.13 SBF-4 SBF-1

4 1
RHD
IGNITION SWITCH
B36 B36 B72

23
i1 i1
RHD
A7
COMBINATION
FUEL METER
GAUGE
A: i10 LHD : 24
*1 RHD : 21
C: i12
A6
C2
LHD : 3
*2 RHD : 2
i2
*1
*2
B37
B135
25 D2 16
ECM
LHD
B209 F76 F60 E3
RHD 16
B22 E3
E B99
11
R3 E E
R15
2
R57
E
R59 R58
1
2
3
5
FUEL SUB FUEL LEVEL

LEVEL SENSOR SENSOR
B72 i1 A: i10 C: i12 B135 R15
1 2 1 2 3 4 5 6 1 2 3 4 5 6
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 1 2
3 4 7 8 9 10 11 12 13 14 7 8 9 10 11 12 13 14
10 11 12 13 14 15 16 17 18 19 3 4 5 6
B209 20 21 22 23 24 25 26 27 28
R59 R58 F60 : LHD A1 A2 A3 A4 A5 B36 B99 i2

B1 B2 B4 B5
1 2 1 2 3 B22 : RHD C1 C2 C3 C4 C5 1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9 10 11
4 5 6 D1 D2 D4 D5
1 2 3 4 12 13 14 15 16 17 18 19 20 21 22 23 24 12 13 14 15 16 17 18 19 20 21 22 23 24
E1 E5
5 6 7 8 (LHD)
9 10 11 12 F1 F5 1 2 3 4 5 6 7 8 9
13 14 15 16 G1G2 G4 G5 10 11 12 13 14 15 16 17 18 19 20 21
H1 H2 H3 H4 H5 22 23 24 25 26 27 28 29 30 31 32
I1 I2 I4 I5 (RHD)
J1 J2 J3 J4 J5
EN1442
EN(TURBO)-216
Step Check Yes No

IDI-4, Combina-
tion Meter Sys-
tem.>
2 CHECK INPUT SIGNAL FOR ECM. Is the voltage more than 4.75 Go to step 3. Even if MIL lights
1)Turn the ignition switch to ON. (engine OFF) V? 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-
(B135) No. 25 (+) — Chassis ground (−): rary poor contact
of the connector
may be the cause.
NOTE:
the following:
• Poor contact in
fuel pump connec-
tor
• Poor contact in
coupling connector
3 CHECK INPUT VOLTAGE OF ECM. Is the voltage more than 4.75 Go to step 4. Repair the battery
1)Turn the ignition switch to OFF. V? short circuit
2)Disconnect the combination meter connector between ECM and
(i10) and ECM connector. combination meter
FUEL TANK CORD. Ω? circuit between
1)Turn the ignition switch to OFF. ECM and fuel tank
2)Separate the fuel tank cord connector (R57) cord.
fuel tank cord.
(B135) No. 25 — (R15) No. 2:
5 CHECK HARNESS BETWEEN FUEL TANK Is the resistance less than 5 Go to step 6. Repair the open
CORD AND CHASSIS GROUND. Ω? circuit between
Measure the resistance between fuel tank cord fuel tank cord and
and chassis ground. chassis ground.
(R15) No. 6 — Chassis ground: In this case, repair
the following:
Poor contact in
coupling connec-
tors
(R57) No. 6 — (R58) No. 5:
EN(TURBO)-217
Step Check Yes No

1)Disconnect the connector from fuel sub level Ω? circuit between
sensor. fuel level sensor
2)Measure the resistance between fuel level and fuel sub level
sensor and fuel sub level sensor. sensor.
(R58) No. 3 — (R59) No. 2:
Measure the resistance between fuel sub level Ω? circuit between
sensor and coupling connector. coupling connector
Connector & terminal and fuel sub level
(R57) No. 2 — (R59) No. 1: sensor.
9 CHECK FUEL LEVEL SENSOR. Is the resistance more than 53 Replace the fuel Go to step 10.
1)Remove the fuel pump assembly. <Ref. to Ω? level sensor. <Ref.
FU(TURBO)-60, Fuel Pump.> to FU(TURBO)-62,
and down, measure the resistance between sor.>
fuel level sensor terminals.
Terminals
No. 3 — No. 5:
10 CHECK FUEL SUB LEVEL SENSOR. Is the resistance more than 45 Replace the fuel Replace the com-
1)Remove the fuel sub level sensor. <Ref. to Ω? sub level sensor. bination meter.
FU(TURBO)-63, Fuel Sub Level Sensor.> <Ref. to <Ref. to IDI-15,
2)While moving the fuel sub level sensor float FU(TURBO)-63, Combination
up and down, measure the resistance between Fuel Sub Level Meter Assembly.>
fuel sub level sensor terminals. Sensor.>
Terminals
No. 1 — No. 2:
EN(TURBO)-218
EN(TURBO)-219
AY:DTC P0464 — FUEL LEVEL SENSOR INTERMITTENT INPUT—

CAUTION:
• WIRING DIAGRAM:
No.13 SBF-4 SBF-1

4 1
RHD
IGNITION SWITCH
B36 B36 B72

23
i1 i1
RHD
A7
COMBINATION
FUEL METER
GAUGE
A: i10 LHD : 24
*1 RHD : 21
C: i12
A6
C2
LHD : 3
*2 RHD : 2
i2
*1
*2
B37
B135
25 D2 16
ECM
LHD
B209 F76 F60 E3
RHD 16
B22 E3
E B99
11
R3 E E
R15
2
R57
E
R59 R58
1
2
3
5
FUEL SUB FUEL LEVEL

LEVEL SENSOR SENSOR
B72 i1 A: i10 C: i12 B135 R15
1 2 1 2 3 4 5 6 1 2 3 4 5 6
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 1 2
3 4 7 8 9 10 11 12 13 14 7 8 9 10 11 12 13 14
10 11 12 13 14 15 16 17 18 19 3 4 5 6
B209 20 21 22 23 24 25 26 27 28
R59 R58 F60 : LHD A1 A2 A3 A4 A5 B36 B99 i2

B1 B2 B4 B5
1 2 1 2 3 B22 : RHD C1 C2 C3 C4 C5 1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9 10 11
4 5 6 D1 D2 D4 D5
1 2 3 4 12 13 14 15 16 17 18 19 20 21 22 23 24 12 13 14 15 16 17 18 19 20 21 22 23 24
E1 E5
5 6 7 8 (LHD)
9 10 11 12 F1 F5 1 2 3 4 5 6 7 8 9
13 14 15 16 G1G2 G4 G5 10 11 12 13 14 15 16 17 18 19 20 21
H1 H2 H3 H4 H5 22 23 24 25 26 27 28 29 30 31 32
I1 I2 I4 I5 (RHD)
J1 J2 J3 J4 J5
EN1442
EN(TURBO)-220
Step Check Yes No

Trouble Code
(DTC)”. <Ref. to
EN(TURBO)-75,
List of Diagnostic
Trouble Code
(DTC).>
2 CHECK FUEL LEVEL SENSOR. Does the resistance change Go to step 3. Replace the fuel
1)Remove the fuel pump assembly. <Ref. to smoothly between approx. 0.5 level sensor. <Ref.
FU(TURBO)-60, Fuel Pump.> Ω and approx. 52 Ω? to FU(TURBO)-62,
and down, make sure that the resistance sor.>
between fuel level sensor terminals changes
smoothly.
Terminals
No. 3 — No. 5:
3 CHECK FUEL SUB LEVEL SENSOR. Does the resistance change Repair the poor Replace the fuel
1)Remove the fuel sub level sensor. <Ref. to smoothly between approx. 0.5 contact in ECM, sub level sensor.
FU(TURBO)-63, Fuel Sub Level Sensor.> Ω and approx. 44 Ω? combination meter <Ref. to
2)While moving the fuel sub level sensor float and coupling con- FU(TURBO)-63,
up and down, make sure that the resistance nectors. Fuel Sub Level
between fuel level sensor terminals changes Sensor.>
smoothly.
Terminals
No. 1 — No. 2:
EN(TURBO)-221
EN(TURBO)-222
AZ:DTC P0480 — COOLING FAN RELAY 1 CIRCUIT LOW INPUT —

• Overheating
CAUTION:
EN(TURBO)-223
• WIRING DIAGRAM:
BATTERY
SBF-1
IGNITION
B72 SWITCH
SBF-4 No.18
LHD : 2
*1 RHD : 7
No.17
LHD : 12
*2 RHD : 17
17
B137 ECM
28 * 12
*
B62 F45
17
19
20
18
24
22
21
23
25
27
28
26
8
6
5
7
2
1
4
3
30A
30A
1
3
2
1
3
2
F16 F17

M M
E E F29 F28 F30 F66 F27
SUB FAN MAIN FAN
B72 (BLUE) F27 F28 F29 F30 F66 B137 F45 F16
1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 10 11 F17
1 2 1 2 5 6 9 13 14 17 21 22 25 29
3 4 7 10 15 18 23 26 10 11 12 13 14 15 16 17 18 19 20 21 12 13 14 15 16 17 18 19 20 21 22 23 24
3 4 8 11 12 16 19 20 24 27 28 30 22 23 24 25 26 27 28 29 30 31 (LHD) 3 2 1
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18
(RHD)
EN0981
EN(TURBO)-224
Step Check Yes No

1 CHECK OUTPUT SIGNAL FROM ECM. Does the voltage change Repair the poor Go to step 2.
1)Turn the ignition switch to OFF. between 0 and 10 V? contact in ECM
2)Connect the test mode connector at the connector.
lower portion of instrument panel (on the
driver's side).
4)While operating the radiator fan relay, mea-
sure the voltage between ECM terminal and
ground.
NOTE:
Check Mode”.<Ref. to EN(TURBO)-34, Subaru
Select Monitor.>
2 CHECK GROUND SHORT CIRCUIT IN RADI- Is the resistance less than 10 Repair the ground Go to step 3.
ATOR MAIN FAN RELAY CONTROL CIR- Ω? short circuit in radi-
CUIT. ator main fan relay
1)Turn the ignition switch to OFF. control circuit.
2)Disconnect the connectors from ECM.
3 CHECK POWER SUPPLY FOR RELAY. Is the voltage more than 10 V? Go to step 4. Repair the open
1)Remove the main fan relay 1 and 2 from A/C circuit in harness
relay holder. between ignition
2)Turn the ignition switch to ON. switch and fuse
3)Measure the voltage between fuse and relay and relay box
box (F/B) connector and chassis ground. (F/B) connector.
4 CHECK MAIN FAN RELAY. Is the resistance between 87 Go to step 5. Replace the main
1)Turn the ignition switch to OFF. and 107 Ω? fan relay.
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- Is the resistance less than 1 Go to step 6. Repair the har-
LAY CONTROL CIRCUIT. Ω? ness and connec-
ECM and main fan relay connector. NOTE:
(B137) No. 17 — (F66) No. 28: the following:
(B137) No. 28 — (F30) No. 21: • Open circuit in
harness between
ECM and main fan
relay connector
• Poor contact in
coupling connector
6 CHECK POOR CONTACT. Is there poor contact in ECM or Repair the poor Contact with your
Check poor contact in ECM or main fan relay main fan relay connector? contact in ECM or Subaru distributor
connector. main fan relay service.
connector.
EN(TURBO)-225
EN(TURBO)-226
BA:DTC P0483 — COOLING FAN FUNCTION PROBLEM —

• Occurrence of noise
• Overheating
CAUTION:
NOTE:
If the vehicle, with the engine idling, is placed very close to a wall or another vehicle, preventing normal cool-
ing function, the OBD system may detect malfunction.
EN(TURBO)-227
• WIRING DIAGRAM:
BATTERY
SBF-1
IGNITION
B72 SWITCH
SBF-4 No.18
LHD : 2
*1 RHD : 7
No.17
LHD : 12
*2 RHD : 17
17
B137 ECM
28 * 12
*
B62 F45
17
19
20
18
24
22
21
23
25
27
28
26
8
6
5
7
2
1
4
3
30A
30A
1
3
2
1
3
2
F16 F17

M M
E E F29 F28 F30 F66 F27
SUB FAN MAIN FAN
B72 (BLUE) F27 F28 F29 F30 F66 B137 F45 F16
1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 10 11 F17
1 2 1 2 5 6 9 13 14 17 21 22 25 29
3 4 7 10 15 18 23 26 10 11 12 13 14 15 16 17 18 19 20 21 12 13 14 15 16 17 18 19 20 21 22 23 24
3 4 8 11 12 16 19 20 24 27 28 30 22 23 24 25 26 27 28 29 30 31 (LHD) 3 2 1
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18
(RHD)
EN0981
EN(TURBO)-228
Step Check Yes No

1 CHECK ANY OTHER DIAGNOSTIC TROU- Is any other DTC displayed? Inspect the rele- Check the radiator
BLE CODE (DTC) ON DISPLAY. vant DTC using fan, fan motor and
“List of Diagnostic thermostat. <Ref.
Trouble Code to CO-10, Radiator
(DTC)”. <Ref. to Main Fan Sys-
EN(TURBO)-75, tem.> and <Ref. to
List of Diagnostic CO-18, Radiator
Trouble Code Sub Fan Sys-
(DTC).> tem.> If thermostat
is stuck, replace
thermostat.
EN(TURBO)-229
BB:DTC P0500 — VEHICLE SPEED SENSOR MALFUNCTION —

CAUTION:
• WIRING DIAGRAM:
B157
IGNITION
RELAY BATTERY
1 2
No.15
3 4 9 14 15 16 19 24 25 26 29 34 35 36
* 12 10 17 20 27 30 37
* 5 6
11 12 13 18 21 22 23 28 31 32 33 38
7 8
B157 LHD : 10
*1 RHD : 38
LHD : 9 i2
*2 RHD : 37
1 2 3 4 5 6 7 8 9 10 11
LHD : 9
*3 RHD : 7
12 13 14 15 16 17 18 19 20 21 22 23 24
(LHD)
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
3
22 23 24 25 26 27 28 29 30 31 32
VEHICLE (RHD)
SPEED
SENSOR
B17
B209
1
2
A1 A2 A3 A4 A5
B1 B2 B4 B5
C1 C2 C3 C4 C5
B56 TCM D1 D2 D4 D5
17 AT MT
E1 E5
RHD
COMBINATION F1 F5
LHD
METER G1G2 G4 G5
H1 H2 H3 H4 H5
i10
I1 I2 I4 I5
J1 J2 J3 J4 J5
B209
N2
2
*3 F76
i2 B37
LHD
i10 B17
RHD 1 2 3 4 5 6 7 8 9 10 1 2
3 4
F60 : LHD B22 : RHD

16
F60 : LHD
1
E3
B134 B22 : RHD
1 2 3 4 5 6 7 1 2 3 4
B134 ECM
8 9 10 11 12 13 14 15 5 6 7 8
E E 16 17 18 19 20 21 22 9 10 11 12
13 14 15 16
EN1443
Step Check Yes No

1 CHECK TRANSMISSION TYPE. Is the transmission type AT? Go to step 2. Go to step 3.
EN(TURBO)-230
Step Check Yes No

<Ref. to AT-57,
DTC 33 FRONT
VEHICLE SPEED
SENSOR, Diag-
nostic Procedure
with Diagnostic
Trouble Code
(DTC).>
cle speed sensor.
<Ref. to IDI-17,
Speedometer.>
and <Ref. to AT-
32, Front Vehicle
Speed Sensor.>
nation meter con-
nector
• Poor contact in
ECM connector
• Poor contact in
combination meter
connector
• Poor contact in
coupling connector
EN(TURBO)-231
BC:DTC P0506 — IDLE CONTROL SYSTEM RPM LOWER THAN EXPECTED —

• Engine is difficult to start.
• Engine stalls.
CAUTION:
• WIRING DIAGRAM:
MAIN RELAY
6 BATTERY
RHD
RHD
4 B209 F44
SBF-5
5 LHD 8 LHD A1 A2 A3 A4 A5
1 2 3 4
3 B1 B2 B4 B5
5 6 7 8
B61 F44 C1 C2 C3 C4 C5
2 RHD
D1 D2 D4 D5
1 E1 E5
LHD
B47
B47 F1 F5
B61 G1G2 G4 G5 1 2
H1 H2 H3 H4 H5 3 4
1
F44 I1 I2 I4 I5 5 6
J1 J2 J3 J4 J5
LHD
RHD
F60 : LHD
F60 : LHD B22 : RHD B22 : RHD

1
E3 1 2 3 4
5 6 7 8
9 10 11 12
2
13 14 15 16
IDLE
AIR CONTROL
SOLENOID
VALVE
E7
E7
1 2 3
1
3
LHD F61 : LHD

E2
RHD
B21 : RHD
12
F61
E2 1 2 3 4
12
5 6 7 8
F76 B21 9 10 11 12
G5
RHD
13 14 15 16
B209 17 18 19 20
LHD
10
B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16
B136 ECM 17 18 19 20 21 22 23 24
E E
EN1444
EN(TURBO)-232
Step Check Yes No

Trouble Code
(DTC)”. <Ref. to
EN(TURBO)-75,
List of Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0506.
2 CHECK IDLE AIR CONTROL SOLENOID Does air flow out? Go to step 4. Replace the idle
VALVE. air control solenoid
1)Turn the ignition switch to OFF. valve. <Ref. to
2)Remove the idle air control solenoid valve FU(TURBO)-36,
from throttle body. <Ref. to FU(TURBO)-36, Idle Air Control
REMOVAL, Idle Air Control Solenoid Valve.> Solenoid Valve.>
3)Using an air gun, force air into the idle air After replace, Go
control solenoid valve by-pass air inlet. Con- to step 3.
both main air passage and assist air passage.
3 CHECK IDLE AIR CONTROL SOLENOID Is the value more than 60 %? Go to step 4. END.
VALVE DUTY RATIO.
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 or
NOTE:
tor.>
4 CHECK BY-PASS AIR LINE. Does air flow out? Replace the idle Replace the throt-
2)Remove the idle air control solenoid valve valve. <Ref. to FU(TURBO)-14,
from throttle body. <Ref. to FU(TURBO)-36, FU(TURBO)-36, Throttle Body.>
REMOVAL, Idle Air Control Solenoid Valve.> Idle Air Control
3)Remove the throttle body to intake manifold. Solenoid Valve.>
<Ref. to FU(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
escapes from both these areas.
EN(TURBO)-233
BD:DTC P0507 — IDLE CONTROL SYSTEM RPM HIGHER THAN EXPECTED —

CAUTION:
• WIRING DIAGRAM:
MAIN RELAY
6 BATTERY
RHD
RHD
4 B209 F44
SBF-5
1 2 3 4
3 B1 B2 B4 B5
5 6 7 8
B61 F44 C1 C2 C3 C4 C5
2 RHD
D1 D2 D4 D5
1 E1 E5
LHD
B47
B47 F1 F5
B61 G1G2 G4 G5 1 2
H1 H2 H3 H4 H5 3 4
1
F44 I1 I2 I4 I5 5 6
J1 J2 J3 J4 J5
LHD
RHD
F60 : LHD

1
E3 1 2 3 4
5 6 7 8
9 10 11 12
2
13 14 15 16
IDLE
AIR CONTROL
SOLENOID
VALVE
E7
E7
1 2 3
1
3
LHD F61 : LHD

E2
RHD
B21 : RHD
12
F61
E2 1 2 3 4
12
5 6 7 8
F76 B21 9 10 11 12
G5
RHD
13 14 15 16
B209 17 18 19 20
LHD
10
B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16
B136 ECM 17 18 19 20 21 22 23 24
E E
EN1444
EN(TURBO)-234
Step Check Yes No

Trouble Code
(DTC)”. <Ref. to
EN(TURBO)-75,
List of Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P0507.
9, INSTALLA-
TION, Accelerator
Control Cable.>
3 CHECK AIR INTAKE SYSTEM. Is there a fault in air intake sys- Repair the air suc- Replace the idle
1)Turn the ignition switch to ON. tem? tion and leaks. air control solenoid
2)Start the engine, and idle it. valve. <Ref. to
3)Check the following items. FU(TURBO)-36,
•Loose installation of intake manifold, idle air Idle Air Control
control solenoid valve and throttle body Solenoid Valve.>
gasket
EN(TURBO)-235
BE:DTC P0508 — IDLE CONTROL SYSTEM CIRCUIT LOW INPUT —

• Engine stalls.
CAUTION:
• WIRING DIAGRAM:
MAIN RELAY
6 BATTERY
RHD
RHD
4 B209 F44
SBF-5
1 2 3 4
3 B1 B2 B4 B5
5 6 7 8
B61 F44 C1 C2 C3 C4 C5
2 RHD
D1 D2 D4 D5
1 E1 E5
LHD
B47
B47 F1 F5
B61 G1G2 G4 G5 1 2
H1 H2 H3 H4 H5 3 4
1
F44 I1 I2 I4 I5 5 6
J1 J2 J3 J4 J5
LHD
RHD
F60 : LHD

1
E3 1 2 3 4
5 6 7 8
9 10 11 12
2
13 14 15 16
IDLE
AIR CONTROL
SOLENOID
VALVE
E7
E7
1 2 3
1
3
LHD F61 : LHD

E2
RHD
B21 : RHD
12
F61
E2 1 2 3 4
12
5 6 7 8
F76 B21 9 10 11 12
G5
RHD
13 14 15 16
B209 17 18 19 20
LHD
10
B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16
B136 ECM 17 18 19 20 21 22 23 24
E E
EN1444
EN(TURBO)-236
Step Check Yes No

1)Turn the ignition switch to ON. contact in ECM
chassis ground.
solenoid valve and engine ground. harness between
main relay con-
nector
• Poor contact in
coupling connector
CONNECTOR. tor.
ECM and idle air control solenoid valve con- • Open circuit in
nector. harness between
Connector & terminal ECM and idle air
(B136) No. 10 — (E7) No. 1: control solenoid
valve connector
• Poor contact in
coupling connector
IDLE AIR CONTROL SOLENOID VALVE Ω? short circuit in har-
ECM and chassis ground. control solenoid
5 CHECK GROUND CIRCUIT OF IDLE AIR Is the resistance less than 5 Go to step 6. Repair the open
CONTROL SOLENOID VALVE. Ω? circuit 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: cable.
6 CHECK POOR CONTACT. Is there poor contact in ECM Repair the poor Replace the idle
Check poor contact in ECM and idle air control and idle air control solenoid contact in ECM air control solenoid
solenoid valve connectors. valve connectors? and idle air control valve. <Ref. to
solenoid valve FU(TURBO)-36,
connectors. Idle Air Control
Solenoid Valve.>
EN(TURBO)-237
BF:DTC P0509 — IDLE CONTROL SYSTEM CIRCUIT HIGH INPUT —

• Engine stalls.
CAUTION:
• WIRING DIAGRAM:
MAIN RELAY
6 BATTERY
RHD
RHD
4 B209 F44
SBF-5
1 2 3 4
3 B1 B2 B4 B5
5 6 7 8
B61 F44 C1 C2 C3 C4 C5
2 RHD
D1 D2 D4 D5
1 E1 E5
LHD
B47
B47 F1 F5
B61 G1G2 G4 G5 1 2
H1 H2 H3 H4 H5 3 4
1
F44 I1 I2 I4 I5 5 6
J1 J2 J3 J4 J5
LHD
RHD
F60 : LHD

1
E3 1 2 3 4
5 6 7 8
9 10 11 12
2
13 14 15 16
IDLE
AIR CONTROL
SOLENOID
VALVE
E7
E7
1 2 3
1
3
LHD F61 : LHD

E2
RHD
B21 : RHD
12
F61
E2 1 2 3 4
12
5 6 7 8
F76 B21 9 10 11 12
G5
RHD
13 14 15 16
B209 17 18 19 20
LHD
10
B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16
B136 ECM 17 18 19 20 21 22 23 24
E E
EN1444
Step Check Yes No

9, INSTALLA-
TION, Accelerator
Control Cable.>
EN(TURBO)-238
Step Check Yes No

chassis ground.
3 CHECK OUTPUT SIGNAL FROM ECM. Is the voltage more than 10 V? Repair the battery Replace the idle
1)Turn the ignition switch to OFF. short circuit in har- air control solenoid
2)Disconnect the connector from idle air con- ness between valve. <Ref. to
trol solenoid valve. ECM and idle air FU(TURBO)-36,
3)Turn the ignition switch to ON. control solenoid Idle Air Control
4)Measure the voltage between ECM and valve connector. Solenoid Valve.>
chassis ground. After repair, and ECM <Ref. to
Connector & terminal replace the ECM. FU(TURBO)-49,
(B136) No. 10 (+) — Chassis ground (−): <Ref. to Engine Control
FU(TURBO)-49, Module.>
Engine Control
Module.>
4 CHECK OUTPUT SIGNAL FROM ECM. Does the voltage change more Repair the battery Contact with your
Measure the voltage between ECM and chas- than 10 V by shaking harness short circuit in har- Subaru distributor
sis ground. and connector of ECM while ness between service.
Connector & terminal monitoring the value with volt- ECM and idle air NOTE:
(B136) No. 10 (+) — Chassis ground (−): age meter? control solenoid Inspection by DTM
valve connector. is required, be-
After repair, cause probable
replace the ECM. cause is deteriora-
<Ref. to tion of multiple
FU(TURBO)-49, parts.
Engine Control
Module.>
EN(TURBO)-239
BG:DTC P0512 — STARTER SWITCH CIRCUIT HIGH INPUT —

CAUTION:
• WIRING DIAGRAM:
BATTERY
SBF-4 SBF-1
1
IGNITION
SWITCH
B72
3
P R N D 3 2 1
AT 12 12
11 7
MT
B12 T3 T7
MT
AT
B134 ECM 16
B14
STARTER
MOTOR
E E
B72 B134 B12 T7
1 2 1 2 3 4 5 6 7 1 2 3 4 1 2 3 4 5 6
3 4 8 9 10 11 12 13 14 15 5 6 7 8 7 8 9 10 11 12
16 17 18 19 20 21 22 9 10 11 12
EN1428
EN(TURBO)-240
Step Check Yes No

1 CHECK OPERATION OF STARTER MOTOR. Does the starter motor oper- Repair the battery Check the starter
NOTE: ate when ignition switch is short circuit in motor circuit. <Ref.
Place the inhibitor switch in each position. turned to ON? starter motor cir- to EN(TURBO)-60,
cuit. After repair, STARTER
replace the ECM. MOTOR CIR-
<Ref. to CUIT, Diagnostics
FU(TURBO)-49, for Engine Start-
Engine Control ing Failure.>
Module.>
EN(TURBO)-241
BH:DTC P0545 — EXHAUST GAS TEMPERATURE SENSOR CIRCUIT LOW IN-

PUT —
• Hard to start
CAUTION:
• WIRING DIAGRAM:
B83
EXHAUST GAS 1 2 3
TEMPERATURE 4 5 6
SENSOR (LHD)
1 2 3 4 5 6
(RHD)
1
2
B279
B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
B279
1 2
5 LHD : 6
* * RHD : 1
B83
19
16
B136 ECM
EN0984
EN(TURBO)-242
Step Check Yes No

1 CHECK CURRENT DATA. Is the value greater than Go to step 2. Repair the poor
1)Start the engine. 1200°C (2192°F)? contact.
2)Read the data of exhaust gas temperature NOTE:
•Subaru Select Monitor exhaust gas tem-
For detailed operation procedure, refer to the perature sensor
<Ref. to EN(TURBO)-34, Subaru Select Moni- ECM
tor.> • Poor contact in
•OBD-II general scan tool joint connector
2 CHECK HARNESS BETWEEN EXHAUST Is the value less than 372°C Replace the Repair the 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 exhaust gas tem-
2)Disconnect the connector from exhaust gas FU(TURBO)-48, 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
NOTE:
tor.>
EN(TURBO)-243
BI: DTC P0546 — EXHAUST GAS TEMPERATURE SENSOR CIRCUIT HIGH IN-
PUT —
• Hard to start
CAUTION:
• WIRING DIAGRAM:
B83
EXHAUST GAS 1 2 3
TEMPERATURE 4 5 6
SENSOR (LHD)
1 2 3 4 5 6
(RHD)
1
2
B279
B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
B279
1 2
5 LHD : 6
* * RHD : 1
B83
19
16
B136 ECM
EN0984
EN(TURBO)-244
Step Check Yes No

1 CHECK CURRENT DATA. Is the value less than 372°C Go to step 2. Repair the poor
2)Read the data of exhaust gas temperature NOTE:
•Subaru Select Monitor exhaust gas tem-
For detailed operation procedure, refer to the perature sensor
<Ref. to EN(TURBO)-34, Subaru Select Moni- ECM
tor.> • Poor contact in
•OBD-II general scan tool joint connector
2 CHECK HARNESS BETWEEN EXHAUST Is the voltage more than 10 V? Repair the battery Go to step 3.
GAS TEMPERATURE SENSOR AND ECM short circuit in har-
1)Turn the ignition switch to OFF. ECM and exhaust
2)Disconnect the connector from exhaust gas gas temperature
temperature sensor. sensor connector.
3)Measure the voltage between exhaust gas
ground.
3 CHECK HARNESS BETWEEN EXHAUST Is the voltage more than 10 V? Repair the battery Go to step 4.
GAS TEMPERATURE SENSOR AND ECM short circuit in har-
1)Turn the ignition switch to ON. ECM and exhaust
2)Measure the voltage between exhaust gas gas temperature
temperature sensor connector and engine sensor connector.
ground.
4 CHECK HARNESS BETWEEN EXHAUST Is the voltage more than 4 V? Go to step 5. Repair the har-
GAS TEMPERATURE SENSOR AND ECM ness and connec-
CONNECTOR. tor.
Measure the voltage between exhaust gas NOTE:
(B279) No. 1 (+) — Engine ground (−): harness between
ECM and exhaust
gas temperature
sensor connector
• Poor contact in
exhaust gas tem-
perature sensor
connector
• Poor contact in
ECM connector
• Poor contact in
joint connector
EN(TURBO)-245
Step Check Yes No

5 CHECK HARNESS BETWEEN EXHAUST Is the resistance less than 5 Replace the Repair the har-
GAS TEMPERATURE SENSOR AND ECM Ω? exhaust gas tem- ness and connec-
CONNECTOR. perature sensor. tor.
1)Turn the ignition switch to OFF. <Ref. to NOTE:
exhaust gas temperature sensor connector Exhaust Tempera- the following:
and engine ground. ture Sensor.> • Open circuit in
(B279) No. 2 — Engine ground: ECM and exhaust
gas temperature
sensor connector
• Poor contact in
exhaust gas tem-
perature sensor
connector
• Poor contact in
ECM connector
• Poor contact in
joint connector
EN(TURBO)-246
BJ:DTC P0604 — INTERNAL CONTROL MODULE MEMORY CHECK SUM ER-

ROR —
• Engine stalls.
CAUTION:
• WIRING DIAGRAM:
EN(TURBO)-247
• LHD model
MAIN RELAY

6 2
SBF-5
5 8
3
B61 F44
1 SWITCH
No.11 SBF-4 SBF-1
B47 4 1
D10
A14
D2
D3
A2
A : B134
C : B136
ECM
D : B137
E: B84
C17
C18
A22
A15
D8
D9
C8
E1
A7
B209
C3
D2
A3
F1
J3
F76
F60
13
14
16
15
3
E3
E E E
B72 B47 F60 A : B134 C : B136
1 2 1 2 1 2 3 4 1 2 3 4 5 6 7 1 2 3 4 5 6 7
3 4 3 4 5 6 7 8 8 9 10 11 12 13 14 15 8 9 10 11 12 13 14 15 16
5 6 9 10 11 12 16 17 18 19 20 21 22 17 18 19 20 21 22 23 24
13 14 15 16
B209 D : B137 E: B84
A1 A2 A3 A4 A5 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6
B1 B2 B4 B5 10 11 12 13 14 15 16 17 18 19 20 21 7 8 9 10 11 12
C1 C2 C3 C4 C5 22 23 24 25 26 27 28 29 30 31 13 14 15 16 17
D1 D2 D4 D5
E1 E5
F1 F5
G1G2 G4 G5
H1 H2 H3 H4 H5
I1 I2 I4 I5
J1 J2 J3 J4 J5
EN1429
EN1429
EN(TURBO)-248
• RHD model
MAIN RELAY

6
SBF-5
5
3
2 B72 IGNITION
1 SWITCH BATTERY
No.11 SBF-4 SBF-1
B47 4 1
D10
A14
D2
D3
A2
A: B134
C : B136
ECM
D : B137
E: B84
C17
C18
A22
A15
D8
D9
C8
E1
A7
B22
13
14
16
15
3
E3
E E E
B72 B47 B22 A : B134 C : B136 D : B137
1 2 1 2 1 2 3 4 1 2 3 4 5 6 7 1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9
3 4 3 4 5 6 7 8 8 9 10 11 12 13 14 15 8 9 10 11 12 13 14 15 16 10 11 12 13 14 15 16 17 18 19 20 21
5 6 9 10 11 12 16 17 18 19 20 21 22 17 18 19 20 21 22 23 24 22 23 24 25 26 27 28 29 30 31
13 14 15 16
E: B84
1 2 3 4 5 6
7 8 9 10 11 12
13 14 15 16 17
EN0960
Step Check Yes No

BLE CODE (DTC) ON DISPLAY. tor or OBD-II general scan tool <Ref. to to inspect DTC
indicate DTC P0604? FU(TURBO)-49, P0604.
Engine Control
Module.>
EN(TURBO)-249
BK:DTC P0703 — BRAKE SWITCH INPUT MALFUNCTION —

CAUTION:
ERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(TURBO)-42, Inspection Mode.>.
• WIRING DIAGRAM:
BATTERY
SBF-1
SBF-2
BRAKE LIGHT
SWITCH
B65
NO. 16
1
2
TO STOP LIGHTS
12
B55 TCM
B65 B55
1 2 1 2 3 4 5 6 7 8 9
3 4 10 11 12 13 14 15 16 17 18
19 20 21 22 23 24
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(TURBO)-250
Step Check Yes No

2 CHECK HARNESS BETWEEN TCM AND Is the resistance less than 1 Go to step 3. Repair or replace
BRAKE LIGHT SWITCH CONNECTOR. Ω? the harness and
1)Disconnect the connectors from TCM and connector.
brake light switch. NOTE:
TCM and brake light switch connector. the following:
TCM and brake
light switch con-
nector
• Poor contact in
TCM connector
• Poor contact in
brake light switch
connector
3 CHECK HARNESS BETWEEN TCM AND Is the resistance more than 1 Go to step 4. Repair the ground
BRAKE LIGHT SWITCH CONNECTOR. MΩ? short circuit in har-
TCM and chassis ground. TCM and brake
Connector & terminal light switch con-
(B55) No. 12 — Chassis ground: nector.
4 CHECK INPUT SIGNAL FOR TCM. Is the voltage less than 1 V Go to step 5. Adjust or replace
1)Connect 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 8, STOP LIGHT
chassis ground. SWITCH,
Connector & terminal INSPECTION,
(B55) No. 12 (+) — Chassis ground (−): Stop Light Sys-
tem.>
5 CHECK INPUT SIGNAL FOR TCM. Is the voltage more than 10 V Go 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 8, STOP LIGHT
(B55) No. 12 (+) — Chassis ground (−): SWITCH,
INSPECTION,
Stop Light Sys-
tem.>
trol Module
(TCM).>
EN(TURBO)-251
BL:DTC P0731 — GEAR 1 INCORRECT RATIO —

NOTE:
For the diagnostic procedure, refer to DTC P0734. <Ref. to EN(TURBO)-253, DTC P0734 — GEAR 4 IN-
CORRECT RATIO —, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
BM:DTC P0732 — GEAR 2 INCORRECT RATIO —

NOTE:
BN:DTC P0733 — GEAR 3 INCORRECT RATIO —

NOTE:
EN(TURBO)-252
BO:DTC P0734 — GEAR 4 INCORRECT RATIO —

• Shift point too high or too low; engine brake not effective in “3” range; excessive shift shock; excessive
tight corner “braking”
CAUTION:
• WIRING DIAGRAM:
Step Check Yes No

Trouble Code
(DTC)”. <Ref. to
EN(TURBO)-75,
List of 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 the front vehicle speed sensor circuit. sensor 2 circuit.
<Ref. to AT-57, DTC 33 FRONT VEHICLE
SPEED SENSOR, Diagnostic Procedure with
Code (DTC).>
connector.
INSPECTION, (TCM).>
Road Test.>
EN(TURBO)-253
BP:DTC P0741 — TORQUE CONVERTER CLUTCH SYSTEM MALFUNCTION —

• No lock-up (after engine warm-up)
• No shift or excessive tight corner “braking”
CAUTION:
Step Check Yes No

Trouble Code
(DTC)”. <Ref. to
EN(TURBO)-75,
List of Diagnostic
Trouble 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 the lock-up duty solenoid circuit. <Ref. solenoid circuit.
to AT-94, DTC 77 LOCK-UP DUTY SOLE-
NOID, Diagnostic Procedure with Diagnostic
Code (DTC).>
5 CHECK ENGINE SPEED INPUT CIRCUIT. Is there any trouble in engine Repair or replace Go to step 6.
Check the engine speed input circuit. <Ref. to speed input circuit? the engine speed
AT-42, DTC 11 ENGINE SPEED SIGNAL, input circuit.
Code (DTC).>
6 CHECK INHIBITOR SWITCH CIRCUIT. Is there any trouble in inhibitor Repair or replace Go to step 7.
Check the inhibitor switch circuit. <Ref. to AT- switch circuit? the inhibitor switch
119, CHECK INHIBITOR SWITCH., Diagnostic circuit.
(DTC).>
7 CHECK BRAKE LIGHT SWITCH CIRCUIT. Is there any trouble in brake Repair or replace Go to step 8.
Check the brake light switch circuit. <Ref. to light switch circuit? the brake light
AT-110, CHECK BRAKE SWITCH., Diagnostic switch circuit.
(DTC).>
EN(TURBO)-254
Step Check Yes No

8 CHECK ATF TEMPERATURE SENSOR CIR- Is there any trouble in ATF Repair or replace Go to step 9.
CUIT. temperature sensor circuit? the ATF tempera-
Check the ATF temperature sensor circuit. ture sensor circuit.
connector.
INSPECTION, (TCM).>
Road Test.>
EN(TURBO)-255
BQ:DTC P0851 — NEUTRAL POSITION SWITCH CIRCUIT HIGH INPUT [AT VE-
HICLES] —
CAUTION:
• WIRING DIAGRAM:
B134 ECM
8
B134
7 6 5 4 3 2 1
15 14 13 12 11 10 9 8
22 21 20 19 18 17 16
INHIBITOR SWITCH
P R N D 3 2 1
12 12 B12
11 7
1 2 3 4
B12 T3 T7 5 6 7 8
9 10 11 12
13 14 15 16
STARTER MOTOR T7
1 2 3 4 5 6
7 8 9 10 11 12
B14
B2M4370
EN(TURBO)-256
Step Check Yes No

Trouble Code
(DTC)”. <Ref. to
EN(TURBO)-75,
List of Diagnostic
Trouble Code
(DTC).>
positions.
Measure the voltage between ECM and chas- 5.5 V?
sis ground in selector lever except for “N” and
“P” positions.
connector. service.
NOTE:
Inspection by DTM
is required, be-
cause probable
cause is deteriora-
tion of multiple
parts.
Connector & terminal ECM and inhibitor
(B134) No. 8 (+) — Chassis ground (−): switch connector.
switch connector
• Poor contact in
coupling connector
• Poor contact in
inhibitor switch
connector
• Poor contact in
ECM connector
EN(TURBO)-257
Step Check Yes No

Measure the resistance of harness between Ω? circuit 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:
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
8 CHECK INHIBITOR SWITCH. Is the resistance less than 1 Go to step 9. Replace the inhibi-
Measure the resistance between inhibitor Ω? tor switch. <Ref. to
switch connector receptacle's terminals in AT-28, Inhibitor
selector lever “N” and “P” positions. Switch.>
Terminals
No. 7 — No. 12:
INSPECTION, NOTE:
is required, be-
cause probable
cause is deteriora-
tion of multiple
parts.
EN(TURBO)-258
EN(TURBO)-259
BR:DTC P0852 — NEUTRAL POSITION SWITCH CIRCUIT LOW INPUT [AT VE-
HICLES] —
CAUTION:
• WIRING DIAGRAM:
B134 ECM
8
B134
7 6 5 4 3 2 1
15 14 13 12 11 10 9 8
22 21 20 19 18 17 16
INHIBITOR SWITCH
P R N D 3 2 1
12 12 B12
11 7
1 2 3 4
B12 T3 T7 5 6 7 8
9 10 11 12
13 14 15 16
STARTER MOTOR T7
1 2 3 4 5 6
7 8 9 10 11 12
B14
B2M4370
EN(TURBO)-260
Step Check Yes No

Trouble Code
(DTC)”. <Ref. to
EN(TURBO)-75,
List of Diagnostic
Trouble Code
(DTC).>
2 CHECK INPUT SIGNAL FOR ECM. Is the voltage between 4.5 and Even if MIL lights Go 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-
Connector & terminal this time.
2)Disconnect the connectors from ECM and ECM and trans-
transmission harness connector (T3). mission harness
4 CHECK TRANSMISSION HARNESS CON- Is the resistance less than 10 Repair the ground Go to step 5.
NECTOR. Ω? 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.
5 CHECK INHIBITOR SWITCH. Is the resistance more than 1 Go to step 6. Replace the inhibi-
Measure the resistance between inhibitor MΩ at except “N” and “P” posi- tor switch. <Ref. to
switch connector receptacle's terminals in tions? AT-28, Inhibitor
selector lever except for “N” position. Switch.>
Terminals
No. 7 — No. 12:
INSPECTION, NOTE:
is required, be-
cause probable
cause is deteriora-
tion of multiple
parts.
EN(TURBO)-261
BS:DTC P0864 — AUTOMATIC TRANSMISSION DIAGNOSIS INPUT SIGNAL

CIRCUIT MALFUNCTION —
CAUTION:
• WIRING DIAGRAM:
B56 TCM
21
20
B135 ECM
B55 B135
1 2 3 4 5 6 7 8 9 7 6 5 4 3 2 1
10 11 12 13 14 15 16 17 18 15 14 13 12 11 10 9 8
19 20 21 22 23 24 22 21 20 19 18 17 16
B2M4371
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-46,
tor fan makes one complete rotation. Transmission Con-
2)Drive the vehicle. trol Module
(TCM).>
EN(TURBO)-262
Step Check Yes No

2 CHECK ACCESSORY. Are car phone and/or CB Repair the ground- Replace the TCM.
installed on vehicle? ing line of car <Ref. to AT-46,
phone or CB sys- Transmission Con-
tem. trol Module
(TCM).>
EN(TURBO)-263
BT: DTC P1086 — TUMBLE GENERATOR VALVE #2 (LH) POSITION SENSOR

• Engine stalls.
CAUTION:
• WIRING DIAGRAM:
• LHD model
E50
TUMBLE GENERATOR VALVE
POSITION SENSOR
1 2 3
F61
1 2 3 4
3
1
E50 5 6 7 8
9 10 11 12
13 14 15 16
17 18 19 20
B209
E2
A1 A2 A3 A4 A5
20
10
18
B1 B2 B4 B5
F61 C1 C2 C3 C4 C5
D1 D2 D4 D5
E1 E5
F76
A1
G2
B2
F1 F5
B209 G1G2 G4 G5
H1 H2 H3 H4 H5
I1 I2 I4 I5
J1 J2 J3 J4 J5
1
6
B83
B83
1 2 3
4 5 6
B135
1 2 3 4 5 6 7 8 9
19
13
9
10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 28
B135 ECM
EN1445
EN(TURBO)-264
• RHD model

POSITION SENSOR
E50
1 2 3
1
3
2 E50
B21
1 2 3 4
5 6 7 8
E2 9 10 11 12
13 14 15 16
20
18
10
B21 17 18 19 20
B83
3
1 1 2 3 4 5 6
B83
B135
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19
19
13
20 21 22 23 24 25 26 27 28
9
B135 ECM
EN0986
EN(TURBO)-265
Step Check Yes No

• Poor contact in
ECM connector
• Poor contact in
coupling connector
and chassis ground while tumble generator
valve is fully closed.
is required, be-
cause probable
cause is deteriora-
tion of multiple
parts.
and chassis ground.
EN(TURBO)-266
Step Check Yes No

TUMBLE GENERATOR VALVE POSITION ness and connec-
SENSOR CONNECTOR. tor.
2)Disconnect the connectors from tumble gen- In this case, repair
erator valve position sensor. the following:
4)Measure the voltage between tumble gener- harness between
ator valve position sensor connector and tumble generator
engine ground. valve position sen-
(E50) No. 1 (+) — Engine ground (−): nector
• Poor contact in
tumble generator
valve position sen-
sor connector
• Poor contact in
ECM connector
• Poor contact in
coupling connector
• Poor contact in
joint connector
TUMBLE GENERATOR VALVE POSITION Ω? ness and connec-
ECM connector and tumble generator valve the following:
position sensor connector. • Open circuit in
(B135) No. 13 — (E50) No. 3: tumble generator
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 connector
TUMBLE GENERATOR VALVE POSITION Ω? short circuit in har-
SENSOR CONNECTOR. ness between
Measure the resistance of harness between tumble generator
tumble generator valve position sensor con- valve position sen-
nector and engine ground. sor and ECM con-
9 CHECK POOR CONTACT. Is there poor contact in tumble Repair the poor Replace the tum-
Check poor contact in tumble generator valve generator valve position sen- contact in tumble ble generator
position sensor connector. sor connector? generator valve valve assembly.
position sensor <Ref. to
Tumble Generator
Valve Assembly.>
EN(TURBO)-267
BU:DTC P1087 — TUMBLE GENERATOR VALVE #2 (LH) POSITION SENSOR

• Engine stalls.
CAUTION:
• WIRING DIAGRAM:
E50
POSITION SENSOR
1 2 3
F61
1 2 3 4
3
1
E50 5 6 7 8
9 10 11 12
13 14 15 16
17 18 19 20
B209
E2
A1 A2 A3 A4 A5
20
10
18
B1 B2 B4 B5
F61 C1 C2 C3 C4 C5
D1 D2 D4 D5
E1 E5
F76
A1
G2
B2
F1 F5
B209 G1G2 G4 G5
H1 H2 H3 H4 H5
I1 I2 I4 I5
J1 J2 J3 J4 J5
1
6
B83
B83
1 2 3
4 5 6
B135
1 2 3 4 5 6 7 8 9
19
13
9
10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 28
B135 ECM
EN1445
EN(TURBO)-268

POSITION SENSOR
E50
1 2 3
1
3
2
E50
B21
1 2 3 4
5 6 7 8
E2 9 10 11 12
13 14 15 16
20
18
10
B21 17 18 19 20
B83
3
1 1 2 3 4 5 6
B83
B135
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19
19
13
20 21 22 23 24 25 26 27 28
9
B135 ECM
EN0986
EN(TURBO)-269
Step Check Yes No

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 connector
2 CHECK HARNESS BETWEEN TUMBLE Is the resistance less than 5 Go to step 3. Repair the har-
GENERATOR VALVE POSITION SENSOR Ω? ness and connec-
ground. tumble generator
Connector & terminal valve position sen-
(E50) No. 2 — Engine ground: sor and ECM con-
nector
• Poor contact in
coupling connector
• Poor contact in
joint connector
3 CHECK HARNESS BETWEEN THROTTLE Is the voltage more than 4.9 V? Repair the battery Replace the tum-
POSITION SENSOR AND ECM CONNEC- short circuit in har- ble generator
TOR. ness between valve assembly.
1)Turn the ignition switch to ON. tumble generator <Ref. to
2)Measure the voltage between throttle posi- valve position sen- FU(TURBO)-41,
tion sensor connector and engine ground. sor and ECM con- Tumble Generator
Connector & terminal nector. After Valve Assembly.>
(E50) No. 3 (+) — Engine ground (−): repair, replace the
ECM. <Ref. to
FU(TURBO)-49,
Engine Control
Module.>
EN(TURBO)-270
BV: DTC P1088 — TUMBLE GENERATOR VALVE #1 (RH) POSITION SENSOR

• Engine stalls.
CAUTION:
• WIRING DIAGRAM:
• LHD model

POSITION SENSOR
E54
1 2 3
1
3
2
E54 F61
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
17 18 19 20
E2
20
18
9
B209
F61
A1 A2 A3 A4 A5
B1 B2 B4 B5
F76 C1 C2 C3 C4 C5
D1 D2 D4 D5
A1
B1
G2
B209 E1 E5
F1 F5
G1G2 G4 G5
1 H1 H2 H3 H4 H5
6 I1 I2 I4 I5
J1 J2 J3 J4 J5
B83
B83
1 2 3
4 5 6
19
B135
23
9
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19
B135 ECM 20 21 22 23 24 25 26 27 28
EN1446
EN(TURBO)-271
• RHD model

POSITION SENSOR
E54
1 2 3
1
3
2 E54
B21
1 2 3 4
5 6 7 8
E2 9 10 11 12
13 14 15 16
20
18
9
B21 17 18 19 20
B83
3
1 1 2 3 4 5 6
B83
B135
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19
19
13
20 21 22 23 24 25 26 27 28
9
B135 ECM
EN0988
EN(TURBO)-272
Step Check Yes No

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-
sor connector
• Poor contact in
ECM connector
• Poor contact in
coupling connector
closed.
is required, be-
cause probable
cause is deteriora-
tion of multiple
parts.
and chassis ground.
EN(TURBO)-273
Step Check Yes No

TUMBLE GENERATOR VALVE POSITION ness and connec-
tion sensor connector and engine ground. tumble generator
(E54) No. 1 (+) — Engine ground (−): sor and ECM con-
nector
• Poor contact in
throttle position
sensor connector
• Poor contact in
ECM connector
• Poor contact in
coupling connector
• Poor contact in
joint connector
TUMBLE GENERATOR VALVE POSITION Ω? ness and connec-
(B135) No. 23 — (E54) No. 3: tumble generator
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 connector
TOR. ness between
Measure the resistance of harness between tumble generator
tumble generator valve position sensor con- valve position sen-
nector and engine ground. sor and ECM con-
Check poor contact in tumble generator valve generator valve position sen- contact in tumble ble generator
position sensor connector. sor connector? generator valve valve assembly.
position sensor <Ref. to
Tumble Generator
Valve Assembly.>
EN(TURBO)-274
BW:DTC P1089 — TUMBLE GENERATOR VALVE #1 (RH) POSITION SENSOR

• Engine stalls.
CAUTION:
• WIRING DIAGRAM:
• LHD model

POSITION SENSOR
E54
1 2 3
1
3
2
E54 F61
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
17 18 19 20
E2
20
18
9
B209
F61
A1 A2 A3 A4 A5
B1 B2 B4 B5
F76 C1 C2 C3 C4 C5
D1 D2 D4 D5
A1
B1
G2
B209 E1 E5
F1 F5
G1G2 G4 G5
1 H1 H2 H3 H4 H5
6 I1 I2 I4 I5
J1 J2 J3 J4 J5
B83
B83
1 2 3
4 5 6
19
B135
23
9
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19
B135 ECM 20 21 22 23 24 25 26 27 28
EN1446
EN(TURBO)-275
• RHD model

POSITION SENSOR
E54
1 2 3
1
3
2 E54
B21
1 2 3 4
5 6 7 8
E2 9 10 11 12
13 14 15 16
20
18
9
B21 17 18 19 20
B83
3
1 1 2 3 4 5 6
B83
B135
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19
19
13
20 21 22 23 24 25 26 27 28
9
B135 ECM
EN0988
EN(TURBO)-276
Step Check Yes No

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-
sor connector
• Poor contact in
ECM connector
• Poor contact in
coupling connector
2 CHECK HARNESS BETWEEN TUMBLE Is the resistance less than 5 Go to step 3. Repair the har-
GENERATOR VALVE POSITION SENSOR Ω? ness and connec-
tumble generator valve position sensor con- harness between
nector and engine ground. tumble generator
(E54) No. 2 — Engine ground: sor and ECM con-
nector
• Poor contact in
coupling connector
• Poor contact in
joint connector
3 CHECK HARNESS BETWEEN TUMBLE Is the voltage more than 4.9 V? Repair the battery Replace the tum-
GENERATOR VALVE POSITION SENSOR short circuit in har- ble generator
AND ECM CONNECTOR. ness between valve assembly.
1)Turn the ignition switch to ON. tumble generator <Ref. to
2)Measure the voltage between throttle posi- valve position sen- FU(TURBO)-41,
tion sensor connector and engine ground. sor and ECM con- Tumble Generator
Connector & terminal nector. After Valve Assembly.>
(E54) No. 3 (+) — Engine ground (−): repair, replace the
ECM. <Ref. to
FU(TURBO)-49,
Engine Control
Module.>
EN(TURBO)-277
BX:DTC P1090 — TUMBLE GENERATOR VALVE SYSTEM #1 (RH) MALFUNC-

TION (STUCK OPEN) —
CAUTION:
Step Check Yes No

Trouble Code
(DTC)” <Ref. to
EN(TURBO)-75,
List of Diagnostic
Trouble Code
(DTC).>
2 CHECK TUMBLE GENERATOR VALVE RH Does the tumble generator Replace the tum- Clean the tumble
1)Remove the tumble generator valve assem- valve move smoothly? (No dirt ble generator generator valve.
bly. or foreign materials clogged) valve assembly.
2)Check the tumble generator valve body. <Ref. to
FU(TURBO)-41,
Tumble Generator
Valve Assembly.>
BY:DTC P1091 — TUMBLE GENERATOR VALVE SYSTEM #1 (RH) MALFUNC-

TION (STUCK CLOSE) —
CAUTION:
Step Check Yes No

Trouble Code
(DTC)” <Ref. to
EN(TURBO)-75,
List of Diagnostic
Trouble Code
(DTC).>
FU(TURBO)-41,
Tumble Generator
Valve Assembly.>
EN(TURBO)-278
BZ:DTC P1092 — TUMBLE GENERATOR VALVE SYSTEM #2 (LH) MALFUNC-

TION (STUCK OPEN) —
CAUTION:
Step Check Yes No

Trouble Code
(DTC)” <Ref. to
EN(TURBO)-75,
List of Diagnostic
Trouble Code
(DTC).>
FU(TURBO)-41,
Tumble Generator
Valve Assembly.>
CA:DTC P1093 — TUMBLE GENERATOR VALVE SYSTEM #2 (LH) MALFUNC-

TION (STUCK CLOSE) —
CAUTION:
Step Check Yes No

Trouble Code
(DTC)” <Ref. to
EN(TURBO)-75,
List of Diagnostic
Trouble Code
(DTC).>
FU(TURBO)-41,
Tumble Generator
Valve Assembly.>
EN(TURBO)-279
CB:DTC P1094 — TUMBLE GENERATOR VALVE CIRCUIT #1 (OPEN CIRCUIT)

—
CAUTION:
• WIRING DIAGRAM:
TUMBLE
GENERATOR VALVE
ACTUATOR RH
2
1
E55
E2
5
6
F61 : LHD B21 : RHD
RHD RHD
LHD
LHD
F76
A2
A4
B209
LHD
LHD
RHD RHD
5
4
B84 ECM
E55 F61 : LHD B209 B84
B21 : RHD A1 A2 A3 A4 A5
1 2 1 2 3 4 5 6
B1 B2 B4 B5
7 8 9 10 11 12
1 2 3 4 C1 C2 C3 C4 C5 13 14 15 16 17
D1 D2 D4 D5
5 6 7 8
E1 E5
9 10 11 12
13 14 15 16
F1 F5
17 18 19 20
G1G2 G4 G5
H1 H2 H3 H4 H5
I1 I2 I4 I5
J1 J2 J3 J4 J5
EN1447
EN(TURBO)-280
Step Check Yes No

TUMBLE GENERATOR VALVE ACTUATOR circuit between
CONNECTOR. ECM and tumble
1)Turn the ignition switch to OFF. generator valve
2)Disconnect the connector from tumble gen- connector.
erator valve and ECM connector. NOTE:
3)Measure the resistance between tumble In this case, repair
generator valve actuator and ECM connector. the following:
(E55) No. 1 — (B84) No.4: harness between
(E55) No. 2 — (B84) No.5: ECM and tumble
generator valve
actuator connec-
tor.
• Poor contact in
coupling connec-
tor.
Check poor contact in tumble generator valve generator valve actuator con- contact in tumble ble generator
actuator connector. nector. generator valve valve assembly.
actuator connec- <Ref. to
tor. FU(TURBO)-41,
Tumble Generator
Valve Assembly.>
EN(TURBO)-281
CC:DTC P1095 — TUMBLE GENERATOR VALVE CIRCUIT #1 (OVERCURRENT)

—
CAUTION:
• WIRING DIAGRAM:
TUMBLE
GENERATOR VALVE
ACTUATOR RH
2
1
E55
E2
5
6
F61 : LHD B21 : RHD
RHD RHD
LHD
LHD
F76
A2
A4
B209
LHD
LHD
RHD RHD
5
4
B84 ECM
E55 F61 : LHD B209 B84
B21 : RHD A1 A2 A3 A4 A5
1 2 1 2 3 4 5 6
B1 B2 B4 B5
7 8 9 10 11 12
1 2 3 4 C1 C2 C3 C4 C5 13 14 15 16 17
D1 D2 D4 D5
5 6 7 8
E1 E5
9 10 11 12
13 14 15 16
F1 F5
17 18 19 20
G1G2 G4 G5
H1 H2 H3 H4 H5
I1 I2 I4 I5
J1 J2 J3 J4 J5
EN1447
EN(TURBO)-282
Step Check Yes No

1 CHECK HARNESS BETWEEN ECM AND Is the voltage less than 5 V? Replace the tum- Repair the battery
TUMBLE GENERATOR VALVE ACTUATOR ble generator short circuit
CONNECTOR. valve assembly. between ECM and
1)Turn the ignition switch to OFF. <Ref. to tumble generator
2)Disconnect the connector from tumble gen- FU(TURBO)-41, valve actuator.
erator valve connector. Tumble Generator
3)Measure the voltage between tumble gener- Valve Assembly.>
ator valve actuator and chassis ground.
EN(TURBO)-283
CD:DTC P1096 — TUMBLE GENERATOR VALVE CIRCUIT #2 (OPEN CIRCUIT)

—
CAUTION:
• WIRING DIAGRAM:
TUMBLE
GENERATOR VALVE
ACTUATOR LH
2
E51
E2
7
8
F61 : LHD B21 : RHD
RHD RHD
LHD
LHD
F76
A5
B5
B209
LHD
LHD
RHD RHD
11
10
B84 ECM
E55 F61 : LHD B209 B84
B21 : RHD A1 A2 A3 A4 A5
1 2 1 2 3 4 5 6
B1 B2 B4 B5
7 8 9 10 11 12
1 2 3 4 C1 C2 C3 C4 C5 13 14 15 16 17
D1 D2 D4 D5
5 6 7 8
E1 E5
9 10 11 12
13 14 15 16
F1 F5
17 18 19 20
G1G2 G4 G5
H1 H2 H3 H4 H5
I1 I2 I4 I5
J1 J2 J3 J4 J5
EN1448
EN(TURBO)-284
Step Check Yes No

TUMBLE GENERATOR VALVE ACTUATOR circuit between
CONNECTOR. ECM and tumble
1)Turn the ignition switch to OFF. generator valve
2)Disconnect the connector from tumble gen- connector.
erator valve and ECM connector. NOTE:
3)Measure the resistance between tumble In this case, repair
generator valve actuator and ECM connector. the following:
(E51) No. 1 — (B84) No. 10: harness between
(E51) No. 2 — (B84) No. 11: ECM and tumble
generator valve
actuator connec-
tor.
• Poor contact in
coupling connec-
tor.
Check poor contact in tumble generator valve generator valve actuator con- contact in tumble ble generator
actuator connector. nector. generator valve valve assembly.
actuator connec- <Ref. to
tor. FU(TURBO)-41,
Tumble Generator
Valve Assembly.>
EN(TURBO)-285
CE:DTC P1097 — TUMBLE GENERATOR VALVE CIRCUIT #2 (OVERCURRENT)

—
CAUTION:
• WIRING DIAGRAM:
TUMBLE
GENERATOR VALVE
ACTUATOR LH
2
E51
E2
7
8
F61 : LHD B21 : RHD
RHD RHD
LHD
LHD
F76
A5
B5
B209
LHD
LHD
RHD RHD
11
10
B84 ECM
E55 F61 : LHD B209 B84
B21 : RHD A1 A2 A3 A4 A5
1 2 1 2 3 4 5 6
B1 B2 B4 B5
7 8 9 10 11 12
1 2 3 4 C1 C2 C3 C4 C5 13 14 15 16 17
D1 D2 D4 D5
5 6 7 8
E1 E5
9 10 11 12
13 14 15 16
F1 F5
17 18 19 20
G1G2 G4 G5
H1 H2 H3 H4 H5
I1 I2 I4 I5
J1 J2 J3 J4 J5
EN1448
EN(TURBO)-286
Step Check Yes No

1 CHECK HARNESS BETWEEN ECM AND Is the voltage less than 5 V? Replace the tum- Repair the battery
TUMBLE GENERATOR VALVE ACTUATOR ble generator short circuit
CONNECTOR. valve assembly. between ECM and
1)Turn the ignition switch to OFF. <Ref. to tumble generator
2)Disconnect the connector from tumble gen- FU(TURBO)-41, valve actuator.
erator valve connector. Tumble Generator
3)Measure the voltage between tumble gener- Valve Assembly.>
ator valve actuator and chassis ground.
EN(TURBO)-287
CF:DTC P1110 — ATMOSPHERIC PRESSURE SENSOR CIRCUIT LOW INPUT —

CAUTION:
Step Check Yes No

Engine Control
Module.>
NOTE:
Atmospheric pres-
sure sensor is built
into ECM.
CG:DTC P1111 — ATMOSPHERIC PRESSURE SENSOR CIRCUIT HIGH INPUT

—
CAUTION:
Step Check Yes No

Engine Control
Module.>
NOTE:
Atmospheric pres-
sure sensor is built
into ECM.
EN(TURBO)-288
CH:DTC P1112 — ATMOSPHERIC PRESSURE SENSOR CIRCUIT RANGE/PER-

CAUTION:
Step Check Yes No

1 CHECK ANY OTHER DIAGNOSTIC TROU- Is any other DTC displayed? Inspect the rele- Replace the ECM.
BLE CODE (DTC) ON DISPLAY. vant DTC using <Ref. to
“List of Diagnostic FU(TURBO)-49,
Trouble Code Engine Control
(DTC)”.<Ref. to Module.>
EN(TURBO)-75, NOTE:
List of Diagnostic Atmospheric pres-
Trouble Code sure sensor is built
(DTC).> into ECM.
EN(TURBO)-289
CI: DTC P1130 — FRONT OXYGEN (A/F) SENSOR CIRCUIT MALFUNCTION

(OPEN CIRCUIT) [MT VEHICLES] —
CAUTION:
• WIRING DIAGRAM:
B18
1 2
RHD
RHD
MAIN RELAY BATTERY

3 4
SBF-5
6 LHD 2 LHD
4
B61 F44 B47
5
3 1 2
3 4
2 5 6
2
1
FRONT OXYGEN
B47 (A/F) SENSOR
B18 F44
1 2 3 4
1
5 6 7 8
F60 : LHD
B22 : RHD
1 2 3 4
5 6 7 8
19
29
18
9 10 11 12
4
5
13 14 15 16
B137 ECM
B137
8
9
RHD 1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
LHD
22 23 24 25 26 27 28 29 30 31
B209
A3
F76 B209
LHD
A1 A2 A3 A4 A5
E B1 B2 B4 B5
RHD C1 C2 C3 C4 C5
D1 D2 D4 D5
3
E3 F1 F5
G1G2 G4 G5
H1 H2 H3 H4 H5
E I1 I2 I4 I5
J3 J4 J5
J1 J2
EN1433
EN(TURBO)-290
Step Check Yes No

TOR. tor.
(B137) No. 29 — (B18) No. 3: oxygen (A/F) sen-
(B137) No. 19 — (B18) No. 4: sor connector
• Poor contact in
front oxygen (A/F)
sensor connector
• Poor contact in
ECM connector
sor connector. tor? oxygen (A/F) sensor. <Ref. to
sor connector. FU(TURBO)-44,
Front Oxygen (A/
F) Sensor.>
EN(TURBO)-291
CJ: DTC P1131 — FRONT OXYGEN (A/F) SENSOR CIRCUIT MALFUNCTION

(SHORT CIRCUIT) [MT VEHICLES] —
CAUTION:
• WIRING DIAGRAM:
B18
1 2
RHD
RHD
MAIN RELAY BATTERY

3 4
SBF-5
6 LHD 2 LHD
4
B61 F44 B47
5
3 1 2
3 4
2 5 6
2
1
FRONT OXYGEN
B47 (A/F) SENSOR
B18 F44
1 2 3 4
1
5 6 7 8
F60 : LHD
B22 : RHD
1 2 3 4
5 6 7 8
19
29
18
9 10 11 12
4
5
13 14 15 16
B137 ECM
B137
8
9
RHD 1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
LHD
22 23 24 25 26 27 28 29 30 31
B209
A3
F76 B209
LHD
A1 A2 A3 A4 A5
E B1 B2 B4 B5
RHD C1 C2 C3 C4 C5
D1 D2 D4 D5
3
E3 F1 F5
G1G2 G4 G5
H1 H2 H3 H4 H5
E I1 I2 I4 I5
J3 J4 J5
J1 J2
EN1433
EN(TURBO)-292
Step Check Yes No

FRONT OXYGEN (A/F) SENSOR CONNEC- Ω? short circuit in har-
TOR. ness between
2)Disconnect the connector from ECM. oxygen (A/F) sen-
TOR. ness between
Measure the resistance of harness between ECM and front
ECM connector and chassis ground. oxygen (A/F) sen-
3 CHECK OUTPUT SIGNAL FOR ECM. Is the voltage more than 4.5 V? Go to step 4. Go to step 5.
4 CHECK OUTPUT SIGNAL FOR ECM. Is the voltage more than 10 V? Repair the battery Repair the poor
Measure the voltage between ECM connector short circuit in har- contact in ECM
and chassis ground. ness between connector.
(B137) No. 19 (+) — Chassis ground (−): oxygen (A/F) sen-
sor connector.
After repair,
replace the ECM.
<Ref. to
FU(TURBO)-49,
Engine Control
Module.>
5 CHECK OUTPUT SIGNAL FOR ECM. Is the voltage more than 4.95 Go to step 6. Replace the front
Measure the voltage between ECM connector V? oxygen (A/F) sen-
and chassis ground. sor. <Ref. to
(B137) No. 29 (+) — Chassis ground (−): Front Oxygen (A/
F) Sensor.>
sor connector.
After repair,
replace the ECM.
<Ref. to
FU(TURBO)-49,
Engine Control
Module.>
EN(TURBO)-293
CK:DTC P1134 — FRONT OXYGEN (A/F) SENSOR MICRO-COMPUTER PROB-

LEM —
CAUTION:
• WIRING DIAGRAM:
B18
1 2
RHD
RHD
MAIN RELAY BATTERY

3 4
SBF-5
6 LHD 2 LHD
4
B61 F44 B47
5
3 1 2
3 4
2 5 6
2
1
FRONT OXYGEN
B47 (A/F) SENSOR
B18 F44
1 2 3 4
1
5 6 7 8
F60 : LHD
B22 : RHD
1 2 3 4
5 6 7 8
19
29
18
9 10 11 12
4
5
13 14 15 16
B137 ECM
B137
8
9
RHD 1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
LHD
22 23 24 25 26 27 28 29 30 31
B209
A3
F76 B209
LHD
A1 A2 A3 A4 A5
E B1 B2 B4 B5
RHD C1 C2 C3 C4 C5
D1 D2 D4 D5
3
E3 F1 F5
G1G2 G4 G5
H1 H2 H3 H4 H5
E I1 I2 I4 I5
J3 J4 J5
J1 J2
EN1433
Step Check Yes No

Engine Control
Module.>
EN(TURBO)-294
EN(TURBO)-295
CL: DTC P1139 — FRONT OXYGEN (A/F) SENSOR #1 HEATER CIRCUIT

RANGE/PERFORMANCE PROBLEM —
CAUTION:
• WIRING DIAGRAM:
B18
1 2
RHD
RHD
MAIN RELAY BATTERY

3 4
SBF-5
6 LHD 2 LHD
4
B61 F44 B47
5
3 1 2
3 4
2 5 6
2
1
FRONT OXYGEN
B47 (A/F) SENSOR
B18 F44
1 2 3 4
1
5 6 7 8
F60 : LHD
B22 : RHD
1 2 3 4
5 6 7 8
19
29
18
9 10 11 12
4
5
13 14 15 16
B137 ECM
B137
8
9
RHD 1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
LHD
22 23 24 25 26 27 28 29 30 31
B209
A3
F76 B209
LHD
A1 A2 A3 A4 A5
E B1 B2 B4 B5
RHD C1 C2 C3 C4 C5
D1 D2 D4 D5
3
E3 F1 F5
G1G2 G4 G5
H1 H2 H3 H4 H5
E I1 I2 I4 I5
J3 J4 J5
J1 J2
EN1433
EN(TURBO)-296
Step Check Yes No

FRONT OXYGEN (A/F) SENSOR CONNEC- Ω? circuit in harness
1)Start the engine and warm-up engine. front oxygen (A/F)
2)Turn the ignition switch to OFF. sensor connector.
3)Disconnect the connectors from ECM and
ECM and front oxygen (A/F) sensor connector.
(B137) No. 5 — (B18) No. 1:
(B137) No. 4 — (B18) No. 1:
Measure the resistance of harness between front oxygen (A/F)
ECM and front oxygen (A/F) sensor connector. sensor connector.
(B137) No. 19 — (B18) No. 4:
(B137) No. 29 — (B18) No. 3:
Measure the resistance of harness between front oxygen (A/F)
main relay and front oxygen (A/F) sensor con- sensor connector.
nector.
(B47) No. 4 — (B18) No. 2:
4 CHECK FRONT OXYGEN (A/F) SENSOR. Is the resistance less than 5 Go to step 5. Replace the front
Measure the resistance between front oxygen Ω? oxygen (A/F) sen-
(A/F) sensor connector terminals. sor. <Ref. to
Terminals FU(TURBO)-44,
No. 2 — No. 1: Front Oxygen (A/
F) Sensor.>
5 CHECK POOR CONTACT. Is there poor contact in ECM or Repair the poor Replace the front
Check the poor contact in ECM and front oxy- front oxygen (A/F) sensor con- contact in ECM or oxygen (A/F) sen-
gen (A/F) sensor connector. nector? front oxygen (A/F) sor. <Ref. to
sensor connector. FU(TURBO)-44,
Front Oxygen (A/
F) Sensor.>
EN(TURBO)-297
CM:DTC P1141 — MASS AIR FLOW SENSOR CIRCUIT RANGE/PERFORMANCE

• Engine stalls.
CAUTION:
• WIRING DIAGRAM:
MAIN RELAY
RHD
RHD
6 BATTERY
4
SBF-5
5 LHD 8 LHD
3
B61 F44
2
1
1
B47
MASS AIR FLOW AND

B3
5
* 12
*
B83
E13
B19
B27
E8
E7
LHD : 3
*1 RHD : 2
LHD : 6 B: B135 E
*2 RHD : 1 ECM
E: B84
B3 B47 E: B84 B : B135 B83
1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 1 2 3
1 2
1 2 3 4 5 7 8 9 10 11 12 10 11 12 13 14 15 16 17 18 19 4 5 6
3 4
5 6 13 14 15 16 17 20 21 22 23 24 25 26 27 28 (LHD)
F44 1 2 3 4 5 6
(RHD)
1 2 3 4
5 6 7 8
EN0970
EN(TURBO)-298
Step Check Yes No

1 CHECK ANY OTHER DIAGNOSTIC TROU- Is any other DTC displayed? Inspect the rele- Replace the mass
BLE CODE (DTC) ON DISPLAY. vant DTC using air flow and intake
“Diagnostics Chart air temperature
with Trouble sensor.
Code” <Ref. to
EN(TURBO)-75,
List of Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P1141.
EN(TURBO)-299
CN:DTC P1142 — THROTTLE POSITION SENSOR CIRCUIT RANGE/PERFOR-

• Engine stalls.
CAUTION:
• WIRING DIAGRAM:
• LHD model
THROTTLE
POSITION
E13 F61
SENSOR
1 2 3 1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
17 18 19 20
1
3
2
E13
B83
1 2 3
E2
4 5 6
20
19
18
F61
F76
A1
G2
i2
B135
B209
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19
1 20 21 22 23 24 25 26 27 28
6
B83
B209
A1 A2 A3 A4 A5
B1 B2 B4 B5
C1 C2 C3 C4 C5
D1 D2 D4 D5
E1 E5
19
7
9
F1 F5
G1G2 G4 G5
H1 H2 H3 H4 H5
I1 I2 I4 I5
B135 ECM J1 J2 J3 J4 J5
EN1437
EN(TURBO)-300
• RHD model
THROTTLE
POSITION
SENSOR
E13
1 2 3
1
3
2
E13
B21
1 2 3 4
5 6 7 8
E2 9 10 11 12
13 14 15 16
20
19
18
B21 17 18 19 20
B83
3
1 1 2 3 4 5 6
B83
B135
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19
19
23 24 25 26 27 28
7
20 21 22
9
B135 ECM
EN0972
Step Check Yes No

(DTC)”. <Ref. to Throttle Position
EN(TURBO)-75, Sensor.>
List of Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P1142.
EN(TURBO)-301
CO:DTC P1146 — PRESSURE SENSOR CIRCUIT RANGE/PERFORMANCE

CAUTION:
• WIRING DIAGRAM:
• LHD model
THROTTLE BODY
PRESSURE SENSOR
1
2
3
E21
E2
18
20
16
F61
F76
A1
G2
F5
B209
1
6
B83
19
9
8
B135 ECM
E21 B83 F61 B135 B209
1 2 3 A1 A2 A3 A4 A5
1 2 3 1 2 3 4 1 2 3 4 5 6 7 8 9
4 5 6 B1 B2 B4 B5
5 6 7 8 10 11 12 13 14 15 16 17 18 19
C1 C2 C3 C4 C5
9 10 11 12 20 21 22 23 24 25 26 27 28 D4 D5
D1 D2
13 14 15 16 E1 E5
17 18 19 20
F1 F5
G1G2 G4 G5
H1 H2 H3 H4 H5
I1 I2 I4 I5
J1 J2 J3 J4 J5
EN1435
EN(TURBO)-302
• RHD model
THROTTLE BODY
PRESSURE SENSOR
2
3
1
E21
E2
18
20
16
B21
3
1
B83
19
9
8
B135 ECM
E21 B83 B21 B135
1 2 3 1 2 3 4 5 6 1 2 3 4 1 2 3 4 5 6 7 8 9
5 6 7 8 10 11 12 13 14 15 16 17 18 19
9 10 11 12 20 21 22 23 24 25 26 27 28
13 14 15 16
17 18 19 20
EN0968
Step Check Yes No

NOTE: “List of Diagnostic
In this case, it is not necessary to inspect DTC Trouble Code
P1146. (DTC)”. <Ref. to
EN(TURBO)-75,
List of Diagnostic
Trouble Code
(DTC).>
intake system?
EN(TURBO)-303
Step Check Yes No

2)Place the shift lever in the selector lever in to FU(TURBO)-35,
“N” or “P” position. Pressure Sensor.>
4)Turn all accessory switches to OFF.
NOTE:
tor.>
Specification:
Ignition ON
73.3 — 106.6 kPa (550 — 800 mmHg,
21.65 — 31.50 inHg)
Idling
20.0 — 46.7 kPa (150 — 350 mmHg, 5.91
— 13.78 inHg)
Read the data of throttle position signal using equal to or less than 5% when the throttle posi-
tool. to FU(TURBO)-33,
NOTE: Throttle Position
•Subaru Select Monitor Sensor.>
tor.>
equal to or more than 85% air temperature tle position sensor.
when throttle is fully open? and pressure sen- <Ref. to
sor. <Ref. to FU(TURBO)-33,
FU(TURBO)-35, Throttle Position
Pressure Sensor.> Sensor.>
EN(TURBO)-304
EN(TURBO)-305
CP: DTC P1152 — FRONT OXYGEN (A/F) SENSOR CIRCUIT RANGE/PERFOR-

MANCE PROBLEM (LOW INPUT) [AT VEHICLES] —
CAUTION:
• WIRING DIAGRAM:
B18
BATTERY 1 2
MAIN RELAY
3 4
SBF-5
6
4
B47
5
3 1 2
3 4
2 5 6
2
1
FRONT OXYGEN
B47 (A/F) SENSOR
B18 B22
1 2 3 4
1
5 6 7 8
9 10 11 12
13 14 15 16
B137
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31
19
29
18
4
5
B137 ECM
B209
A1 A2 A3 A4 A5
B1 B2 B4 B5
8
9
C1 C2 C3 C4 C5
D1 D2 D4 D5
E1 E5
F1 F5
G1G2 G4 G5
H1 H2 H3 H4 H5
I1 I2 I4 I5
J1 J2 J3 J4 J5
E
B22
3
E3
EN1449
EN(TURBO)-306
Step Check Yes No

TOR. tor.
(B137) No. 29 — (B18) No. 3: oxygen (A/F) sen-
(B137) No. 19 — (B18) No. 4: sor connector
• Poor contact in
front oxygen (A/F)
sensor connector
• Poor contact in
ECM connector
sor connector. tor? oxygen (A/F) sensor. <Ref. to
sor connector. FU(TURBO)-44,
Front Oxygen (A/
F) Sensor.>
EN(TURBO)-307
CQ: DTC P1153 — FRONT OXYGEN (A/F) SENSOR CIRCUIT RANGE/PERFOR-

MANCE PROBLEM (HIGH INPUT) [AT VEHICLES] —
CAUTION:
• WIRING DIAGRAM:
B18
BATTERY 1 2
MAIN RELAY
3 4
SBF-5
6
4
B47
5
3 1 2
3 4
2 5 6
2
1
FRONT OXYGEN
B47 (A/F) SENSOR
B18 B22
1 2 3 4
1
5 6 7 8
9 10 11 12
13 14 15 16
B137
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31
19
29
18
4
5
B137 ECM
B209
A1 A2 A3 A4 A5
B1 B2 B4 B5
8
9
C1 C2 C3 C4 C5
D1 D2 D4 D5
E1 E5
F1 F5
G1G2 G4 G5
H1 H2 H3 H4 H5
I1 I2 I4 I5
J1 J2 J3 J4 J5
E
B22
3
E3
EN1449
EN(TURBO)-308
Step Check Yes No

TOR. ness between
2)Disconnect the connector from ECM. oxygen (A/F) sen-
TOR. ness between
Measure the resistance of harness between ECM and front
ECM connector and chassis ground. oxygen (A/F) sen-
3 CHECK OUTPUT SIGNAL FOR ECM. Is the voltage more than 4.5 V? Go to step 4. Go to step 5.
sor connector.
After repair,
replace the ECM.
<Ref. to
FU(TURBO)-49,
Engine Control
Module.>
5 CHECK OUTPUT SIGNAL FOR ECM. Is the voltage more than 4.95 Go to step 6. Replace the front
Measure the voltage between ECM connector V? oxygen (A/F) sen-
and chassis ground. sor. <Ref. to
(B137) No. 29 (+) — Chassis ground (−): Front Oxygen (A/
F) Sensor.>
sor connector.
After repair,
replace the ECM.
<Ref. to
FU(TURBO)-49,
Engine Control
Module.>
EN(TURBO)-309
CR:DTC P1230 — FUEL PUMP CONTROLLER MALFUNCTION —

CAUTION:
• WIRING DIAGRAM:
RHD
RHD
BATTERY
SBF-5
4 2 LHD 8 LHD
B97 B61 F44

FUEL PUMP
*3
RELAY
B46
R1
10
FUEL PUMP
CONTROLLER
R122
5
9
8
7
6
LHD : 20
R15 R3 *1 RHD : 15
*21
*
1
3
R57 B99 LHD : 19

*2 RHD : 14
A13
C16
2
1
*3 LHD : 7
RHD : 5
FUEL ECM
PUMP
A: B134
E E
R58 M
C: B136
F44 B97 B46 R122 B99 R58
1 2 3 4 1 2 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 1 2 3
5 6 7 8 3 4 5 6 7 8 9 10 12 13 14 15 16 17 18 19 20 21 22 23 24 4 5 6
A : B134 C : B136
1 2 3 4 5 6 7 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 8 9 10 11 12 13 14 15 16
16 17 18 19 20 21 22 17 18 19 20 21 22 23 24
EN0991
EN(TURBO)-310
Step Check Yes No

1 CHECK POWER SUPPLY CIRCUIT TO FUEL Is the voltage more than 10V? Go to step 2. Repair the power
PUMP CONTROLLER. supply circuit.
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
2 CHECK GROUND CIRCUIT OF FUEL PUMP Is the resistance less than 5 Go to step 3. Repair the har-
CONTROLLER. Ω? ness and connec-
fuel pump controller and chassis ground. In this case, repair
(R122) No. 5 — Chassis ground: • Open circuit
between fuel
pump controller
and chassis
ground
• Poor contact in
fuel pump control-
ler connector
3 CHECK HARNESS BETWEEN FUEL PUMP Is the resistance less than 1 Go to step 4. Repair the open
CONTROLLER AND FUEL PUMP CONNEC- Ω? circuit between
TOR. fuel pump control-
1)Disconnect the connector from fuel pump. ler and fuel pump.
fuel pump controller and fuel pump connector.
(R122) No. 7 — (R58) No. 2:
(R122) No. 6 — (R58) No. 1:
4 CHECK HARNESS BETWEEN FUEL PUMP Is the resistance more than 1M Go to step 5. Repair the ground
CONTROLLER AND FUEL PUMP CONNEC- Ω? short circuit
TOR. between fuel
Measure the resistance of harness between pump controller
fuel pump controller and chassis ground. and fuel pump.
EN(TURBO)-311
Step Check Yes No

CONTROLLER AND ECM CONNECTOR. Ω? ness and connec-
fuel pump controller and ECM connector. the following:
Connector & terminal • Open circuit
(R122) No. 9 — (B134) No. 13: between fuel
(R122) No. 8 — (B136) No. 16: pump controller
and ECM
• Poor contact in
fuel pump control-
ler and ECM con-
nector
6 CHECK HARNESS BETWEEN FUEL PUMP Is the resistance more than 1M Go to step 7. Repair the ground
CONTROLLER AND ECM CONNECTOR. Ω? short circuit
Measure the resistance of harness between between fuel
fuel pump controller and chassis ground. pump controller
Connector & terminal and ECM.
7 CHECK POOR CONTACT. Is there poor contact in ECM Repair the poor Replace the fuel
Check poor contact in ECM and fuel pump and fuel pump controller con- contact in ECM pump controller.
controller connector. nector. and fuel pump <Ref. to
controller. FU(TURBO)-52,
Fuel Pump Con-
troller.>
EN(TURBO)-312
EN(TURBO)-313
CS:DTC P1244 — WASTEGATE CONTROL SOLENOID VALVE RANGE/PER-

FORMANCE PROBLEM (LOW INPUT) [MT VEHICLES] —
CAUTION:
• WIRING DIAGRAM:
MAIN RELAY
RHD
RHD
6 BATTERY
4
SBF-5 F44
5 LHD 8 LHD
3 1 2 3 4
B61 F44 5 6 7 8
2
1
B47
B47
1 2
3 4
5 6
B137 ECM
B137
1 2 3 4 5 6 7 8 9
24
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31
B127
1 2
B127
2
1
WASTEGATE
E
CONTROL SOLENOID
VALVE
EN0974
EN(TURBO)-314
Step Check Yes No

(DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P1244.
EN(TURBO)-315
CT:DTC P1245 — WASTEGATE CONTROL SOLENOID VALVE MALFUNCTION

(FAIL-SAFE) [MT VEHICLES] —
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(TURBO)-45, Op-
eration.> and Inspection Mode <Ref. to EN(TURBO)-42, Inspection Mode.> .
• WIRING DIAGRAM:
MAIN RELAY
RHD
RHD
6 BATTERY
4
SBF-5 F44
5 LHD 8 LHD
3 1 2 3 4
B61 F44 5 6 7 8
2
1
B47
B47
1 2
3 4
5 6
B137 ECM
B137
1 2 3 4 5 6 7 8 9
24
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31
B127
1 2
B127
2
1
WASTEGATE
E
CONTROL SOLENOID
VALVE
EN0974
EN(TURBO)-316
Step Check Yes No

(DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P1245.
EN(TURBO)-317
CU:DTC P1301 — FIRE DUE TO INCREASED EXHAUST TEMPERATURE —

• Engine stalls.
CAUTION:
• WIRING DIAGRAM:
B83
EXHAUST GAS 1 2 3
TEMPERATURE 4 5 6
SENSOR (LHD)
1 2 3 4 5 6
(RHD)
1
2
B279
B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
B279
1 2
5 LHD : 6
* * RHD : 1
B83
19
16
B136 ECM
EN0984
EN(TURBO)-318
Step Check Yes No

1 CHECK ANY OTHER DIAGNOSTIC TROU- Does failure for repair or Repair or replace Contact with your
BLE CODE (DTC). replacement exist? the failure, then Subaru distributor
Conduct the troubleshooting for all DTC replace precata- service.
P0301, P0302, P0303 and P0304. <Ref. to lytic converter. NOTE:
EN(TURBO)-75, List of Diagnostic Trouble Inspection by DTM
Code (DTC).> is required, be-
cause probable
cause is deteriora-
tion of multiple
parts.
EN(TURBO)-319
CV:DTC P1312 — EXHAUST GAS TEMPERATURE CIRCUIT MALFUNCTION —

CAUTION:
• WIRING DIAGRAM:
B83
EXHAUST GAS 1 2 3
TEMPERATURE 4 5 6
SENSOR (LHD)
1 2 3 4 5 6
(RHD)
1
2
B279
B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
B279
1 2
5 LHD : 6
* * RHD : 1
B83
19
16
B136 ECM
EN0984
EN(TURBO)-320
Step Check Yes No

BLE CODE (DTC) ON DISPLAY. vant DTC using exhaust gas tem-
“List of Diagnostic perature sensor.
EN(TURBO)-75, Exhaust Tempera-
List of Diagnostic ture Sensor.>
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P1312.
EN(TURBO)-321
EN(TURBO)-322
CW:DTC P1480 — COOLING FAN RELAY 1 CIRCUIT HIGH INPUT —

• Overheating
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(TURBO)-45, Op-
eration.> and Inspection Mode <Ref. to EN(TURBO)-42, Inspection Mode.> .
EN(TURBO)-323
• WIRING DIAGRAM:
BATTERY
SBF-1
IGNITION
B72 SWITCH
SBF-4 No.18
LHD : 2
*1 RHD : 7
No.17
LHD : 12
*2 RHD : 17
17
B137 ECM
28 * 12
*
B62 F45
17
19
20
18
24
22
21
23
25
27
28
26
8
6
5
7
2
1
4
3
30A
30A
1
3
2
1
3
2
F16 F17

M M
E E F29 F28 F30 F66 F27
SUB FAN MAIN FAN
B72 (BLUE) F27 F28 F29 F30 F66 B137 F45 F16
1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 10 11 F17
1 2 1 2 5 6 9 13 14 17 21 22 25 29
3 4 7 10 15 18 23 26 10 11 12 13 14 15 16 17 18 19 20 21 12 13 14 15 16 17 18 19 20 21 22 23 24
3 4 8 11 12 16 19 20 24 27 28 30 22 23 24 25 26 27 28 29 30 31 (LHD) 3 2 1
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18
(RHD)
EN0981
EN(TURBO)-324
Step Check Yes No

1 CHECK OUTPUT SIGNAL FROM ECM. Does the voltage change Even if MIL lights Go to step 2.
4)While operating the radiator fan relay, mea- poor contact in
sure the voltage between ECM and chassis ECM connector.
ground.
NOTE:
Check Mode”.<Ref. to EN(TURBO)-46, Com-
pulsory Valve Operation Check Mode.>
2 CHECK SHORT CIRCUIT IN RADIATOR FAN Is the voltage more than 10 V? Repair the battery Go to step 3.
RELAY CONTROL CIRCUIT. short circuit in radi-
1)Turn the ignition switch to OFF. ator fan relay con-
2)Remove the main fan relay and sub fan trol circuit. After
relay. (with A/C models) repair, replace the
3)Disconnect the test mode connector. ECM. <Ref. to
4)Turn the ignition switch to ON. FU(TURBO)-49,
5)Measure the voltage between ECM and Engine Control
chassis ground. Module.>
3 CHECK MAIN FAN RELAY. Is the resistance less than 1 Replace the main Go to step 4.
1)Turn the ignition switch to OFF. Ω? fan relay and
2)Remove the main fan relay 1 and 2. ECM. <Ref. to
3)Measure the resistance between main fan FU(TURBO)-49,
relay terminals. Engine Control
Terminal Module.>
No. 25 — No. 26 (Main fan relay 1)
No. 23 — No. 24 (Main fan relay 2)
4 CHECK SUB FAN RELAY. Is the resistance less than 1 Replace the sub Go to step 5.
1)Remove the sub fan relay. Ω? fan relay and
2)Measure the resistance between sub fan ECM. <Ref. to
relay terminals. FU(TURBO)-49,
Terminal Engine Control
No. 7 — No. 8 (Sub fan relay 1) Module.>
No. 17 — No. 18 (Sub fan relay 2)
Engine Control
Module.>
EN(TURBO)-325
CX:DTC P1507 — IDLE CONTROL SYSTEM MALFUNCTION (FAIL-SAFE) —

• Fuel is cut according to fail-safe function.
CAUTION:
• WIRING DIAGRAM:
MAIN RELAY
6 BATTERY
RHD
RHD
4 B209 F44
SBF-5
1 2 3 4
3 B1 B2 B4 B5
5 6 7 8
B61 F44 C1 C2 C3 C4 C5
2 RHD
D1 D2 D4 D5
1 E1 E5
LHD
B47
B47 F1 F5
B61 G1G2 G4 G5 1 2
H1 H2 H3 H4 H5 3 4
1
F44 I1 I2 I4 I5 5 6
J1 J2 J3 J4 J5
LHD
RHD
F60 : LHD

1
E3 1 2 3 4
5 6 7 8
9 10 11 12
2
13 14 15 16
IDLE
AIR CONTROL
SOLENOID
VALVE
E7
E7
1 2 3
1
3
LHD F61 : LHD

E2
RHD
B21 : RHD
12
F61
E2 1 2 3 4
12
5 6 7 8
F76 B21 9 10 11 12
G5
RHD
13 14 15 16
B209 17 18 19 20
LHD
10
B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16
B136 ECM 17 18 19 20 21 22 23 24
E E
EN1444
EN(TURBO)-326
Step Check Yes No

Trouble Code
(DTC)”. <Ref. to
EN(TURBO)-75,
List of Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P1507.
2 CHECK AIR INTAKE SYSTEM. Is there a fault in air intake sys- Repair the air suc- Go to step 3.
1)Turn the ignition switch to ON. tem? tion and leaks.
gasket
9, INSTALLA-
TION, Accelerator
Control Cable.>
2)Remove the idle air control solenoid valve by-pass air line. valve. <Ref. to
from throttle body. <Ref. to FU(TURBO)-36, FU(TURBO)-36,
3)Confirm that there are no foreign particles in Solenoid Valve.>
by-pass air line.
EN(TURBO)-327
CY:DTC P1518 — STARTER SWITCH CIRCUIT LOW INPUT —

CAUTION:
• WIRING DIAGRAM:
BATTERY
SBF-4 SBF-1
1
IGNITION
SWITCH
B72
3
P R N D 3 2 1
AT 12 12
11 7
MT
B12 T3 T7
MT
AT
B134 ECM 16
B14
STARTER
MOTOR
E E
B72 B134 B12 T7
1 2 1 2 3 4 5 6 7 1 2 3 4 1 2 3 4 5 6
3 4 8 9 10 11 12 13 14 15 5 6 7 8 7 8 9 10 11 12
16 17 18 19 20 21 22 9 10 11 12
EN1428
EN(TURBO)-328
Step Check Yes No

1 CHECK OPERATION OF STARTER MOTOR. Does the starter motor oper- Repair the har- Check the starter
ate when ignition switch is ness and connec- motor circuit. <Ref.
turned to START? tor. to EN(TURBO)-60,
NOTE: STARTER
In this case, repair MOTOR CIR-
the following: CUIT, Diagnostics
• Open or ground for Engine Start-
short circuit in har- ing Failure.>
ness between
ECM and starter
motor connector
• Poor contact in
ECM connector
EN(TURBO)-329
CZ:DTC P1544 — HIGH EXHAUST TEMPERATURE DETECTED —

CAUTION:
• WIRING DIAGRAM:
B83
EXHAUST GAS 1 2 3
TEMPERATURE 4 5 6
SENSOR (LHD)
1 2 3 4 5 6
(RHD)
1
2
B279
B136
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
B279
1 2
5 LHD : 6
* * RHD : 1
B83
19
16
B136 ECM
EN0984
EN(TURBO)-330
Step Check Yes No

Trouble Code
(DTC)”. <Ref. to
EN(TURBO)-75,
List of Diagnostic
Trouble Code
(DTC).>
NOTE:
In this case, it is
not necessary to
inspect DTC
P1544.
2 CHECK EXHAUST SYSTEM. Is there a fault in exhaust sys- Repair or replace Contact with your
Check the exhaust system parts. tem? the failure, then Subaru distributor
NOTE: replace precata- service.
Check the following items. lytic converter. NOTE:
•Loose installation of exhaust manifold Inspection by DTM
•Cracks or hole of exhaust manifold is required, be-
•Loose installation of front oxygen (A/F) sensor cause probable
cause is deteriora-
tion of multiple
parts.
EN(TURBO)-331
DA:DTC P1560 — BACK-UP VOLTAGE CIRCUIT MALFUNCTION —

CAUTION:
• WIRING DIAGRAM:
• LHD model
MAIN RELAY

6 2
SBF-5
5 8
3
B61 F44
1 SWITCH
No.11 SBF-4 SBF-1
B47 4 1
D10
A14
D2
D3
A2
A : B134
C : B136
ECM
D : B137
E: B84
C17
C18
A22
A15
D8
D9
C8
E1
A7
B209
C3
D2
A3
F1
J3
F76
F60
13
14
16
15
3
E3
E E E
B72 B47 F60 A : B134 C : B136
1 2 1 2 1 2 3 4 1 2 3 4 5 6 7 1 2 3 4 5 6 7
3 4 3 4 5 6 7 8 8 9 10 11 12 13 14 15 8 9 10 11 12 13 14 15 16
5 6 9 10 11 12 16 17 18 19 20 21 22 17 18 19 20 21 22 23 24
13 14 15 16
B209 D : B137 E: B84
A1 A2 A3 A4 A5 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6
B1 B2 B4 B5 10 11 12 13 14 15 16 17 18 19 20 21 7 8 9 10 11 12
C1 C2 C3 C4 C5 22 23 24 25 26 27 28 29 30 31 13 14 15 16 17
D1 D2 D4 D5
E1 E5
F1 F5
G1G2 G4 G5
H1 H2 H3 H4 H5
I1 I2 I4 I5
J1 J2 J3 J4 J5
EN1429
EN1429
EN(TURBO)-332
• RHD model
MAIN RELAY

6
SBF-5
5
3
2 B72 IGNITION
1 SWITCH BATTERY
No.11 SBF-4 SBF-1
B47 4 1
D10
A14
D2
D3
A2
A: B134
C : B136
ECM
D : B137
E: B84
C17
C18
A22
A15
D8
D9
C8
E1
A7
B22
13
14
16
15
3
E3
E E E
B72 B47 B22 A : B134 C : B136 D : B137
1 2 1 2 1 2 3 4 1 2 3 4 5 6 7 1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9
3 4 3 4 5 6 7 8 8 9 10 11 12 13 14 15 8 9 10 11 12 13 14 15 16 10 11 12 13 14 15 16 17 18 19 20 21
5 6 9 10 11 12 16 17 18 19 20 21 22 17 18 19 20 21 22 23 24 22 23 24 25 26 27 28 29 30 31
13 14 15 16
E: B84
1 2 3 4 5 6
7 8 9 10 11 12
13 14 15 16 17
EN0960
Step Check Yes No

1 CHECK INPUT SIGNAL FOR ECM. Is the voltage more than 10 V? Repair the poor Go to step 2.
1)Turn the ignition switch to OFF. contact in ECM
chassis ground.
MAIN FUSE BOX CONNECTOR. Ω? 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.
EN(TURBO)-333
Step Check Yes No

3 CHECK FUSE SBF-5. Is the fuse blown? Replace the fuse. Repair the har-
ness and connec-
tor.
NOTE:
the following:
• Open circuit in
harness between
ECM and battery
• Poor contact in
ECM connector
• Poor contact in
battery terminal
EN(TURBO)-334
EN(TURBO)-335
DB:DTC P1595 — AUTOMATIC TRANSMISSION DIAGNOSIS INPUT SIGNAL

CAUTION:
• WIRING DIAGRAM:
B56 TCM
21
20
B135 ECM
B55 B135
1 2 3 4 5 6 7 8 9 7 6 5 4 3 2 1
10 11 12 13 14 15 16 17 18 15 14 13 12 11 10 9 8
19 20 21 22 23 24 22 21 20 19 18 17 16
B2M4371
EN(TURBO)-336
Step Check Yes No

1 CHECK HARNESS BETWEEN ECM AND Is the voltage less than 1 V? Go 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.
(B135) No. 20 (+) — Chassis ground (−): In this case, repair
the following:
• Poor contact in
ECM connector
• Poor contact in
TCM connector
2)Disconnect the connector from ECM and ECM and TCM
TCM. connector.
3 CHECK OUTPUT SIGNAL FOR ECM. Is the voltage more than 5 V? Go to step 4. Repair the poor
1)Connect the connector to ECM. contact in ECM
chassis ground.
4 CHECK TROUBLE CODE FOR AUTOMATIC Does the DTC appear for auto- Inspect the DTC Replace the TCM.
TRANSMISSION. matic transmission? for automatic <Ref. to AT-46,
Read the DTC for automatic transmission. transmission. Transmission Con-
<Ref. to AT-22, Read Diagnostic Trouble Code <Ref. to AT-42, trol Module
(DTC).> Diagnostic Proce- (TCM).>
dure with Diagnos-
tic Trouble Code
(DTC).>
EN(TURBO)-337
DC:DTC P1596 — AUTOMATIC TRANSMISSION DIAGNOSIS INPUT SIGNAL

CAUTION:
• WIRING DIAGRAM:
B56 TCM
21
20
B135 ECM
B55 B135
1 2 3 4 5 6 7 8 9 7 6 5 4 3 2 1
10 11 12 13 14 15 16 17 18 15 14 13 12 11 10 9 8
19 20 21 22 23 24 22 21 20 19 18 17 16
B2M4371
EN(TURBO)-338
Step Check Yes No

1 CHECK HARNESS BETWEEN ECM AND Is the voltage more than 10 V? Repair the battery Go to step 2.
TCM CONNECTOR. short circuit in har-
1)Turn the ignition switch to ON. ness between
2)Measure the voltage between ECM and ECM and TCM
chassis ground. connector. After
(B135) No. 20 (+) — Chassis ground (−): ECM. <Ref. to
FU(TURBO)-49,
Engine Control
Module.>
2 CHECK HARNESS BETWEEN ECM AND Is the voltage more than 4 V? Go to step 5. Go to step 3.
TCM CONNECTOR.
and chassis ground.
3 CHECK HARNESS BETWEEN ECM AND Is the voltage less than 1 V? Repair the poor Go to step 4.
TCM CONNECTOR. contact in ECM
Measure the voltage between ECM connector connector.
and chassis ground.
4 CHECK OUTPUT SIGNAL FROM ECM. Does the voltage change from Even if MIL lights Contact with your
Measure the voltage between ECM and chas- 1 V to 4 V while monitoring the up, the circuit has Subaru distributor
sis ground. value with voltage meter? returned to a nor- service.
Connector & terminal mal condition at NOTE:
(B135) No. 20 (+) — Chassis ground (−): this time. Inspection by DTM
NOTE: is required, be-
In this case, repair cause probable
the following: cause is deteriora-
• Poor contact in tion of multiple
ECM connector parts.
• Poor contact in
TCM connector
5 CHECK HARNESS BETWEEN ECM AND Is the voltage more than 4 V? Go to step 6. Repair the open
TCM CONNECTOR. circuit in harness
Measure the voltage between TCM and chas- between ECM and
sis ground. TCM connector.
6 CHECK POOR CONTACT. Is there poor contact in TCM Repair the poor Check the TCM
Check poor contact in TCM connector. connector? contact in TCM power supply line
connector. and grounding
line.
EN(TURBO)-339
DD:DTC P1698 — ENGINE TORQUE CONTROL CUT SIGNAL CIRCUIT LOW IN-
PUT —
CAUTION:
• WIRING DIAGRAM:
B55 TCM
1410
B136 ECM
B55 B136
1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7
10 11 12 13 14 15 16 17 18 8 9 10 11 12 13 14 15 16
19 20 21 22 23 24 17 18 19 20 21 22 23 24
EN1169
EN(TURBO)-340
Step Check Yes No

1)Start the engine and warm-up engine. contact in ECM
2)Turn the ignition switch to OFF. connector.
chassis ground.
2)Disconnect the connectors from ECM and ECM and TCM
TCM. connector.
3 CHECK HARNESS BETWEEN ECM AND Is the resistance less than 1 Repair the poor Repair the open
TCM CONNECTOR. Ω? contact in ECM or circuit in harness
Measure the resistance of harness between TCM connector. between ECM and
ECM and TCM connector. TCM connector.
(B136) No. 14 — (B55) No. 20:
EN(TURBO)-341
DE:DTC P1699 — ENGINE TORQUE CONTROL CUT SIGNAL CIRCUIT HIGH IN-
PUT —
CAUTION:
• WIRING DIAGRAM:
B55 TCM
1410
B136 ECM
B55 B136
1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7
10 11 12 13 14 15 16 17 18 8 9 10 11 12 13 14 15 16
19 20 21 22 23 24 17 18 19 20 21 22 23 24
EN1169
EN(TURBO)-342
Step Check Yes No

1 CHECK OUTPUT SIGNAL FROM ECM. Is the voltage less than 3 V? Go to step 2. Repair the battery
1)Start the engine and warm-up engine. short circuit in har-
3)Disconnect the connector from TCM. ECM and TCM
chassis ground. ECM. <Ref. to
Module.>
2 CHECK HARNESS BETWEEN ECM AND Does the voltage change more Repair the battery Contact with your
TCM CONNECTOR. than 10 V by shaking harness short circuit in har- Subaru distributor
1)Turn the ignition switch to OFF. and connector of ECM while ness between service.
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-
(B136) No. 14 (+) — Chassis ground (−): ECM. <Ref. to cause probable
FU(TURBO)-49, cause is deteriora-
Engine Control tion of multiple
Module.> parts.
EN(TURBO)-343
DF:DTC P1701 — CRUISE CONTROL SET SIGNAL CIRCUIT MALFUNCTION

FOR AUTOMATIC TRANSMISSION —
CAUTION:
• WIRING DIAGRAM:
B94 CCM
3
11
B54 TCM
B94 B54
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9
11 12 13 14 15 16 17 18 19 20 10 11 12 13 14 15 16 17 18
19 20 21 22 23 24
EN1170
EN(TURBO)-344
Step Check Yes No

1 CHECK HARNESS BETWEEN TCM AND Is the resistance less than 1 Go to step 2. Repair the open
2)Disconnect the connectors from TCM and CCM connector.
CCM.
TCM and CCM connector.
(B55) No. 22 — (B94) No. 3:
2 CHECK HARNESS BETWEEN TCM AND Is the resistance less than 10 Repair the short Go to step 3.
TCM and chassis ground. CCM connector.
3 CHECK INPUT SIGNAL FOR TCM. Is the resistance less than 1 V? Go to step 4. Check the cruise
1)Connect the connector to TCM and CCM. control command
2)Lift-up the vehicle or set the vehicle on free switch circuit.
rollers. <Ref. to CC-6,
CAUTION: INSPECTION,
On AWD models, raise all wheels off Cruise Control
ground. Command
3)Start the engine. Switch.>
4)Turn the cruise control main switch to ON.
MPH).
6)Turn the cruise control command switch to
ON.
chassis ground.
trol Module
(TCM).>
EN(TURBO)-345
DG:DTC P1711 — ENGINE TORQUE CONTROL SIGNAL 1 CIRCUIT MALFUNC-

TION —
CAUTION:
• WIRING DIAGRAM:
B56 TCM
5
19
B134 ECM
B55 B134
1 2 3 4 5 6 7 8 9 7 6 5 4 3 2 1
10 11 12 13 14 15 16 17 18 15 14 13 12 11 10 9 8
19 20 21 22 23 24 22 21 20 19 18 17 16
B2M4374
EN(TURBO)-346
Step Check Yes No

chassis ground.
Engine Control
Module.>
TCM.
(B135) No. 19 — (B54) No. 13:
trol Module
(TCM).>
EN(TURBO)-347
DH:DTC P1712 — ENGINE TORQUE CONTROL SIGNAL 2 CIRCUIT MALFUNC-

TION —
CAUTION:
• WIRING DIAGRAM:
B56 TCM
14
18
B134 ECM
B55 B134
1 2 3 4 5 6 7 8 9 7 6 5 4 3 2 1
10 11 12 13 14 15 16 17 18 15 14 13 12 11 10 9 8
19 20 21 22 23 24 22 21 20 19 18 17 16
B2M4375
EN(TURBO)-348
Step Check Yes No

chassis ground.
Engine Control
Module.>
TCM.
(B134) No. 18 — (B56) No. 4:
trol Module
(TCM).>
EN(TURBO)-349

A: INSPECTION
1. ENGINE
NOTE:
Malfunction of parts other than those listed is also possible. <Ref. to ME(TURBO)-91, Engine Trouble in Gen-
eral.>
2) Pressure sensor
3) Mass air flow and intake temperature sensor
1. Engine stalls during idling.
2) Pressure sensor
6) Air intake system (*5)
2. Rough idling
11) Oxygen sensor
3) Accelerator cable (*6)
3. Engine does not return to idle.
5) Pressure sensor
6) Mass air flow sensor
1) Pressure sensor
4. Poor acceleration 6) Engine coolant temperature sensor (*2)
9) A/C switch and A/C cut relay
10) Engine torque control signal circuit
1) Pressure sensor
5. Engine stalls or engine sags or hesitates at
acceleration.
6) Purge control solenoid valve
EN(TURBO)-350

1) Pressure sensor
6. Surge
1) Pressure sensor
7. Spark knock
4) Knock sensor
1) Pressure sensor
8. After burning in exhaust system 3) Engine coolant temperature sensor (*2)
*1: Check ignition coil & ignitor assembly and spark plug.
*2: Indicate the symptom occurring only in cold temperatures.
*3: Ensure the secure installation.
*4: Check fuel injector, fuel pressure regulator and fuel filter.
*5: Inspect air leak in air intake system.
*6: Adjust accelerator cable.
EN(TURBO)-351
EN(TURBO)-352
TRANSMISSION SECTION
CONTROL SYSTEMS CS
AUTOMATIC TRANSMISSION AT
AUTOMATIC TRANSMISSION AT
(DIAGNOSTICS)
MANUAL TRANSMISSION AND MT

DIFFERENTIAL
CLUTCH SYSTEM CL
of SUBARU vehicles.
sembling, inspection and adjustment of
Please peruse and utilize this manual
their vehicle in optimum condition.
SUBARU genuine parts.

approval.

CONTROL SYSTEMS
CS
Page
2. Select Lever ................................................................................................7
3. Select Cable................................................................................................9
4. MT Gear Shift Lever..................................................................................12
5. MT Drive Select Lever...............................................................................18
6. Drive Select Cable ....................................................................................20
7. General Diagnostic....................................................................................21
GENERAL DESCRIPTION
CONTROL SYSTEMS
A: SPECIFICATIONS
Item Specification
Vibration torque of rod against lever N·m (kgf-m, ft-lb) 0.7 (0.07, 0.5) or less
CS-2
GENERAL DESCRIPTION
CONTROL SYSTEMS
B: COMPONENT
1. AT SELECT LEVER
(2)
(12)
(4)
(3) (5) (13)

T2 (22)
(1)
(6) (14)
(15)
(8) (7)
(22)
(9)
(16)
(10)
(11)
T4
(17)
(18)
(19)
T1
T3 (20)
(21)
TR0928
(1) Indicator light bulb (11) Spacer (21) Nut A

(2) Detent arm (12) Grip (22) Clip
(3) Detent spring (13) Indicator cover
(4) Select lever COMPL (14) Blind Tightening torque: N·m (kgf-m, ft-lb)
(5) Spring pin (15) Cushion plate T1: 7.5 (0.76, 5.5)
(6) Arm COMPL (16) Guide plate T2: 13 (1.3, 9.4)
(7) Bush (17) Snap pin T3: 18 (1.8, 13.0)
(8) Plate (18) Washer T4: 33 (3.4, 25)
(9) Grommet (19) Select cable
(10) Packing (20) Nut B
CS-3
GENERAL DESCRIPTION
CONTROL SYSTEMS
2. MT GEAR SHIFT LEVER
TR0894
(1) Gear shift knob (10) O-ring (19) Stay

(2) Console boot (11) O-ring (20) Spacer
(3) Plate COMPL (12) Bush A (21) Spring pin
(4) Lever (13) Cushion rubber
(5) Bush (14) Bush B Tightening torque: N·m (kgf-m, ft-lb)
(6) Bush (15) Joint T1: 7.5 (0.76, 5.5)
(7) Lock wire (16) Rod T2: 12 (1.2, 8.7)
(8) Boot (17) Bracket T3: 18 (1.8, 13.0)
(9) Snap ring (18) Washer
CS-4
GENERAL DESCRIPTION
CONTROL SYSTEMS
3. DRIVE SELECT LEVER
(1)
T
T
(4)
(3)
(2)
(10)
(7)
(6)
(9)
(5)
(8)
TR0336
(1) Knob (6) Spring Tightening torque: N·m (kgf-m, ft-lb)

(2) Cushion (7) Lever COMPL T: 18 (1.8, 13.0)
(3) Plate COMPL (8) Clip
(4) Bush (9) Clevis pin
(5) Cable (10) Snap pin
CS-5
GENERAL DESCRIPTION
CONTROL SYSTEMS
C: CAUTION
tion.
• Use SUBARU genuine grease etc. or the equiv-
alent. Do not mix grease etc. with that of another
grade or from other manufacturers.
points.
• Apply grease onto sliding or revolution surfaces
before installation.
• Before installing O-rings or snap rings, apply suf-
ficient amount of grease to avoid damage and de-
formation.
• Before securing a part on a vise, place cushion-
ing material such as wood blocks, aluminum plate,
or shop cloth between the part and the vise.
• Before disconnecting electrical connectors, be
sure to disconnect the ground cable from battery.
CS-6
SELECT LEVER
CONTROL SYSTEMS
2. Select Lever B: INSTALLATION

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 a lift. vehicle body, then connect the connector.
3) Move the select lever to “N” position. Tightening torque:
4) Lift-up the vehicle. 13 N·m (1.3 kgf-m, 9.4 ft-lb)
5) Remove the rear exhaust pipe and muffler.
Non-turbo model with OBD
<Ref. to EX-11, REMOVAL, Rear Exhaust Pipe.>,
<Ref. to EX-12, REMOVAL, Muffler.>
Non-turbo model without OBD
<Ref. to EX(w/oOBD)-13, REMOVAL, Rear Ex-
haust Pipe.>, <Ref. to EX(w/oOBD)-14, REMOV-
AL, Muffler.>
Turbo model
<Ref. to EX(TURBO)-13, REMOVAL, Rear Ex-
B3M1796
haust Pipe.>, <Ref. to EX(TURBO)-14, REMOVAL,
Muffler.> 3) Install the console box. <Ref. to EI-38, INSTAL-
6) Remove the heat shield cover. (If equipped) LATION, Glove Box.>
7) Disconnect the cable from select lever, and then 4) Set the location of select lever at “N” position.
remove the cable bracket. 5) Lift-up the vehicle.
6) Set the location of range select lever to “N” posi-
tion.
7) Insert the thread portion of the other inner cable
and into connector hole of the select lever, and fix
the other outer cable end to bracket.
Tightening torque:
18 N·m (1.8kgf-m, 13.0 ft-lb)
8) Adjust the select cable position. <Ref. to CS-10,
ADJUSTMENT, Select Cable.>
B3M1795A 9) After completion of fitting, make sure that the se-
lect lever operates smoothly all across the operat-
(A) Adjusting nuts ing range.
(B) Cable bracket 10) Inspect the following items. If the following in-
spection reveals problems, adjust the select cable
8) Lower the vehicle. and inhibitor switch. <Ref. to CS-10, ADJUST-
9) Remove the console box. <Ref. to EI-40, RE- MENT, Select Cable.> and <Ref. to AT-28, AD-
MOVAL, Console Box.> JUSTMENT, Inhibitor Switch.>
10) Disconnect the connectors, then remove the (1) The engine starts operating when select le-
four bolts to take out the select lever assembly from ver is in position “P”, but not in other positions.
body. (2) The back-up light is lit when the select lever
is in position “R”, but not in other positions.
(3) Select lever and indicator positions are
matched.
11) Install the heat shield cover. (If equipped)
B3M1510
CS-7
SELECT LEVER
CONTROL SYSTEMS
12) Install the rear exhaust pipe and muffler. 5) Remove the cap, and then extract the spring pin.
<Ref. to EX-11, INSTALLATION, Rear Exhaust
Pipe.>, <Ref. to EX-12, INSTALLATION, Muffler.>
<Ref. to EX(w/oOBD)-13, INSTALLATION, Rear
Exhaust Pipe.>, <Ref. to EX(w/oOBD)-14, IN-
STALLATION, Muffler.>
Turbo model
<Ref. to EX(TURBO)-13, INSTALLATION, Rear
Exhaust Pipe.>, <Ref. to EX(TURBO)-14, INSTAL-
LATION, Muffler.> B3M1797A
C: DISASSEMBLY (A) Spring pin

1) Remove the grip. (B) Arm COMPL
2) Remove the indicator light, and then remove the
indicator cover. 6) Remove the select lever lower, and then take
NOTE: away the select lever upper from plate.
Be careful not to break the indicator light during re-
moval.
B3M1848A
(A) Select lever lower

B3M1511A
(B) Select lever upper
(C) Plate
(A) Grip
(B) Indicator cover D: ASSEMBLY
(C) Indicator light 1) Clean all parts before assembly.
3) Remove the blind. 2) Apply grease [NIGTIGHT LYW No. 2 or equiva-
4) Remove the clips, and then remove the guide lent] to each parts. <Ref. to CS-3, AT Select Le-
plate. ver.>
3) Assembly is in the reverse order of disassembly.
4) After completion of fitting, transfer the select le-
ver to range “P” — “1”, 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.
B3M2177A
2) Confirm the following parts for operating condi-
tion before assembly. Moving condition of the se-
(A) Clips lector lever upper, it should move smoothly.
(B) Guide plate
CS-8
SELECT CABLE
CONTROL SYSTEMS
3. Select Cable 9) Disconnect the cable from select lever, and then
remove the cable bracket.
A: REMOVAL
3) Prior to removal, set the lever to “N” position.
5) Remove the front and center exhaust pipe.
<Ref. to EX-7, REMOVAL, Front Exhaust Pipe.>
B3M1795A
Pipe.>
Turbo model
(A) Adjusting nuts
<Ref. to EX(w/oOBD)-12, REMOVAL, Center Ex-
haust Pipe.> (B) Cable bracket
6) Remove the heat shield cover. (If equipped) 10) Remove the select cable from plate assembly.
7) Remove the snap pin from range select lever.
B: INSTALLATION
1) Install the select cable to plate assembly.
Tightening torque:
32 N·m (3.3 kgf-m, 24 ft-lb)
2) Install the select cable to range select lever.
3) Install the plate assembly to transmission.
Tightening torque:
T: 24.5 N·m (2.5 kgf-m, 18.1 ft-lb)
TR0895
(A) Range select lever

(B) Snap pin
(C) Select cable
(D) Clamp
(E) Washer
8) Remove the plate assembly from transmission

case. B3M1030G
(A) Select cable

(B) Plate ASSY
B3M1030E
(A) Select cable

(B) Plate ASSY
(C) Clamp
CS-9
SELECT CABLE
CONTROL SYSTEMS
4) Install the snap pin to range select lever. D: ADJUSTMENT

3) Set the lever to “N” position.
6) Remove the heat shield cover. (If equipped)
7) Loosen the adjusting nut on each side.
TR0895
(A) Range select lever

(B) Snap pin
(C) Select cable
(D) Clamp
(E) Washer
B3M1792A
5) Move the select lever to “N” position, then adjust
the select cable position. <Ref. to CS-10, ADJUST-
(A) Adjusting nut A
MENT, Select Cable.>
(B) Adjusting nut B
7) Install the front and center exhaust pipe. 8) Turn the adjusting nut B until it lightly touches
Non-turbo model with OBD the connector.
Pipe.>
<Ref. to EX(w/oOBD)-10, INSTALLATION, Front
Exhaust Pipe.>
Turbo model
<Ref. to EX(TURBO)-9, INSTALLATION, Center
Exhaust Pipe.>
C: INSPECTION
Check the removed cable and replace if damaged, B3M1793A
rusty, or malfunctioning.
1) Check for smooth operation of the cable. (A) Front side
2) Check the inner cable for damage and rust. (B) Select lever
3) Check the outer cable for damage, bends, and (C) Connector
cracks.
(D) Adjusting nut B
4) Check the boot for damage, cracks, and deterio-
(E) Contact point
ration.
5) Move the select lever from “P” position to “1” po- (F) Adjusting nut A
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.
CS-10
SELECT CABLE
CONTROL SYSTEMS
9) While preventing the adjusting nut B from mov-

ing with a wrench, tighten the adjusting nut A.
Tightening torque:
7.5 N·m (0.76 kgf-m, 5.5 ft-lb)
B3M1794A
(A) Adjusting nut A

(B) Adjusting nut B
10) After completion of fitting, make sure that the

select lever operates smoothly all across the oper-
ating range.
CS-11
MT GEAR SHIFT LEVER
CONTROL SYSTEMS
4. MT Gear Shift Lever 10) Remove the rod from joint.
A: REMOVAL
2) Remove the gear shift knob.
4) Remove the console box. <Ref. to EI-40, RE-
MOVAL, Console Box.>
5) Remove the boot plate from body.
B3M1824A
(A) Stay
(B) Rod
11) Remove the cushion rubber from body.
B3M1822

<Ref. to EX-11, REMOVAL, Rear Exhaust Pipe.>,
<Ref. to EX-12, REMOVAL, Muffler.>
<Ref. to EX(w/oOBD)-13, REMOVAL, Rear Ex- B3M1825A
haust Pipe.>, <Ref. to EX(w/oOBD)-14, REMOV-
AL, Muffler.> (A) Stay
Turbo model (B) Cushion rubber
haust Pipe.>, <Ref. to EX(TURBO)-14, REMOVAL, 12) Remove the joint, and then extract the spring
Muffler.> pin.
9) Remove the stay from transmission bracket.
B3M1826A
(A) Joint
B3M1823A
(B) Spring pin
(A) Stay 13) Lower the vehicle.
(B) Transmission bracket
CS-12
MT GEAR SHIFT LEVER
CONTROL SYSTEMS
14) Remove the gear shift lever. 6) Mount the cushion rubber on the body.
Tightening torque:
18 N·m (1.8 kgf-m, 13.0 ft-lb)
B3M1827
B: INSTALLATION
1) Install the joint to transmission and secure with B3M1825A
the spring pin.
2) Insert the gear shift lever from room side. (A) Stay
(B) Cushion rubber
NOTE:
After inserting the rod and stay, temporarily put 7) Connect the rod to the joint.
them onto transmission mount.
Tightening torque:
18 N·m (1.8 kgf-m, 13.0 ft-lb)
B3M1827
3) Lift-up the vehicle. B3M1824A

4) Install the joint to shifter arm.
5) Insert the straight pin. (A) Stay
(B) Rod
8) Connect the stay to transmission bracket.

Tightening torque:
18 N·m (1.8 kgf-m, 13.0 ft-lb)
B3M1826A
B3M1823A
(A) Stay
(B) Transmission bracket
CS-13
MT GEAR SHIFT LEVER
CONTROL SYSTEMS
10) Install the rear exhaust pipe and muffler. 3) Remove the snap ring from bush B, then discon-
Non-turbo model with OBD nect the stay.
<Ref. to EX-11, INSTALLATION, Rear Exhaust
Pipe.>, <Ref. to EX-12, INSTALLATION, Muffler.>
Turbo model
LATION, Muffler.>
11) Lower the vehicle. B3M0619B
12) Install the boot plate to body.

(A) Snap ring
Tightening torque: (B) Bush B
7.5 N·m (0.76 kgf-m, 5.5 ft-lb) (C) Boot
13) Install the console box. <Ref. to EI-40, INSTAL-
LATION, Console Box.> 4) Remove the boot from gear shift lever.
5) Remove the bush and cushion rubber from stay.
C: DISASSEMBLY
1) Disassemble the lock wire.
B3M0830D
B3M0617C (A) Bush

(B) Stay
(A) Lock wire
(C) Cushion rubber
(B) Stay
6) Remove the O-ring, then disconnect the bush B.
2) Remove the rod from lever.
B3M0620C
B3M1828A
(A) O-ring
(A) Rod
(B) O-ring
(B) Lever
(C) Bush B
(C) Stay
CS-14
MT GEAR SHIFT LEVER
CONTROL SYSTEMS
7) Draw out the spring pin, then remove the bush A 3) Mount each part; boot, O-ring, bush A, spacer,
from gear shift lever. bush B, bush and spring pin on the gear shift lever.
NOTE:
• Always use new O-rings.
• Apply grease [DNIGTIGHT LYW No. 2 or equiv-
alent] to the inner and side surfaces of the bush
when installing the spacer.
B3M0621B
(A) Spring pin

(B) Bush A
D: ASSEMBLY B3M0623C
1) Clean all parts before assembly.
2) Mount the bush and cushion rubber on the stay. (A) Boot
(B) O-ring
(C) Bush
(D) Spacer
(E) Bush A
(F) Bush B
(G) Spring pin
(H) O-ring
4) Insert the gear shift lever into boot hole.

B3M0830C 5) Install the snap ring and stay to bush B.
(A) Bush
(B) Cushion rubber
B3M0619C
(A) Snap ring

(B) Bush B
CS-15
MT GEAR SHIFT LEVER
CONTROL SYSTEMS
6) Tighten with lock wire to the extent that the boot 9) Check the swing torque of the rod in relation to
will not come off. gear shift lever.
NOTE: If the torque exceeds specification, replace the
Always use a new lock wire. bush or retighten nuts.
Rocking torque:
0.7 N·m (0.07 kgf-m, 0.5 ft-lb) or less
B3M0617C
(A) Lock wire B3M1829C

(B) Stay
(A) Center of rotation
7) Insert the rod into boot hole.
(B) Swing torque
8) Connect the rod to gear shift lever.
Tightening torque: 10) Check that there is no excessive play and that
11.8 N·m (1.2 kgf-m, 8.7 ft-lb) parts move smoothly.
B3M1828A
(A) Rod
(B) Lever
(C) Stay
CS-16
MT GEAR SHIFT LEVER
CONTROL SYSTEMS
E: INSPECTION 2) Check the swing torque of the rod in relation of

1) Check each part (bush, cushion rubber, spacer, gear shift lever.
boot, stay and rod, etc.) for deformation, damage If the torque exceeds specification, replace the
and wear. Repair or replace any defective part. De- bush or retighten nuts.
termine defective parts by comparing with new Rocking torque:
parts. 0.7 N·m (0.07 kgf-m, 0.5 ft-lb) or less
B3M1829C
(A) Center of rotation

(B) Swing torque
B3M1765A
(A) Bush
(B) Cushion rubber
(C) Spacer
(D) Boot
(E) Stay
(F) Rod
CS-17
MT DRIVE SELECT LEVER
CONTROL SYSTEMS
5. MT Drive Select Lever B: INSTALLATION

1) Install the drive select lever.
A: REMOVAL
1) Apply parking brake and place chocks to hold Tightening torque:
the wheels. 18 N·m (1.8 kgf-m, 13.0 ft-lb)
2) Disconnect the ground cable from battery. 2) Set the drive select lever to HI position.
3) Set the drive select lever to HI position.
4) Remove the knob.
5) Remove the console box. <Ref. to EI-40, Con-
sole Box.>
6) Remove the bolt installing drive select lever as-
sembly on body.
B3M1516A
(A) HI position
3) Be sure to insert the cable eye end bolt into lever

arm slit.
B3M0766
7) Remove the flange nut, clip and then disconnect

the cable from lever assembly.
B3M1517A
(A) Cable eye end bolt

(B) Lever arm
B3M1846A
4) Tighten the nut where cable end bolt comes to a
(A) Flange nut stop.
(B) Lever COMPL Tightening torque:
(C) Clip 18 N·m (1.8 kgf-m, 13.0 ft-lb)
CS-18
MT DRIVE SELECT LEVER
CONTROL SYSTEMS
C: DISASSEMBLY
1) Remove the spring.
B3M2132A
(A) Spring
2) Remove the lever, cushion and bush.
B3M2133A
(A) Washer
(B) Bush
(C) Plate COMPL
(D) Cushion
(E) Lever COMPL
D: ASSEMBLY
1) Assemble in the reverse order of disassembly.
Tightening torque:
18 N·m (1.8 kgf-m, 13.0 ft-lb)
2) Make sure the select lever moves smoothly.
E: INSPECTION
1) Make sure the select lever moves smoothly. If it
does not move smoothly, repair or replace it.
2) Make sure the drive select lever is not damaged.
If it is damaged, repair or replace it.
CS-19
DRIVE SELECT CABLE
CONTROL SYSTEMS
6. Drive Select Cable D: ADJUSTMENT

1) Set the drive select lever to HI position.
A: REMOVAL 2) Remove the drive select lever knob.
1) Remove the drive select lever. <Ref. to CS-18, 3) Remove the console box. <Ref. to EI-40, Con-
REMOVAL, MT Drive Select Lever.> sole Box.>
2) Remove the intake duct. <Ref. to IN-7, Air Intake 4) Loosen the nut.
Duct.> 5) Make sure the transmission is in HI position. If
3) Remove the air cleaner case. <Ref. to IN-6, Air isn't, pull on the cable to put transmission in HI po-
Cleaner Case.> sition.
4) Remove the snap ring and clevis pin. 6) Tighten the nut in the location where cable end
5) Loosen the nut and disconnect the cable from bolt stops naturally.
cable bracket.
Tightening torque:
18 N·m (1.8 kgf-m, 13.0 ft-lb)
7) Make sure to move the transmission to HI or LO
position by moving the drive select lever. If it
doesn't, readjust the cable.
S3M0641A
(A) Snap pin

(B) Clevis pin
(C) Nut
6) Remove the cable from the under side of vehi-

cle.
B3M0769
B: INSTALLATION
2) Make sure the drive select lever operates prop-
erly.
C: INSPECTION
1) Make sure to move the transmission to HI or LO
position by moving the drive select lever. If it
doesn't, adjust the cable.<Ref. to CS-20, ADJUST-
MENT, Drive Select Cable.>
2) Make sure the cable operates smoothly. If it
catches or fails to work properly, repair or replace
it.
3) Check the cable for damage.
CS-20
GENERAL DIAGNOSTIC
CONTROL SYSTEMS
7. General Diagnostic
A: INSPECTION
Symptom Possible cause Remedy
1. Select lever (1) Starter does not run. Adjust the select cable and inhibitor switch, or
inspect circuit.
(2) Back-up light does not light up. Adjust the select cable and inhibitor switch, or
inspect circuit.
CS-21
GENERAL DIAGNOSTIC
CONTROL SYSTEMS
CS-22
AUTOMATIC TRANSMISSION
AT
Page
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
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......................................................................36
15. Torque Converter Turbine Speed Sensor .................................................37
16. Control Valve Body ...................................................................................38
17. Shift Solenoids, Duty Solenoids and ATF Temperature Sensor ...............40
18. ATF Filter ..................................................................................................45
19. Transmission Control Module (TCM) ........................................................46
20. ATF Cooler Pipe and Hose .......................................................................48
GENERAL DESCRIPTION
1. General Description 5. PLANETARY GEAR AND PLATE

A: SPECIFICATIONS 2.0 L
2.0 L
Model 1.6 L Non- 2.5 L
1. TORQUE CONVERTER CLUTCH Turbo
turbo
Tooth num-
2.0 L ber of front 33
2.0 L
Model 1.6 L Non- 2.5 L sun gear
Turbo
turbo
Tooth num-
Symmetric, 3 element, single stage, 2 phase ber of front 21
Type
torque converter pinion
Stall torque 1.85 — Tooth num-
2.2 — 2.4 2.0 — 2.2 1.9 — 2.1
ratio 2.15 ber of front 75
Nominal 236 mm internal gear
246 mm (9.69 in)
diameter (9.29 in) Tooth num-
2,200 — 2,000 — 2,100 — 2,600 — ber of rear 42
Stall speed
2,700 2,500 2,600 3,300 sun gear
(at sea level)
rpm rpm rpm rpm Tooth num-
One-way ber of rear 17
Sprague type one-way clutch
clutch pinion
Tooth num-
2. OIL PUMP ber of rear 75
internal gear
Type Pracoid constant-displacement pump Drive &
Driving method Driven by engine driven plate
3 4 5
Inner rotor 9 number of
Number of teeth high clutch
Outer rotor 10
Drive &
3. TRANSMISSION CONTROL ELEMENT driven plate
4 6 7
number of
4-forward, 1-reverse, double-row plan- low clutch
Type Drive &
etary gears
Multi-plate clutch 3 sets driven plate
number of 1 2
Multi-plate brake 2 sets
reverse
One-way clutch clutch
1 sets
(sprague type)
Drive &
driven plate
4. TRANSMISSION GEAR RATIO number of 2-
2 3 4
4 brake
Gear ratio
Drive &
1st 2.785 driven plate
2nd 1.545 number of
4 6 7
3rd 1.000 low &
4th 0.694 reverse
brake
Rev 2.272
AT-2
GENERAL DESCRIPTION
6. SELECTOR POSITION 8. COOLING AND HARNESS

Transmission in neutral, output member Liquid-cooled cooler incorpo-
P (Park) Cooling system
immovable, and engine start possible rated in radiator
R Inhibitor switch 12 poles
Transmission in reverse for backing
(Reverse) Transmission harness 20 poles
N (Neu- Transmission in neutral and engine start possi-
tral) ble 9. TRANSFER
← ← ←
Automatic gear change 1st → 2nd → 3rd
D (Drive) 1.6 L and
→ 4th
Model 2.0 L Non- 2.5 L 2.0 L Turbo
Automatic gear change 1st ← → 2nd ←→ 3rd ← turbo
3 (3rd)
4th Variable
Transfer
Automatic gear change 1st ← → 2nd ← 3rd ← Multi-plate transfer (MPT) torque distri-
2 (2nd) type
4th bution (VTD)
1st gear locked (Deceleration possible 1st ← Drive &
1 (1st) driven
2nd ← 3rd ← 4th)
plate num-
Control 4 5 3
Hydraulic remote control ber of
method
transfer
clutch
7. HYDRAULIC CONTROL AND LUBRICA-
Control
TION method
Electronic, hydraulic type
The same Automatic transmission fluid used

Electronic/hydraulic control Lubricant
in automatic transmission
[Four forward speed
Type changes by electrical signals 1st reduc-
of vehicle speed and accel- tion gear 1.000 (53/53)
erator (throttle) opening] ratio
Dexron III type Automatic
Fluid
transmission fluid
1.6 L and
8.4 — 8.7 2 (8.9 — 9.2 US
2.0 L Non-
qt, 7.4 — 7.7 Imp qt)
Fluid capac- turbo model
ity 2.5 L and
9.3 — 9.6 2 (9.8 — 10.1 US
2.0 L Turbo
qt, 8.2 — 8.4 Imp qt)
model
Forced feed lubrication with
Lubrication system
oil pump
Automatic transmission fluid
Oil
(above mentioned)
10.FINAL REDUCTION
Model EXCEPT 1.6 L 1.6 L
Front final gear ratio 4.111 (37/9) 4.444 (40/9)
Lubrication oil
H3M1235A
Front differential oil capacity 1.1 — 1.3 2 (1.2 — 1.4 US qt, 1.0 — 1.1 Imp qt)
AT-3
GENERAL DESCRIPTION
B: COMPONENT
NOTE:
For information about other transmission mounting components, refer to “AUTOMATIC TRANSMISSION”
<Pub. No. G0864ZE> a separate publication.
1. TRANSMISSION MOUNTING
B2M3384A
(1) Pitching stopper Tightening torque: N·m (kgf-m, ft-lb)

(2) Rear cushion rubber T1: 35 (3.6, 26)
(3) Transmission rear 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
C: CAUTION • Use SUBARU genuine gear oil, grease etc. or

• Wear working clothing, including a cap, protec- the equivalent. Do not mix gear oil, grease etc. with
tive goggles, and protective shoes during opera- that of another grade or from other manufacturers.
tion. • Be sure to tighten fasteners including bolts and
• Remove contamination including dirt and corro- nuts to the specified torque.
sion before removal, installation, and disassembly. • Place shop jacks or safety stands at the specified
• Keep the disassembled parts in order and pro- points.
tect them from dust or dirt. • Apply gear oil onto sliding or revolution surfaces
• Until the oil pan is removed, do not place with the before installation.
oil pan side facing up to prevent foreign matter from • Replace deformed or otherwise damaged snap
entering the valve body. rings with new ones.
• Before removal, installation or disassembly, be • Before installing O-rings or oil seals, apply suffi-
sure to clarify the failure. Avoid unnecessary re- cient amount of ATF fluid to avoid damage and de-
moval, installation, disassembly and replacement. formation.
• When disassembling the case and other light al- • Be careful not to incorrectly install or fail to install
loy parts, use a plastic hammer to force it apart. Do O-rings, snap rings and other such parts.
not pry it apart with a screwdriver or other tool. • Before securing a part on a vise, place cushion-
• Be careful not to burn your hands, because each ing material such as wood blocks, aluminum plate,
part on the vehicle is hot after running. or shop cloth between the part and the vise.
• Avoid damaging the mating surface of the case.
• Before applying sealant, completely remove the
old seal.
D: PREPARATION TOOL
1. SPECIAL TOOLS

398527700 PULLER ASSY Used for removing extension case oil seal.
B3M1977
498057300 INSTALLER Used for installing extension oil seal.
B3M1972
AT-5
GENERAL DESCRIPTION

498575400 OIL PRESSURE Used for measuring oil pressure.
GAUGE ASSY
B3M2040
498897200 ADAPTER Used oil pump housing when measuring reverse
clutch pressure and line pressure.
B3M2041
498545400 FILTER WRENCH Used for removing and installing ATF filter.
B3M2042
498277200 STOPPER SET Used for removing and installing automatic
transmission assembly to engine.
B3M2043
AT-6
GENERAL DESCRIPTION

499267300 STOPPER PIN Used for installing and adjusting inhibitor switch.
B3M2008
41099AA020 ENGINE SUPPORT Used for supporting engine.
B3M1976
BRACKET
B3M1975
Except 2.5 L model CRANK PULLEY Used for stopping rotating of crankshaft pulley
499977300 WRENCH when loosening and tightening crankshaft pulley
2.5 L model bolts.
499977100
B2M3870
AT-7
GENERAL DESCRIPTION

<Newly adopted
tool>
B2M3876
22771AA030 SELECT MONITOR Troubleshooting for electrical systems.
KIT • English:
22771AA030 (Without printer)
• German:
• French:
• Spanish:
B2M3877

TOOL NAME REMARKS
Circuit Tester Used for measuring resistance, voltage and ampere.
AT-8
AUTOMATIC TRANSMISSION FLUID
2. Automatic Transmission Flu- (4) Fluid temperature rising speed

• By idling the engine
id Time for temperature rise to 70°C (158°F) with at-
A: INSPECTION mospheric temperature of 0°C (32°F): More than
1) Check the level of ATF. 25 minutes
(1) Raise the ATF temperature to 70 to 80°C <Reference>
(158 to 176°F) from 20 to 30°C (68 to 86°F) Time for temperature rise to 30°C (86°F) with atmo-
(when cold) by driving a distance of 5 to 10 km (3 spheric temperature of 0°C (32°F): Approx. 8 min-
to 6 miles). utes
• By running the vehicle
NOTE: Time for temperature rise to 70°C (158°F) with at-
The level of ATF varies with fluid temperature. Pay mospheric temperature of 0°C (32°F): More than
attention to the fluid temperature when checking oil 10 minutes
level. (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.
B3M1020B B: REPLACEMENT
(A) ATF level gauge 2) Drain the ATF completely.
(B) Upper level CAUTION:
(C) Lower level Directly after the engine has been running, the
ATF is hot. Be careful not to burn yourself.
(2) Make sure the vehicle is level. After select-
ing all positions (P, R, N, D, 3, 2, 1), set the se- NOTE:
lect lever in “P” range. Measure the fluid level Tighten the ATF drain plug after draining the ATF.
with the engine idling. Tightening torque:
NOTE: 25 N·m (2.5 kgf-m, 18.1 ft-lb)
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 specified
range (above the center between upper and
lower marks). When the transmission is hot, the
level should be above the center of upper and
lower marks, and when it is cold, the level
should be found below the center of these two
marks. B3M1036B
NOTE:
• Use care not to exceed the upper limit level. (A) Oil pan
• ATF level varies with temperature. Remember (B) Drain plug (ATF)
that the addition of fluid to the upper limit mark (C) Differential oil drain plug
when the transmission is cold will result in overfill-
ing of fluid.
AT-9
AUTOMATIC TRANSMISSION FLUID
4) Pour ATF into the oil charge pipe.

Recommended fluid:
Capacity:
Fill the same amount of fluid drained from
drain plug hole.
Capacity when transmission is overhauled:
1.6 L and 2.0 L Non-turbo models
8.4 — 8.7 2 (8.9 — 9.2 US qt, 7.4 — 7.7 Imp
qt)
2.5 L and 2.0 L Turbo models
9.3 — 9.6 2 (9.8 — 10.1 US qt, 8.2 — 8.4 Imp
qt)
5) Check the level and leaks of ATF.
<Ref. to AT-9, REPLACEMENT, Automatic Trans-
mission Fluid.>
AT-10
DIFFERENTIAL GEAR OIL
3. Differential Gear Oil 3) Lower the vehicle.

4) Pour gear oil into the gauge hole.
A: INSPECTION
Recommended fluid:
Use GL-5 or equivalent.
3) Reinsert the level gauge all the way. Be sure that Gear oil capacity:
the level gauge is correctly inserted and in the 1.1 — 1.3 2 (1.2 — 1.4 US qt, 1.0 — 1.1 Imp qt)
proper orientation. 5) Check the level of differential gear oil.
4) Remove it again and note the reading. If the dif- <Ref. to AT-11, INSPECTION, Differential Gear
ferential gear oil level is below the “L” line, add oil to Oil.>
bring the level up to the “F” line.
5) To prevent overfilling the differential gear oil, do
not add oil above the “F” line.
S3M0478A
(A) Upper level

(B) Lower level
B: REPLACEMENT
2) Drain the differential gear oil completely.
CAUTION:
Directly after the engine has been running, the
differential gear oil is hot. Be careful not to burn
yourself.
NOTE:
Tighten the differential gear oil drain plug after
draining the differential gear oil.
Tightening torque:
44 N·m (4.5 kgf-m, 32.5 ft-lb)
B3M1036B
(A) Oil pan

(B) Drain plug
(C) Differential oil drain plug
AT-11
ROAD TEST
4. Road Test
A: INSPECTION
1. GENERAL PRECAUTION
Road tests should be conducted to properly diag-
nose the condition of the automatic transmission.
NOTE:
When performing the test, do not exceed posted
speed limit.
2. D RANGE SHIFT FUNCTION
Check shifting between 1st ⇔ 2nd ⇔ 3rd ⇔ 4th
while driving on normal city streets.
3. D RANGE SHIFT SHOCK
Check the shock level when shifting up during nor-
mal driving.
4. KICK-DOWN FUNCTION
Check kick-down for each gear. Also check the
kick-down shock level.
5. ENGINE BRAKE OPERATION
• Check the 3rd gear engine brake when shifting
between D ⇔ 3rd range while driving in 4th gear of
D range [50 to 60 km/h (31 to 37 MPH)].
• Check the 2nd gear engine brake when shifting
between 3 ⇔ 2 range while driving in the 3 range
3rd gear [40 to 50 km/h (25 to 31 MPH)].
• Check the 1st gear engine brake when shifting
between 2 ⇔1 range while driving in the 2 range
2nd gear [20 to 30 km/h (12 to 19 MPH)].
6. LOCK-UP FUNCTION
Check that rpm does not change sharply when the
acclelerator pedal is lightly depressed when driving
on flat roads at normal speed in the lock-up range.
7. P RANGE OPERATION
Stop the vehicle on an uphill grade of 5% or more
and shift to “P” range. Check that the vehicle does
not move when the parking brake is released.
8. UNUSUAL SOUNDS AND VIBRATION
Check for unusual sounds and vibration while 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.OIL LEAKS
After the driving test, inspect for oil leaks.
AT-12
STALL TEST
5. Stall Test 9) If the stall speed in “2” range is higher than spec-
ifications, low clutch slipping and 2-4 brake slipping
A: INSPECTION may occur. To identify it, conduct the same test as
above in “D” range.
1. GENERAL INFORMATION 10) Perform the stall tests with the select lever in
The stall test is of extreme importance in diagnos- “R” range.
ing the condition of the automatic transmission and NOTE:
the engine. It should be conducted to measure the • Do not continue the stall test for MORE THAN 5
engine stall speeds in “R” and “2” ranges. SECONDS at a time (from closed throttle, fully
Purposes of the stall test: open throttle to stall speed reading). Failure to fol-
1) To check the operation of the automatic trans- low this instruction causes the engine oil and ATF
mission clutch. to deteriorate and the clutch and brake to be ad-
2) To check the operation of the torque converter versely affected.
clutch. Be sure to cool down the engine for at least 1
3) To check engine performance. minute after each stall test with the select lever set
2. TEST METHODS in the “P” or “N” range and with the idle speed lower
than 1,200 rpm.
1) Preparations before test: • If the stall speed is higher than the specified
(1) Check that throttle valve opens fully. range, attempt to finish the stall test in as short a
(2) Check that engine oil level is correct. time as possible, in order to prevent the automatic
(3) Check that coolant level is correct. transmission from sustaining damage.
(4) Check that ATF level is correct.
Stall speed (at sea level):
(5) Check that differential gear oil level is cor-
1.6 L model: 2,200 — 2,700 rpm
rect.
2.0 L Non-turbo model: 2,000 — 2,500 rpm
(6) Increase ATF temperature to 50 to 80°C
(122 to 176°F) by idling the engine for approx. 2.0 L Turbo model: 2,600 — 3,300 rpm
30 minutes (with select lever set to “N” or “P”). 2.5 L model: 2,100 — 2,600 rpm
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.
B3M1589B
(A) Brake pedal

(B) Accelerator pedal
6) When the engine speed is stabilized, read that

speed quickly and release the accelerator pedal.
7) Shift the select lever to “N” range, and cool down
the engine by idling it for more than one minute.
8) Record the stall speed.
AT-13
STALL TEST
3. EVALUATION
Stall speed (at sea level) Position Cause
• Throttle valve not fully open
2,
Less than specifications • Erroneous engine operation
R
• Torque converter clutch's one-way clutch slipping
• Line pressure too low
D • Low clutch slipping
• One-way clutch malfunctioning
Greater than specifications R • Reverse clutch slipping
• Low & reverse brake slipping
2 • Low clutch slipping
• 2-4 brake slipping
AT-14
TIME LAG TEST
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.
NOTE:
• Perform the test at normal operating fluid tem-
perature 60 to 80°C (140 to 176°F).
• Be sure to allow a 1 minute interval between
tests.
• Make three measurements and take the average
value.
2. TEST METHODS
1) Fully apply the parking brake.
Check the idling speed (A/C OFF).
3) Shift the select lever from “N” to “D” range.
Using a stop watch, measure the time it takes from
shifting the lever until the shock is felt.
Time lag: Less than 1.2 seconds
4) In the same manner, measure the time lag for
“N” → “R”.
Time lag: Less than 1.5 seconds
3. EVALUATION
1) If “N” → “D” time lag is longer than specified:
• Low clutch worn
• One-way clutch not operating properly
2) If “N” → “R” time lag is longer than specified:
• Reverse clutch worn
• Low & reverse brake worn
AT-15
LINE PRESSURE TEST
7. Line Pressure Test 2. TEST METHODS

A: MEASUREMENT 1) Temporarily attach the ST to a suitable place in
the driver's compartment, remove the blind plug lo-
1. GENERAL INFORMATION cated in front of the toe board and pass the hose of
the ST to 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)
NOTE:
• Before measuring the line pressure, jack-up all B3M0568C
wheels.
• Maintain the temperature of ATF at approx. 50°C (A) Pressure gauge hose
(122°F) during measurement. (B) Hole in toe board (blank cap hole)
(ATF will reach the above temperature after idling (C) Brake pedal
the engine for approx. 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
NOTE:
• Before measuring the line pressure, apply both
foot and parking brakes with all wheels chocked
(Same as for “stall” test conditions).
• Measure the line pressure when select lever is in
“R”, “2” with engine under stall conditions.
• Measure the line pressure within 5 seconds after
shifting the select lever to each position. (If line
pressure needs to be measured again, allow the
engine to idle and then stop. Wait for at least 1
minute before measurement.) B3M2264A
• Maintain the temperature of ATF at approx. 50°C
(122°F) during measurement (ATF will reach the (A) Test plug
above temperature after idling the engine for ap-
prox. 30 minutes with the select lever in “N” or “P”.) 3) Connect the ST1 with ST2.
ST1 498897200 OIL PRESSURE GAUGE
ADAPTER
ST2 498575400 OIL PRESSURE GAUGE
ASSY
AT-16
LINE PRESSURE TEST
4) Check for duty ratio changes by opening and

closing the throttle valve using Subaru Select Mon-
itor.
(1) Insert the cartridge to Subaru Select Moni-
tor. <Ref. to AT-5, PREPARATION TOOL, Gen-
eral Description.>
S2M0286
(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 pressure
Range Line pres-
Throttle Line pressure
posi- sure duty
position kPa (kg/cm2, psi)
tion ratio (%)
1,128 — 1,304
2 5 Full open (11.5 — 13.3,
164 — 189)
1,520 — 1,716
R 5 Full open (15.5 — 17.5,
220 — 249)
304 — 412
D 95 Full closed
(3.1 — 4.2, 44 — 60)
AT-17
TRANSFER CLUTCH PRESSURE TEST
8. Transfer Clutch Pressure 2. EVALUATION

Test • MPT model
A: INSPECTION NOTE:
If oil pressure is not produced or if it does not
1. TEST METHODS change in the AWD mode, the transfer duty sole-
• MPT model noid or transfer valve assembly may be malfunc-
tioning. If 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 pressure kPa (kg/cm2, psi)
SET ON Duty
Throttle FWD
ST 498575400 OIL PRESSURE GAUGE ratio
position
AWD mode
mode
ASSY (%)
AWD mode: “D” range 932 — 1,089
FWD mode: “P” range, engine speed 2,000 rpm 95 Full open (9.5 — 11.1, —
135 — 158)
NOTE: 2/3 216 — 294
Before setting in FWD mode, install the spare fuse 60
throttle (2.2 — 3.0, 31 — 43)
—
on FWD mode switch.
Full
5 — 0 (0, 0)
closed
• VTD model
OFF Duty
Throttle Standard transfer clutch pres-
ratio
position sure kPa (kg/cm2, psi)
(%)
932 — 1,089
95 Full open
(9.5 — 11.1, 135 — 158)
216 — 294
40 2/3 throttle
(2.2 — 3.0, 31 — 43)
B3M1047C
(A) Test plug
• VTD model
Check the transfer clutch pressure in accordance
with the following chart in the same manner as with
line pressure.
ST 498897700 OIL PRESSURE ADAPTER
SET
ST 498575400 OIL PRESSURE GAUGE
ASSY
H3M1840B
(A) Test plug
AT-18
AUTOMATIC TRANSMISSION ASSEMBLY
9. Automatic Transmission As- 11) Separate the torque converter clutch from drive
plate.
sembly (1) Remove the service hole plug.
A: REMOVAL (2) Remove the bolts which hold torque con-
1) Set the vehicle on a lift. verter clutch to drive plate.
2) Open the front hood fully, and support with stay. (3) While rotating the engine, remove the other
3) Disconnect the ground cable from battery. bolts using ST.
4) Remove the air intake duct. (Non-turbo model) CAUTION:
<Ref. to IN-7, REMOVAL, Air Intake Duct.> Be careful not to drop bolts into torque convert-
5) Remove the air cleaner case. (Non-turbo model) er clutch housing.
<Ref. to IN-6, REMOVAL, Air Cleaner Case.> Except 2.5 L model
6) Remove the air cleaner case stay. (Non-turbo ST 499977300 CRANK PULLEY WRENCH
model) 2.5 L model
S2M0901
S2M0207
7) Remove the intercooler. (Turbo model)
<Ref. to IN(TURBO)-10, REMOVAL, Intercooler.> 12) Install the ST to torque converter clutch case.
8) Disconnect the following connectors. ST 498277200 STOPPER SET
(1) Transmission harness connector
H2M1961A
S2M0212
13) Remove the ATF level gauge.
(2) Transmission ground cable
NOTE:
9) Remove the starter. Plug the opening to prevent entry of foreign parti-
<Ref. to SC-5, REMOVAL, Starter.> cles into transmission fluid.
S2M0908
H3M1839
AT-19
14) Set the ST. 21) Drain the ATF to remove the ATF drain plug.
NOTE:
Also the ENGINE SUPPORT BRACKET
41099AA010 can be used.
ST 41099AA020 ENGINE SUPPORT ASSY
B3M1036C
(A) Oil pan

(B) Drain plug
G2M0313 22) Disconnect the ATF cooler hoses from pipes of
15) Remove the bolt which holds right upper side of transmission side, and remove the ATF level gauge
transmission to engine. guide.
B3M2191
B3M2044
16) Lift-up the vehicle. 23) Remove the propeller shaft. <Ref. to DS-15,
17) Remove the under cover. REMOVAL, Propeller Shaft.>
18) Remove the front, center, rear exhaust pipe 24) Remove the shift select cable. <Ref. to CS-9,
and muffler. (Non-turbo model) <Ref. to EX(w/ REMOVAL, Select Cable.>
oOBD)-9, REMOVAL, Front Exhaust Pipe.>, <Ref. 25) Disconnect the stabilizer link from transverse
to EX(w/oOBD)-13, REMOVAL, Rear Exhaust link.
Pipe.> and <Ref. to EX(w/oOBD)-14, REMOVAL,
Muffler.> or <Ref. to EX-7, REMOVAL, Front Ex-
haust Pipe.>, <Ref. to EX-11, REMOVAL, Rear Ex-
haust Pipe.> and <Ref. to EX-12, REMOVAL,
Muffler.>
19) Remove the center, rear exhaust pipe and muf-
fler. (Turbo model)
<Ref. to EX(TURBO)-8, REMOVAL, Center Ex-
Rear Exhaust Pipe.> and <Ref. to EX(TURBO)-14,
REMOVAL, Muffler.>
AT-20
26) Remove the bolt securing ball joint of trans- 29) Place the transmission jack under transmis-
verse link to housing. sion.
• Except sedan turbo MODEL NOTE:
Make sure that the support plates of transmission
jack don't touch the oil pan.
30) Remove the transmission rear crossmember
from vehicle.
S4M0090
• Sedan turbo MODEL
S2M0221
31) Remove the transmission.

CAUTION:
Move the transmission and torque converter as
a unit away from engine.
TR0090
27) Remove the spring pins and separate the front

drive shafts from each side of transmission.
B3M0035
32) Separate the transmission assembly and rear

cushion rubber.
B: INSTALLATION
G2M0325 1) Install the rear cushion rubber to transmission
assembly.
transmission to engine. Tightening torque:
39 N·m (4.0 kgf-m, 29 ft-lb)
2) Install the ST to torque converter clutch case.
B3M2047
H2M1961A
AT-21
3) Install the transmission onto engine. 8) Connect the engine and transmission.
(1) Gradually raise the transmission with trans- (1) Remove the ST from torque converter clutch
mission jack. case.
NOTE:
Be careful not to drop the ST into torque converter
clutch case when removing the ST.
(2) Install the starter.
<Ref. to SC-6, INSTALLATION, Starter.>
(3) Tighten the bolt which holds right upper side
of transmission to engine.
Tightening torque:
B2M0035 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 N·m (7.1 kgf-m, 51 ft-lb)
B3M2044
9) Install the torque converter clutch to drive plate.

er clutch to drive plate.
(2) Tighten the other bolts while rotating the en-
S2M0021A
gine by using ST.
NOTE:
5) Take off the transmission jack.
Be careful not to drop bolts into torque converter
6) Tighten the nuts and bolts which hold lower side
clutch housing.
of transmission to engine.
Except 2.5 L model
Tightening torque: ST 499977300 CRANK PULLEY WRENCH
50 N·m (5.1 kgf-m, 36.9 ft-lb) 2.5 L model
Tightening torque:
25 N·m (2.5 kgf-m, 18.1 ft-lb)
B3M2047
S2M0207
(3) Clog the plug onto service hole.
AT-22
10) Remove the ST. 14) Tighten the installing bolts.

Tightening torque:
49 N·m (5.0 kgf-m, 36 ft-lb)
G2M0313

B2M3402A
Tightening torque:
T1: 50 N·m (5.1 kgf-m, 37 ft-lb)
(A) Transverse link
T2: 58 N·m (5.9 kgf-m, 43 ft-lb)
(B) Ball joint
15) Install the stabilizer link from transverse link.

• Except sedan turbo MODEL
Tightening torque:
30 N·m (3.1 kgf-m, 22.1 ft-lb)
H3M1839A

Install the front drive shafts into transmission.
(1) Lift-up the vehicle.
(2) Install the front drive shaft into transmission.
(3) Drive a new spring pin into chamfered hole TR0089
of drive shaft. • Sedan turbo MODEL
Tightening torque:
45 N·m (4.6 kgf-m, 33.2 ft-lb)
G2M0325
13) Connect the ball joint into housing.

TR0090
16) Install the shift select cable onto select lever.

<Ref. to CS-9, INSTALLATION, Select Cable.>
AT-23
17) Install the ATF level gauge guide, and connect 28) Install the air cleaner case stay. (Non-turbo
the ATF cooler hoses to pipe. model)
Tightening torque:
16 N·m (1.6 kgf-m, 11.6 ft-lb)
29) Install the air cleaner case and intake duct.
(Non-turbo model) <Ref. to IN-6, INSTALLATION,
Air Cleaner Case.>, <Ref. to IN-7, INSTALLATION,
Air Intake Duct.>
30) Install the intercooler. (Turbo model)
<Ref. to IN(TURBO)-11, INSTALLATION, Inter-
cooler.>
B3M2191 31) Connect the battery ground cable to battery.
18) Install the propeller shaft. <Ref. to DS-16, IN- level gauge by using the gauge hole. <Ref. to AT-9,
STALLATION, Propeller Shaft.> Automatic Transmission Fluid.>
19) Install the heat shield cover. (If equipped) 33) Take off the vehicle from lift arms.
20) Install the rear exhaust pipe and muffler as- 34) Check the select lever operation.
sembly. <Ref. to AT-28, INSPECTION, Inhibitor Switch.>
Non-turbo model 35) Check the ATF level. <Ref. to AT-9, Automatic
<Ref. to EX(w/oOBD)-13, INSTALLATION, Rear Transmission Fluid.>
Exhaust Pipe.> and <Ref. to EX(w/oOBD)-14, IN- 36) Check the vehicle on the road tester. <Ref. to
STALLATION, Muffler.> or <Ref. to EX-11, IN- AT-12, Road Test.>
STALLATION, Rear Exhaust Pipe.> and <Ref. to
EX-12, INSTALLATION, Muffler.>
Turbo model
LATION, Muffler.>
21) Install the front and center exhaust pipe. (Non-
turbo model) <Ref. to EX(w/oOBD)-10, INSTALLA-
TION, Front Exhaust Pipe.> or <Ref. to EX-8, IN-
STALLATION, Front Exhaust Pipe.>
22) Install the center exhaust pipe. (Turbo model)
Exhaust Pipe.>
25) Install the ATF level gauge.
S2M0214
26) Connect the following connectors.

(1) Transmission harness connectors
27) Connect the following cables.
(1) Cruise control cable (With cruise control ve-
hicles)
AT-24
TRANSMISSION MOUNTING SYSTEM
10.Transmission Mounting Sys- 7) Remove the transmission rear crossmember.

tem
A: REMOVAL
1. PITCHING STOPPER
2) Remove the air cleaner case. (Non-turbo model)
<Ref. to IN(TURBO)-10, REMOVAL, Intercooler.>
S2M0221
8) Remove the rear cushion rubber.
B: INSTALLATION
1. PITCHING STOPPER
Tightening torque:
T1: 50 N·m (5.1 kgf-m, 37 ft-lb)
T2: 58 N·m (5.9 kgf-m, 43 ft-lb)
TR0072
2. CROSSMEMBER AND CUSHION RUB-

BER
T1
2) Jack-up the vehicle and support it with sturdy T2
racks.
3) Remove the front, center, rear exhaust pipes
and muffler. (Non-turbo model) <Ref. to EX(w/
oOBD)-9, REMOVAL, Front Exhaust Pipe.>, <Ref. TR0086
to EX(w/oOBD)-13, REMOVAL, Rear Exhaust
2) Install the air cleaner case. (Non-turbo model)
Pipe.> and <Ref. to EX(w/oOBD)-14, REMOVAL,
Muffler.> or <Ref. to EX-7, REMOVAL, Front Ex-
3) Install the intercooler. (Turbo model).
haust Pipe.>, <Ref. to EX-11, REMOVAL, Rear Ex-
haust Pipe.> and <Ref. to EX-12, REMOVAL, <Ref. to IN(TURBO)-11, INSTALLATION, Inter-
Muffler.> cooler.>
fler. (Turbo model)
Rear Exhaust Pipe.> and <Ref. to EX(TURBO)-14,
REMOVAL, Muffler.>
6) Set the transmission jack under the transmis-
sion.
CAUTION:
Make sure that the support plates of transmis-
sion jack don't touch the oil pan.
AT-25
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 ft-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:
T1: 35 N·m (3.6 kgf-m, 26 ft-lb) 2. CROSSMEMBER AND CUSHION RUB-
T2: 70 N·m (7.1 kgf-m, 51 ft-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.
S2M0221A
3) Remove the transmission jack.

5) Install the front, center, rear exhaust pipes and
the muffler. (Non-turbo model) <Ref. to EX(w/
oOBD)-10, INSTALLATION, Front Exhaust Pipe.>,
Exhaust Pipe.> and <Ref. to EX(w/oOBD)-14, IN-
STALLATION, Muffler.> or <Ref. to EX-8, INSTAL-
LATION, Front Exhaust Pipe.>, <Ref. to EX-11,
INSTALLATION, Rear Exhaust Pipe.> and <Ref. to
EX-12, INSTALLATION, Muffler.>
6) Install the center, rear exhaust pipe and muffler.
(Turbo model)
LATION, Rear Exhaust Pipe.> and <Ref. to
EX(TURBO)-14, INSTALLATION, Muffler.>
AT-26
EXTENSION CASE OIL SEAL
11.Extension Case Oil Seal 10) Install the rear exhaust pipe and muffler.
Non-turbo model
A: INSPECTION <Ref. to EX(w/oOBD)-13, INSTALLATION, Rear
Make sure the ATF does not leak from the joint of Exhaust Pipe.> and <Ref. to EX(w/oOBD)-14, IN-
transmission and propeller shaft. If so, replace the STALLATION, Muffler.> or <Ref. to EX-11, IN-
oil seal. <Ref. to AT-27, REPLACEMENT, Exten- STALLATION, Rear Exhaust Pipe.> and <Ref. to
sion Case Oil Seal.> EX-12, INSTALLATION, Muffler.>
B: REPLACEMENT Turbo model
<Ref. to EX(TURBO)-13, Installation, Rear Ex-
1) Clean the transmission exterior.
haust Pipe.> and <Ref. to EX(TURBO)-14, IN-
2) Drain the ATF completely.
NOTE: 11) Pour ATF and check the ATF level. <Ref. to
Tighten the ATF drain plug after draining the ATF. AT-9, Automatic Transmission Fluid.>
Tightening torque:
25 N·m (2.5 kgf-m, 18.1 ft-lb)
B3M1036B
(A) Oil pan

(B) Drain plug

Non-turbo model
haust Pipe.> and <Ref. to EX(w/oOBD)-14, RE-
MOVAL, Muffler.> or <Ref. to EX-11, REMOVAL,
Rear Exhaust Pipe.> and <Ref. to EX-12, REMOV-
AL, Muffler.>
Turbo model
haust Pipe.> and <Ref. to EX(TURBO)-14, RE-
MOVAL, Muffler.>
5) Remove the propeller shaft. <Ref. to DS-15, RE-
MOVAL, Propeller Shaft.>
6) Using the ST, remove the oil seal.
ST 398527700 PULLER ASSY
7) Using the ST, install the oil seal.
ST 498057300 INSTALLER
8) Install the propeller shaft. <Ref. to DS-16, IN-
STALLATION, Propeller Shaft.>
AT-27
INHIBITOR SWITCH
12.Inhibitor Switch 3) Check if there is continuity at equal points when

the select lever is turned 1.5° in both directions
A: INSPECTION from “N” range.
When the driving condition or starter motor opera- If there is continuity in one direction and the conti-
tion is erroneous, first check the shift linkage for im- nuity in the other or if there is continuity at unequal
proper operation. If the shift linkage is functioning points, adjust the inhibitor switch. <Ref. to AT-28,
properly, check the inhibitor switch. ADJUSTMENT, Inhibitor Switch.>
1) Disconnect the inhibitor switch connector.
2) Check continuity in inhibitor switch circuits with
the select lever moved to each position.
NOTE:
Also check that continuity in ignition circuit does not
exist when the select lever is in “R”, “D”, “3”, “2” and
“1” ranges.
NOTE:
If the inhibitor switch is inoperative, check for poor
contact of connector on transmission side. B3M1586A
Position Pin No.

(A) Continuity does not exist.
P 4—3
(B) Continuity exists.
R 4—2
(C) 1.5°
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-10, AD-
2 4—6 JUSTMENT, Select Cable.>
1 4—5 B: ADJUSTMENT
Ignition circuit P/N 12 — 11 1) Shift the select lever to “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 inhibitor switch lever and switch body.
ST 499267300 STOPPER PIN
B3H0016B
B3M1027A
4) Tighten the three inhibitor switch bolts.

Tightening torque:
3.5 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
INHIBITOR SWITCH
C: REMOVAL 10) Remove the plate assembly from transmission

1) Set up the vehicle on a lift. case.
2) Move the select lever to “N” range.
5) Disconnect the inhibitor switch connector.
B3M1030H
(A) Select cable

(B) Plate ASSY
11) Remove the bolts.

B3M1028B
(A) Inhibitor switch
6) Remove the inhibitor switch connector from stay.

Pipe.> or <Ref. to EX-7, REMOVAL, Front Exhaust
Pipe.>
B3M1031B
9) Remove the snap pin and washer from range se-
lect lever.
12) Move the range select lever to parking position

(left side).
TR0908
(A) Snap pin

(B) Select cable B3M1032B
(C) Range select lever
(D) Washer (A) Range select lever
AT-29
INHIBITOR SWITCH
13) Remove the inhibitor switch from transmission. 6) Install the plate assembly to transmission.
Tightening torque:
T: 25 N·m (2.5 kgf-m, 18.1 ft-lb)
B3M1033B

B3M1030I
14) Disconnect the inhibitor switch harness con-
nector from inhibitor switch. (A) Select cable
(B) Plate ASSY
D: INSTALLATION
1) Connect the inhibitor switch harness connector 7) Install the washer and snap pin to range select
to inhibitor switch. lever.
2) Install the inhibitor switch to transmission case.
TR0908
B3M1033B
(A) Snap ring
(A) Inhibitor switch (B) Select cable
(C) Range select lever
3) Move the range select lever to neutral position.
4) Using the ST, tighten the bolts of inhibitor switch. (D) Washer
ST 499267300 STOPPER PIN 8) Install the front and center exhaust pipes. (Non-
Tightening torque: turbo model)
3.5 N·m (0.36 kgf-m, 2.6 ft-lb) Except 3.0 L model
Exhaust Pipe.> or <Ref. to EX-8, INSTALLATION,
Front Exhaust Pipe.>
Exhaust Pipe.>
11) Install the inhibitor switch connector from stay.
B3M1034B

(B) Range select lever
5) Install the select cable to range select lever.
AT-30
INHIBITOR SWITCH
12) Connect the inhibitor switch connector.
B3M1028B

cooler.>
15) Inspect the inhibitor switch. <Ref. to AT-28, IN-
SPECTION, Inhibitor Switch.>
AT-31
FRONT VEHICLE SPEED SENSOR
13.Front Vehicle Speed Sensor 10) Drain the ATF completely.

NOTE:
A: REMOVAL Tighten the ATF drain plug after draining the ATF.
1) Set up the vehicle on a lift.
25 N·m (2.5 kgf-m, 18.1 ft-lb)
G6M0095
B3M1036B
(A) Oil pan
(B) Drain plug
5) Disconnect the transmission connector.
11) Remove the front, center, exhaust pipes and
muffler. (Non-turbo model)
Pipe.>, <Ref. to EX(w/oOBD)-13, REMOVAL, Rear
Exhaust Pipe.> and <Ref. to EX(w/oOBD)-14, RE-
Front Exhaust Pipe.>, <Ref. to EX-11, REMOVAL,
AL, Muffler.>
S3M0039B fler. (Turbo model)
(A) Transmission connector haust Pipe.>, <Ref. to EX(TURBO)-13, REMOVAL,
6) Remove the pitching stopper. <Ref. to AT-25, Rear Exhaust Pipe.> and <Ref. to EX(TURBO)-14,
REMOVAL, Transmission Mounting System.> REMOVAL, Muffler.>
7) Remove the transmission connector from stay. 13) Remove the shield cover. (If equipped)
8) Lift-up the vehicle. 14) Remove the propeller shaft. <Ref. to DS-15,
REMOVAL, Propeller Shaft.>
15) Place the transmission jack under transmis-
sion.
NOTE:
Make sure that the support plates of transmission
jack don't touch the crossmember.
AT-32
16) Remove the transmission rear crossmember 21) Disconnect the duty solenoids and ATF tem-
bolts. perature sensor connectors. Remove the connec-
tors from clip and disconnect the connectors.
TR0544
B3M2263I
17) Lower the AT jack.
NOTE: (A) Lock-up duty solenoid (Blue)
Do not separate the AT jack and transmission. (B) Low clutch timing solenoid (Gray)
18) Remove the oil cooler inlet and outlet pipe. (C) Line pressure duty solenoid (Red)
NOTE: (D) Shift solenoid 2 (Yellow)
When removing the outlet pipe, be careful not to (E) Shift solenoid 1 (Green)
lose balls and springs used with retaining screws. (F) 2-4 brake timing solenoid (Black)
19) Remove the front and rear vehicle speed sen- (G) 2-4 brake duty solenoid (Red)
sor and torque converter turbine speed sensor. (H) ATF temperature sensor
• Front vehicle speed sensor and torque (I) Transfer duty solenoid (Brown)
converter turbine speed sensor (J) Transmission ground
22) Remove the harness assembly.

B: INSTALLATION
1) Pass the harness assembly through the hole in
the transmission case.
B3M1066B
(A) Front vehicle speed sensor

(B) Torque converter turbine speed sensor
• Rear vehicle speed sensor

B3M1067
B3M1056B
(A) Rear vehicle speed sensor

(B) Front vehicle speed sensor
20) Remove the oil pan.
AT-33
2) Connect the harness connectors. 4) Apply liquid gasket fully to three holes other than
Connect the connectors of same color, and secure screw holes on transmission case.
the connectors to valve body using clips.
Fluid packing:
Tightening torque (Transmission ground cable) THREE BOND 1217B
8 N·m (0.8 kgf-m, 5.8 ft-lb)
B3M2265
B2M22631
5) Install the oil pan.
(A) Lock-up duty solenoid (Blue) Tightening torque:
(B) Low clutch timing solenoid (Gray) 5 N·m (0.5 kgf-m, 3.6 ft-lb)
(C) Line pressure duty solenoid (Red) 6) Install the front and rear vehicle speed sensor,
(D) Shift solenoid 2 (Yellow) and also the torque converter turbine speed sen-
(E) Shift solenoid 1 (Green) sor, and then fasten the harness.
(F) 2-4 brake timing solenoid (Black) Tightening torque:
(G) 2-4 brake duty solenoid (Red) 7 N·m (0.7 kgf-m, 5.1 ft-lb)
(H) ATF temperature sensor 7) Install the oil cooler pipes.
(I) Transfer duty solenoid (Brown)
NOTE:
(J) Transmission ground
Be sure to use a new aluminum washer.
3) Apply proper amount of liquid gasket to the en- Tightening torque:
tire oil pan mating surface. T1: 44 N·m (4.5 kgf-m, 32.5 ft-lb)
Fluid packing: T2: 25 N·m (2.5 kgf-m, 18.1 ft-lb)
THREE BOND 1217B
B3M2059A
B3M1040
8) Install the transmission rear crossmember bolts.
Tightening torque:
70 N·m (7.1 kgf-m, 51 ft-lb)
AT-34

10) Install the shield cover. (If equipped)
11) Install the front, center, rear exhaust pipes and
muffler. (Non-turbo model)
STALLATION, Rear Exhaust Pipe.> and <Ref. to
EX(w/oOBD)-14, INSTALLATION, Muffler.> or
Pipe.>, <Ref. to EX-11, INSTALLATION, Rear Ex-
haust Pipe.> and <Ref. to EX-12, INSTALLATION,
Muffler.>
12) Install the center, rear exhaust pipes and muf-
fler. (Turbo model)
14) Install the transmission connector to the stay.
15) Install the pitching stopper. <Ref. to AT-25, IN-
STALLATION, Transmission Mounting System.>
cooler.>
AT-35
REAR VEHICLE SPEED SENSOR
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-36
TORQUE CONVERTER TURBINE SPEED SENSOR
15.Torque Converter Turbine

Speed Sensor
A: REMOVAL
When removing the torque converter turbine speed
sensor, refer to “Front Vehicle Speed Sensor.”
<Ref. to AT-32, REMOVAL, Front Vehicle Speed
Sensor.>
B: INSTALLATION
When installing the torque converter turbine speed
sensor, refer to “Front Vehicle Speed Sensor.”
<Ref. to AT-33, INSTALLATION, Front Vehicle
Speed Sensor.>
AT-37
CONTROL VALVE BODY
16.Control Valve Body 5) Disconnect the duty solenoids and ATF temper-
ature sensor connectors. Remove the connectors
A: REMOVAL from clip and disconnect the connectors.
NOTE:
Tighten the ATF drain plug after draining the ATF.
Tightening torque:
25 N·m (2.5 kgf-m, 18.1 ft-lb)
B2M2263I
(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)
B3M1036B
(G) 2-4 brake duty solenoid (Red)
(H) ATF temperature sensor
(A) Oil pan
(B) Drain plug
(J) Transmission ground
6) Remove the control valve.
4) Remove the oil pan.
NOTE:
NOTE: When removing the control valve body, be careful
• Remove and clean the magnet. not to interfere with transfer duty solenoid wiring.
• Remove the old gasket on the oil pan and trans-
mission case completely.
B3M1037
AT-38
CONTROL VALVE BODY
B: INSTALLATION 5) Apply proper amount of liquid gasket to the en-

1) Set the range select lever in “N” range. tire oil pan mating surface.
2) Install the control valve and ground connectors. Fluid packing:
Tightening torque: THREE BOND 1217B
8 N·m (0.8 kgf-m, 5.8 ft-lb)
B3M1040
B3M1037A 6) Apply liquid gasket fully to three holes other than

screw holes on transmission case.
(A) Short bolts
(B) Long bolts
Fluid packing:
THREE BOND 1217B
3) Connect all connectors.
B3M2265
B3M2263I
7) Install the oil pan.
(A) Lock-up duty solenoid (Blue) Tightening torque:
(B) Low clutch timing solenoid (Gray) 5 N·m (0.5 kgf-m, 3.6 ft-lb)
(C) Line pressure duty solenoid (Red) 8) Pour ATF into the oil charge pipe.
Recommended fluid:
(G) 2-4 brake duty solenoid (Red) Fluid capacity:
(H) ATF temperature sensor Fill the same amount of fluid drained from
(I) Transfer duty solenoid (Brown) drain plug hole.
(J) Transmission ground 9) Check the level of ATF.
<Ref. to AT-9, Automatic Transmission Fluid.>
4) Attach the magnet at the specified position.
C: DISASSEMBLY
Refer to “AUTOMATIC TRANSMISSION” <Pub.
No. G0864ZE> a separate publication.
D: ASSEMBLY
E: INSPECTION
B3M1105
AT-39
SHIFT SOLENOIDS, DUTY SOLENOIDS AND ATF TEMPERATURE SENSOR
17.Shift Solenoids, Duty Sole- 6) Remove the solenoids, duty solenoids and ATF
temperature sensor.
noids and ATF Temperature
Sensor
A: REMOVAL
NOTE:
Tighten the ATF drain plug after draining the ATF.
Tightening torque: B3M1039A
25 N·m (2.5 kgf-m, 18.1 ft-lb)
B3M1036C
1. TRANSFER DUTY SOLENOID AND
TRANSFER VALVE BODY
(A) Oil pan 1) Set the vehicle on a lift.
(B) Drain plug 2) Disconnect the ground cable from battery.
4) Remove the oil pan. <Ref. to IN-6, INSTALLATION, Air Cleaner Case.>
5) Disconnect the solenoid and sensor connectors. 4) Remove the intercooler. (Turbo model)
Remove the connectors from clip and disconnect <Ref. to IN(TURBO)-10, REMOVAL, Intercooler.>
the connectors. 5) Remove the pitching stopper.
B2M2263J
H3M1839
(A) Lock-up duty solenoid (Blue) 6) Remove the front exhaust pipe with center ex-
(B) Low clutch timing solenoid (Gray) haust pipe. (Non-turbo model)
(C) Line pressure duty solenoid (Red) <Ref. to EX(w/oOBD)-9, REMOVAL, Front Exhaust
(D) Shift solenoid 2 (Yellow) Pipe.> or <Ref. to EX-7, REMOVAL, Front Exhaust
Pipe.>
7) Remove the center exhaust pipe. (Turbo model)
haust Pipe.>
AT-40
8) Remove the rear exhaust pipe and muffler. 13) Remove the rear vehicle speed sensor.
Non-turbo model
haust Pipe.> and <Ref. to EX(w/oOBD)-14, RE-
AL, Muffler.>
Turbo model
haust Pipe.> and <Ref. to EX(TURBO)-14, RE-
MOVAL, Muffler.>
9) Raise the vehicle and drain the ATF. B3M1043
14) Remove the select cable nut.
B3M1036B
B3M0308
(A) Oil pan
(B) Drain plug 15) Move the gear select cable so that extension
(C) Deferential oil drain plug bolts can be removed.
16) Remove the bolts.
10) Remove the heat shield cover. 17) Remove the extension case.
11) Remove the propeller shaft. <Ref. to DS-15, NOTE:
REMOVAL, Propeller Shaft.> Use a container to catch oil flowing from extension.
12) Remove the transmission 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.
B3M1044
18) Disconnect the transfer duty solenoid connec-

tor.
S2M0221
AT-41
19) Remove the transfer duty solenoid and transfer 2) Connect the harness connectors.
valve body. Connect the connectors of same color, and secure
the connectors to valve body using clips.
B3M1045F
B2M2263J
(A) Transfer valve body
(B) Transfer duty solenoid connector (A) Lock-up duty solenoid (Blue)
(C) Transfer duty solenoid (B) Low clutch timing solenoid (Gray)
B: INSTALLATION (D) Shift solenoid 2 (Yellow)
1) Install the solenoids and ATF temperature sen- (E) Shift solenoid 1 (Green)
sor. (F) 2-4 brake timing solenoid (Black)
Tightening torque: (G) 2-4 brake duty solenoid (Red)
T: 8 N·m (0.8 kgf-m, 5.8 ft-lb) (H) ATF temperature sensor
3) Apply proper amount of liquid gasket to the en-

tire oil pan mating surface.
Fluid packing:
THREE BOND 1217B
B3M1039B

(E) Shift solenoid 1 (Green) B3M1040
(F) 2-4 brake timing solenoid (Black) 4) Apply liquid gasket fully to three holes other than
(G) 2-4 brake duty solenoid (Red) screw holes on transmission case.
Fluid packing:
THREE BOND 1217B
B3M2265
AT-42
5) Install the oil pan. 2) Install the extension case to transmission case.
(1) Tighten eleven bolts.
Tightening torque:
5 N·m (0.5 kgf-m, 3.6 ft-lb) Tightening torque:
25 N·m (2.5 kgf-m, 18.1 ft-lb)
(2) Adjust the select cable. <Ref. to CS-10, AD-
JUSTMENT, Select Cable.>
3) Install the rear vehicle speed sensor.
Tightening torque:
T: 7 N·m (0.7 kgf-m, 5.1 ft-lb)
B3M1036C
(A) Oil pan

(B) Drain plug

level gauge by using the gauge hole. <Ref. to AT-9,
Automatic Transmission Fluid.> B3M1043A
7) Check the ATF level. <Ref. to AT-9, Automatic
Transmission Fluid.>
(1) Tighten the bolts.
1. TRANSFER DUTY SOLENOID AND Tightening torque:
TRANSFER VALVE BODY T1: 35 N·m (3.6 kgf-m, 26 ft-lb)
1) Install the transfer duty solenoid and transfer T2: 70 N·m (7.1 kgf-m, 51 ft-lb)
valve body.
(1) Install the transfer duty solenoid and trans-
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.
S2M0221B
(2) Lower and remove the transmission jack.

6) Install the front, center rear exhaust pipe and
muffler. (Turbo model) <Ref. to EX(w/oOBD)-10,
INSTALLATION, Front Exhaust Pipe.>, <Ref. to
B3M1045G EX(w/oOBD)-13, INSTALLATION, Rear Exhaust
Pipe.> and <Ref. to EX(w/oOBD)-14, INSTALLA-
(A) Transfer valve body TION, Muffler.> or <Ref. to EX-8, INSTALLATION,
(B) Transfer duty solenoid connector Front Exhaust Pipe.>, <Ref. to EX-11, INSTALLA-
(C) Transfer duty solenoid TION, Rear Exhaust Pipe.> and <Ref. to EX-12, IN-
7) Install the center, rear exhaust pipes and muf-
fler. (Turbo model)
AT-43
8) Lower and remove the jack.

9) Connect the transmission harness connector.
S2M0212

Tightening torque:
T1: 50 N·m (5.1 kgf-m, 37 ft-lb)
T2: 58 N·m (5.9 kgf-m, 43 ft-lb)
H3M1839A
11) Install the air cleaner case. <Ref. to IN-6, IN-

STALLATION, Air Cleaner Case.>
cooler.>
level gauge by using the gauge hole. <Ref. to AT-9,
Automatic Transmission Fluid.>
14) Check the ATF level. <Ref. to AT-9, Automatic
Transmission Fluid.>
AT-44
ATF FILTER
18.ATF Filter
A: REMOVAL
NOTE:
The ATF filter is maintenance free.
2) Using the ST, remove the ATF filter.
B3M1665B
(A) ATF filter
3) Use a new ATF filter and apply a thin coat of ATF

to the oil seal.
B: INSTALLATION
1) Install the ATF filter. Turn it by hand, being care-
ful not to damage the oil seal.
2) Using the ST, tighten the ATF filter to transmis-
sion case.
Calculate the ATF filter torque specifications using
the following formula.
T2 = L2/(L1 + L2) × T1
T1: 14 N·m (1.4 kgf-m, 10.1 ft-lb)
[Required torque setting]
T2: Tightening torque
L1: ST length 0.078 m (3.07 in)
L2: Torque wrench length
Example:
Torque wrench length Tightening torque
mm (in) N·m (kgf-m, ft-lb)
100 (3.94) 7.7 (0.79, 5.7)
150 (5.91) 9.0 (0.92, 6.7)
200 (7.87) 10 (1.0, 7.2)
NOTE:
Align the ST with torque wrench while tightening
ATF filter.
3) Add ATF.
4) Inspect the level of ATF. <Ref. to AT-9, Automat-
ic Transmission Fluid.>
AT-45
TRANSMISSION CONTROL MODULE (TCM)
19.Transmission Control Mod- 3) Disconnect the connectors from transmission

control module.
ule (TCM) • LHD MODEL
A: REMOVAL
B3M1592A
(A) Transmission control module

G6M0095
(B) Brake pedal bracket
2) Remove the lower cover and then disconnect
the connector. • RHD MODEL
B3M1591 B3M1593A

(B) Column shaft
4) Remove the transmission control module.
AT-46
TRANSMISSION CONTROL MODULE (TCM)
B: INSTALLATION
1) Install the transmission control module.
Tightening torque:
LHD model
7.5 N·m (0.76 kgf-m, 5.5 ft-lb)
RHD model
25 N·m (2.5 kgf-m, 18.1 ft-lb)
• LHD MODEL
B3M1592A

(B) Brake pedal bracket
• RHD MODEL
B3M1648A

(B) Column shaft
2) Connect the connectors to transmission control

module.
AT-47
ATF COOLER PIPE AND HOSE
20.ATF Cooler Pipe and Hose 7) Remove the ATF cooler pipe from frame.
A: REMOVAL
2) Remove the battery and washer tank.
5) Disconnect the ATF cooler hose from radiator.
NOTE:
• Do not remove with a screwdriver or other point-
ed tools.
• 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.
B3M2054
8) Remove the oil cooler inlet and outlet pipes.

B3M2052
NOTE:
6) Disconnect the ATF cooler hoses from pipes. When removing the outlet pipe, be careful not to
NOTE: lose ball and spring used with retaining screw.
• Do not remove with a screwdriver or other point-
ed tools.
• 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.
B3M2059B
(A) Inlet pipe

(B) Outlet pipe
B3M2191
AT-48
B: INSTALLATION 3) Connect the ATF cooler hose to pipe transmis-

1) Install the oil cooler outlet and inlet pipes. sion side.
NOTE: NOTE:
Be sure to use a new aluminum washer. • Install so that the hose is not folded over, exces-
sively bent, or twisted.
Tightening torque: • Be careful to insert the hose to the specified po-
T1: 44 N·m (4.5 kgf-m, 32.5 ft-lb) sition.
T2: 25 N·m (2.5 kgf-m, 18.1 ft-lb)
B3M2191
B3M2059A
4) Connect the ATF cooler hose to the pipe of radi-
2) Install the ATF cooler pipe to frame. ator side.
NOTE:
• Install so that the hose is not folded over, exces-
sively bent, or twisted.
• Be careful to insert the hose to the specified po-
sition.
B3M2052

6) Install the battery and washer tank.
7) Fill ATF. <Ref. to AT-9, Automatic Transmission
Fluid.>
B3M2054
NOTE:
Make sure there are no ATF leaks in joints between
the transmission, radiator, pipes, and hoses.
AT-49
C: INSPECTION
Repair or replace any defective hoses, pipes,
clamps, and washers found from the inspection be-
low.
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 by pressing with your
fingernail.
5) Check for peeling, cracks, and deformation at
the tip of the hose.
AT-50
(DIAGNOSTICS)
AT
Page
4. Electrical Components Location..................................................................8
8. Inspection Mode........................................................................................24
10. POWER Indicator Light Display ................................................................26
12. Diagnostic Procedure for POWER Indicator Light ....................................28
13. Diagnostic Procedure for Select Monitor Communication.........................37
15. Diagnostic Procedure for No-diagnostic Trouble Code (DTC) ................105
16. Symptom Related Diagnostic..................................................................133
AUTOMATIC TRANSMISSION (DIAGNOSTICS)

A: PROCEDURE
Step Check Yes No
1 CHECK PRE-INSPECTION. Is the unit that might influence Go to step 2. Repair or replace
1)Ask the customer when and how trouble AT problem normal? each item.
occurred using interview checklist. <Ref. to
AT-4, Check List for Interview.>
2)Before performing the diagnosis, inspect 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-13, Stall Test.>
•Line pressure test <Ref. to AT-16, Line Pres-
sure Test.>
•Transfer clutch pressure test <Ref. to AT-18,
Transfer Clutch Pressure Test.>
•Time lag test <Ref. to AT-15, Time Lag Test.>
•Road test <Ref. to AT-12, Road Test.>
•Inhibitor switch <Ref. to AT-28, Inhibitor
Switch.>
2 CHECK POWER INDICATOR LIGHT. Does not the POWER indicator Go to step 3. Go to step 4.
Turn the ignition switch to ON. light up?
3 CHECK POWER INDICATOR LIGHT. Is the POWER indicator light Go to step 4. Go to step 5.
1)Turn the ignition switch to OFF. flashing?
2)Repair the POWER indicator light circuit or
power supply and ground line circuit.
<Ref. to AT-28, Diagnostic Procedure for
POWER Indicator Light.>
4 CHECK INDICATION OF DIAGNOSTIC Is the DTC displayed? Go to step 6. Go to step 5.
TROUBLE CODE (DTC). NOTE:
Calling up the DTC. Record all DTC.
Without SUBARU SELECT MONITOR
<Ref. to AT-22, WITHOUT SUBARU SELECT
MONITOR, Read Diagnostic Trouble Code
(DTC).>
With SUBARU SELECT MONITOR
<Ref. to AT-23, WITH SUBARU SELECT
(DTC).>
NOTE:
If the communication function of select monitor
cannot be executed normally, check the com-
munication circuit. <Ref. to AT-37, COMMUNI-
CATION FOR INITIALIZING IMPOSSIBLE,
Diagnostic Procedure for Select Monitor Com-
munication.>
AT-2
Step Check Yes No

5 PERFORM THE GENERAL DIAGNOSTICS. Is the DTC displayed? Complete the Go to step 6.
1)Inspect using “Diagnostic Procedure for No- diagnosis.
diagnostic trouble code (DTC)”.<Ref. to AT-
105, Diagnostic Procedure for No-diagnostic
2)Inspect using “Symptom Related Diagnos-
tic”. <Ref. to AT-133, Symptom Related Diag-
nostic.>
3)Perform the clear memory mode.
MONITOR, Clear Memory Mode.>
4)Perform the inspection mode. <Ref. to AT-
Calling up the DTC.
(DTC).>
MONITOR, OPERATION, Read Diagnostic
6 PERFORM THE DIAGNOSIS. Is the DTC displayed? Complete the Inspect using
1)Inspect using “Diagnostics Chart with Diag- diagnosis. “Diagnostics Chart
nostic Trouble Code (DTC)”.<Ref. to AT-42, with Diagnostic
Diagnostic Procedure with Diagnostic Trouble Connector”. <Ref.
Code (DTC).> to AT-42, Diagnos-
NOTE: tic Procedure with
For trouble code table, refer to “List of Diagnos- Diagnostic Trou-
tic Trouble Code (DTC)”.<Ref. to AT-27, List of ble Code (DTC).>
2)Repair the trouble cause.
3)Perform the clear memory mode.
MONITOR, OPERATION, Clear Memory
Mode.>
4)Perform the inspection mode. <Ref. to AT-
5)Calling up the DTC.
AT-3

A: CHECK
NOTE:
Customer's name
Data vehicle brought in
Data of repair
Trans. model TRANSMISSION VIN
Odometer reading km/h or mile
Frequency ❏ Continuous ❏ Intermittent ( times a day)
Weather ❏ Fine ❏ Cloudy ❏ Rainy ❏ Snowy
❏ Various/Others
( )
Place ❏ High ❏ Suburbs ❏ Inner city ❏ Uphill ❏ Rough road
❏ Others
( )
Outdoor temperature ❏ Hot ❏ Warm ❏ Cool ❏ Cold
Vehicle speed km/h (MPH)
Malfunction indicator lamp (MIL) ❏ Continuously lit ❏ Not lit
Select lever position ❏P ❏R ❏N ❏D ❏3 ❏2 ❏1
Driving condition ❏ Not affected ❏ At starting ❏ While idling
❏ At racing ❏ While accelerating ❏ While cruising
❏ While decelerating ❏ While turning (❏ RH/❏
LH)
POWER switch ❏ ON ❏ OFF
HOLD switch ❏ ON ❏ OFF
Symptoms ❏ No up-shift
❏ No down-shift
❏ No kick down
❏ Vehicle does not move (❏ Any position ❏ Particular position)
❏ Lock-up malfunction
❏ Noise or vibration
❏ Shift shock or slip
❏ Select lever does not move
❏ Others
( )
AT-4
GENERAL DESCRIPTION
3. General Description 3. ATF LEVEL

A: CAUTION Make sure that ATF level is in the specification.
<Ref. to AT-9, INSPECTION, Automatic Transmis-
• Supplemental Restraint System “Airbag”
sion Fluid.>
The airbag system wiring harness is routed near
the transmission control module (TCM).
CAUTION:
nectors are colored yellow. Do not use an elec-
trical test equipment on these circuit.
wiring harness when performing diagnostics
and servicing the TCM.
• Measurement
When measuring the voltage and resistance of B3M0173B
ECM, TCM or each sensor, use a tapered pin with

diameter of less than 0.64 mm (0.025 in) in order to (A) Upper level
avoid poor contact. Do not insert the pin more than (B) Lower level
6.5 mm (0.256 in).
4. FRONT DIFFERENTIAL OIL LEVEL
B: INSPECTION
Make sure that front differential oil level is in the
1. BATTERY specification. <Ref. to AT-11, INSPECTION, Differ-
Measure the battery voltage and specific gravity of ential Gear Oil.>
electrolyte.
Standard voltage: 12V or more
Specific gravity: Above 1.260
2. TRANSMISSION GROUND
Make sure that the ground terminal bolt is tightened
securely.
• Chassis side
Tightening torque: B3M0174B
13 N·m (1.3 kgf-m, 9.4 ft-lb)
(A) Upper level
(B) Lower level
5. OPERATION OF SHIFT SELECT LEVER

Make sure there is no abnormal noise, dragging or
contact pattern in each select lever range.
WARNING:
Stop the engine while checking operation of se-
lector lever.
TR0373
B3M1747
AT-5
GENERAL DESCRIPTION
6. POWER SWITCH 7. HOLD SWITCH

Make sure that the POWER indicator light in com- Make sure that the HOLD indicator light in combi-
bination meter comes ON, when turning the power nation meter comes ON, when turning the hold
switch to ON. switch to ON.
TR0377 TR0378
C: PREPARATION TOOL
1. SPECIAL TOOLS
(Newly adopted tool)
B2M3876
22771AA030 SELECT MONITOR Troubleshooting for electrical systems.
KIT • English:
• German:
• French:
• Spanish:
B2M3877

TOOL NAME REMARKS
Oscilloscope Used for measuring sensor.
AT-6
GENERAL DESCRIPTION
AT-7

A: LOCATION
1. CONTROL MODULE
(1)
(3) (2) (4)

TR0379
(3) (2) (4)
(1)
TR0521
(1) Engine control module (ECM) (3) Transmission control module (TCM)
(2) POWER indicator light (AT diagnostic indicator light) (4) Data link connector
AT-8
(2)
B3M1575A TR0383
B3M1592B B3M1652A
(4)
TR0382
AT-9
2. SENSOR
(1) (3) (6)
(5) (2) (4)

TR0385
(1) Throttle position sensor (4) Rear vehicle speed sensor (6) ATF temperature sensor
(2) Front vehicle speed sensor (5) Torque converter turbine speed
(3) Inhibitor switch sensor
AT-10
Non-turbo model
(2)
(4)
S2M0262B TR0387
Turbo model
(2)
(4)
(3)
TR0592 TR0388
(5)
(6)
TR0390 TR0389
AT-11
3. SOLENOID
B3M1186A
(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
B2M2263D B2M2264E
AT-12
AT-13

to B54 to B55
9 8 7 6 5 4 3 2 1 9 8 7 6 5 4 3 2 1
18 17 16 15 14 13 12 11 10 18 17 16 15 14 13 12 11 10
24 23 22 21 20 19 24 23 22 21 20 19
to B56
9 8 7 6 5 4 3 2 1
18 17 16 15 14 13 12 11 10
24 23 22 21 20 19
TR0532

Con- Resistance
Content nector Terminal No. Measuring conditions Voltage (V) to body
No. (ohms)
B54 24 engine OFF)
“P” range Select lever in any other
B55 1 —
switch than “P” range (except “N” More than 8
range)
“N” range Select lever in any other
B55 14 —
switch than “N” range (except “P” More than 8
range)
“R” range
B55 3 Select lever in any other —
switch More than 8
than “R” range
Inhibitor Select lever in “D” range Less than 1
switch “D” range
switch More than 8
than “D” range
“3” range
switch More than 8
than “3” range
“2” range
switch More than 8
than “2” range
“1” range
switch More than 8
than “1” range
AT-14

Con- Resistance
No. (ohms)
Throttle fully opened. Less than 1
Kick-down switch B55 11 —
Throttle fully closed. More than 6.5
AT OIL TEMP warning light B56 10 —
Throttle fully closed. 0.2 — 1.0
Throttle fully open. 4.2 — 4.7
Throttle position sensor Ignition switch ON (with
B54 2 4.8 — 5.3 —
power supply engine OFF)
1.6 — 2.0 2.1 k — 2.9 k
(68°F)
0.4 — 0.9 275 — 375
(176°F)
Vehicle stopped. 0
km/h (12 MPH)
Vehicle stopped. 0
Front vehicle speed sensor B55 18 Vehicle speed at least 20 450 — 650
km/h (12 MPH)
Engine idling after warm-
0
Torque converter turbine up. (D range)
B55 8 450 — 650
speed sensor Engine idling after warm-
up. (N range)
More than 10.5
engine OFF)
8 — 11
engine ON)
Less than 1
(SET lamp ON)
More than 6.5
set. (SET lamp OFF)
Torque control signal 1 B56 5 More than 4 —
engine ON)
Torque control signal 2 B56 14 More than 4 —
engine ON)
Intake manifold pressure Engine idling after warm-
B54 1 0.4 — 1.6 —
signal (Non-turbo model) up.
Mass air flow signal (Turbo Engine idling after warm-
B54 1 0.9 — 1.4 —
model) up.
AT-15

Con- Resistance
No. (ohms)
engine OFF)
1.5 — 4.0
warm-up.
engine OFF)
Less than 0.5
warm-up.
Transfer duty solenoid Fuse removed from FWD
B54 6 switch (with throttle fully 10 — 17
(Non-turbo model) Less than 0.5
open and with select lever
in 1st gear).
Transfer duty solenoid Throttle fully closed. More than 8.5
B56 6 10 — 17
(Turbo model) Throttle fully open. Less than 0.5
engine OFF) after warm- 1.5 — 5.0
up.
engine OFF) after warm- Less than 0.5
up.
Hold switch ON Less than 1 —
Hold switch B55 16
Hold switch OFF More than 8 —
Power switch ON Less than 1 —
Power switch B55 23
Power switch OFF More than 10 —
Light ON Less than 1 —
Power indicator light B56 11
Light OFF More than 9 —
Fuse removed. 6 — 9.1 —
FWD switch B55 20
Fuse installed. Less than 1 —
Fused ON FWD switch Less than 1 —
FWD indicator light B56 2 Fuse removed from FWD
More than 9 —
switch.
ABS switch ON Less than 1 —
ABS signal B55 21
ABS switch OFF 6.5 — 15 —
B56 19
B54 21
Less than 1 ←
AT diagnosis signal B56 21 Ignition switch ON —
→ More than 4
Data link signal (Subaru
B56 15 — — —
Select Monitor)
AT-16
AT-17
B: SCHEMATIC
(2) (31)
(3) (32)
(33)
(4) (34)
(35)
(5) (36) (39)
(37)
(6)
(38)
(7)
(40)
(1)
(8)
(9)
(41)
(10)
(11)
(42)
(12)
(13) (43)
(14)
(44)
(15) (45)
(17) (16) (46)
(19) (18) (47)
(21) (20) (48)
(23) (22) (49)
(25) (24) (50)
(27) (26) (51)
(29) (28)
(30)
TR0395
AT-18
(1) Transmission control module (18) “P” range switch (37) Non-turbo model:
(2) Cruise control module (19) “R” range indicator light Intake manifold pressure signal
(3) ABS control module (20) “R” range switch Turbo model:
Mass air flow signal
(4) Ignition switch (21) “N” range indicator light
(5) Brake switch (22) “N” range switch (38) AT diagnostics signal
(6) Brake light (23) “D” range indicator light (39) Engine control module
(7) Battery (24) “D” range switch (40) ATF temperature sensor
(8) Combination meter (Speedome- (25) “3” range indicator light (41) Torque converter turbine speed
ter circuit) (26) “3” range switch sensor
(9) AT OIL TEMP light (27) “2” range indicator light (42) Rear vehicle speed sensor
(10) FWD indicator light (Non-turbo (28) “2” range switch (43) Front vehicle speed sensor
model) (29) “1” range indicator light (44) Shift solenoid 1
(11) POWER indicator light (30) “1” range switch (45) Shift solenoid 2
(12) FWD switch (Non-turbo model) (31) Data link connector (46) 2-4 brake timing solenoid
(13) Power switch (32) Throttle position sensor (47) Line pressure duty solenoid
(14) Kick-down switch (33) Engine speed signal (48) 2-4 brake duty solenoid
(15) Hold indicator light (34) Torque control cut signal (49) Lock-up duty solenoid
(16) Hold switch (35) Torque control signal 2 (50) Low clutch timing solenoid
(17) “P” range indicator light (36) Torque control signal 1 (51) Transfer duty solenoid
AT-19
6. Subaru Select Monitor 5) Turn the ignition switch to ON (engine OFF) and
A: OPERATION
1) Prepare the Subaru Select Monitor kit.
S2M0288C
(A) Power switch
S2M0285 6) On the «Main Menu» display screen, select the

{Each System Check} and press [YES] key.
2) Connect the diagnosis cable to Subaru Select 7) On the «System Selection Menu» display
Monitor. screen, select the {Transmission Control System}
3) Insert the cartridge into Subaru Select Monitor. and press [YES] key.
<Ref. to AT-6, PREPARATION TOOL, General De- 8) Press the [YES] key after displayed information
scription.> of transmission type.
9) On the «Transmission Diagnosis» display
screen, select the {Diagnostic Code(s) Display}
and press [YES] key.
screen, select the {Latest Diagnostic Code(s)} or
{Memorized Diagnostic Code(s)} and press [YES]
key.
NOTE:
S2M0286 SUBARU SELECT MONITOR OPERATION MAN-
UAL.
4) Connect the Subaru Select Monitor to data link • For detailed concerning the diagnostic trouble
connector. codes (DTC), refer to the DIAGNOSTIC TROUBLE
(1) Data link connector located in the lower por- CODE LIST. <Ref. to AT-27, List of Diagnostic
tion of instrument panel (on driver's side). Trouble Code (DTC).>
2. READ CURRENT DATA
{Each System Check} and press [YES] key.
screen, select the {Transmission Control System}
3) Press the [YES] key after displayed information
of transmission type.
4) On the «Transmission Diagnosis» display
EN0768 screen, select the {Current Data Display & Save}
(2) Connect the diagnosis cable to data link and press [YES] key.
connector. 5) On the «Data Display Menu» display screen, se-
lect the {Data Display} and press [YES] key.
NOTE: 6) Using the scroll key, move the display screen up
Do not connect scan tools except for Subaru Select or down until desired data is shown.
Monitor and OBD-II general scan tool. • A list of the support data is shown in the following
table.
AT-20

Rear vehicle speed sensor signal Rear Wheel Speed km/h or MPH
Front vehicle speed sensor signal Front Wheel Speed km/h or MPH
Torque converter turbine speed signal Turbine Revolution Speed rpm
2-4 brake timing pressure control duty ratio Brake Clutch Duty Ratio %
Mass air flow sensor signal (Turbo model) Air Flow Sensor Voltage V
Intake manifold pressure sensor voltage (Non-turbo model) Mani. Pressure Voltage V
2 wheel drive switch signal (Non-turbo model) FWD Switch ON or OFF
Stop lamp switch signal Stop Light Switch ON or OFF
Parking range signal P Range Signal ON or OFF
Neutral range signal N Range Signal 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
Automatic transmission diagnosis indicator lamp Diagnosis Lamp ON or OFF
Power mode switch signal Power Mode Switch ON or OFF
Hold mode switch signal Hold Mode Switch ON or OFF
Kick down switch signal Kick Down Switch ON or OFF
Automatic transmission fluid temperature lamp ATF Temperature Lamp ON or OFF
NOTE: 4) On the «Transmission Diagnosis» display
For detailed operation procedure, refer to the SUB- screen, select the {Clear Memory} and press [YES]
ARU SELECT MONITOR OPERATION MANUAL. key.
5) When the `Done' and `Turn Ignition Switch OFF'
3. CLEAR MEMORY MODE are shown on display screen, turn the Subaru Se-
1) On the «Main Menu» display screen, select the lect Monitor and ignition switch to OFF.
{2. Each System Check} and press [YES] key. NOTE:
2) On the «System Selection Menu» display For detailed operation procedure, refer to the SUB-
screen, select the {Transmission Control System} ARU SELECT MONITOR OPERATION MANUAL.
3) Press the [YES] key after displayed information
of transmission type.
AT-21
7. Read Diagnostic Trouble Code (DTC)

A: OPERATION
Step Check Yes No

1 PERFORM READ DIAGNOSTIC TROUBLE Does the indicator light blink at Repair the power Go to step 2.
CODE. 4 Hz intervals? NOTE: Blinks supply and ground
1)Warm-up the engine. every 0.125 (1/8) seconds circuit.<Ref. to AT-
2)Turn the ignition switch to OFF. (until the ignition switch is 34, CHECK
3)Turn the ignition switch to ON. turned OFF). POWER SUPPLY
4)Start the engine. AND GROUND
5)Drive the vehicle at speeds greater than 20 LINE, Diagnostic
km/h (12 MPH). Procedure for
6)Stop the vehicle. POWER Indicator
7)The brake pedal depressed and move select Light.>
lever to 1 range.
10)Move the select lever 2 range.
14)Move the select lever D range.
2 CHECK INDICATOR LIGHT. Does the indicator light blink at The AT system is Go to step 3.
2 Hz intervals? NOTE: Blinks normal.
every 0.25 (1/4) seconds (until
ignition switch is turned to
OFF).
3 CHECK INDICATOR LIGHT. Is the DTC outputted? Inspect the prob- Go to step 4.
lem correspond-
ing with DTC.
NOTE:
Record all DTCs.
4 CHECK INDICATOR LIGHT. Does the indicator light remain Repair the power Calling up the DTC
illuminated? indicator light cir- again.
cuit <Ref. to AT-
28, Diagnostic
Procedure for
POWER Indicator
Light.>, or Inspect
inhibitor switch,
wiring, TCM, etc.
AT-22
The power indicator light flashes the code corresponding to faulty part.
The long segment (1.2 sec on) indicates a “ten”, and the short segment (0.2 sec on) signifies a “one”.
B3M1199B

Refer to SUBARU SELECT MONITOR for informa-
tion about how to obtain and understand diagnostic
trouble codes (DTC). <Ref. to AT-20, OPERA-
TION, Subaru Select Monitor.>
AT-23
INSPECTION MODE
8. Inspection Mode
A: OPERATION
Raise the vehicle using a garage jack and place on
WARNING:
brake is applied.
safety stand.
pedal or accelerator pedal during works even
• In order to prevent the vehicle from slipping
due to vibration, do not place any wooden
blocks or similar items between safety stands
and the vehicle.
B2M2969C
(A) Safety stand

(B) Free rollers
AT-24
CLEAR MEMORY MODE
9. Clear Memory Mode

A: OPERATION
Current diagnostic trouble codes (DTC) shown on
display are cleared by turning the ignition switch to
OFF after conducting on-board diagnostics opera-
tion. Previous diagnostic trouble codes (DTC),
however, cannot be cleared since they are stored
in the TCM memory which is operating on back-up
power supply. These diagnostic trouble codes
(DTC) can be cleared by removing the specified
fuse (located under light or left lower position of the
instrument panel).
CLEAR MEMORY:
Removal of No. 4 fuse (for at least one
minute)
• The No. 4 fuse is located in the line to memory
back-up power supply of TCM. Removal of this
fuse clears the previous diagnostic trouble codes
(DTC) stored in TCM memory.
• Be sure to remove the No. 4 fuse for at least the
specified length of time. Otherwise, the diagnostic
trouble codes (DTC) may not be cleared.
Refer to SUBARU SELECT MONITOR for informa-
tion about how to clear trouble codes.
<Ref. to AT-21, CLEAR MEMORY MODE, OPER-
ATION, Subaru Select Monitor.>
AT-25
POWER INDICATOR LIGHT DISPLAY
10.POWER Indicator Light Dis- by a diagnostic trouble code (DTC) during on-board
diagnostics operation. Problems which occurred
play previously can also be identified through the mem-
A: INSPECTION ory function. If the POWER indicator does not show
a problem (although a problem is occurring), the
When any on-board diagnostics item is malfunc-
problem can be determined by checking the perfor-
tioning, the display on POWER indicator light blinks
mance characteristics of each sensor using select
from the time malfunction is detected after starting
monitor. The indicator signal is as shown in the fig-
the engine until ignition switch is turned to OFF.
ure.
The malfunctioning part or unit can be determined
S3M0062F
AT-26

A: LIST
DTC No. Item Content of diagnosis Index
<Ref. to AT-42, DTC 11 ENGINE SPEED SIG-
Detects open or shorted input
11 Engine speed signal NAL, Diagnostic Procedure with Diagnostic Trou-
signal circuit.
ble Code (DTC).>
<Ref. to AT-44, DTC 23 MASS AIR FLOW SIG-
Mass air flow signal Detects open or shorted input
23 NAL (TURBO MODEL), Diagnostic Procedure
(Turbo model) signal circuit.
ATF temperature sen- Detects open or shorted input
27 SENSOR, Diagnostic Procedure with Diagnostic
sor signal circuit.
<Ref. to AT-50, DTC 31 THROTTLE POSITION
31 Throttle position sensor SENSOR, Diagnostic Procedure with Diagnostic
signal circuit.
<Ref. to AT-57, DTC 33 FRONT VEHICLE
Front vehicle speed Detects open or shorted input
33 SPEED SENSOR, Diagnostic Procedure with
sensor signal circuit.
<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.
<Ref. to AT-66, DTC 38 TORQUE CONTROL
38 Torque control signal SIGNAL, Diagnostic Procedure with Diagnostic
signal circuit.
<Ref. to AT-68, DTC 45 INTAKE MANIFOLD
Intake manifold pres-
Detects open or shorted input PRESSURE SIGNAL (NON-TURBO MODEL),
45 sure signal
signal circuit. Diagnostic Procedure with Diagnostic Trouble
(Non-turbo model)
Code (DTC).>
<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,
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.
<Ref. to AT-82, DTC 74 2-4 BRAKE TIMING
2-4 brake timing sole- Detects open or shorted out-
<Ref. to AT-86, DTC 75 LINE PRESSURE DUTY
Line pressure duty sole- Detects open or shorted out-
<Ref. to AT-90, DTC 76 2-4 BRAKE DUTY SOLE-
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-
77 Lock-up duty solenoid NOID, Diagnostic Procedure with Diagnostic Trou-
put signal circuit.
ble Code (DTC).>
<Ref. to AT-98, DTC 79 TRANSFER DUTY
79 Transfer duty solenoid SOLENOID, Diagnostic Procedure with Diagnostic
put signal circuit.
<Ref. to AT-102, DTC 93 REAR VEHICLE SPEED
Rear vehicle speed Detects open or shorted input
93 SENSOR, Diagnostic Procedure with Diagnostic
sensor signal circuit.
AT-27
DIAGNOSTIC PROCEDURE FOR POWER INDICATOR LIGHT
12.Diagnostic Procedure for POWER Indicator Light

A: POWER INDICATOR LIGHT DOES NOT COME ON OR GO OFF
DIAGNOSIS:
The POWER Indicator light circuit is open or shorted.
TROUBLE SYMPTOM:
• When the ignition switch is turned to ON (engine OFF), POWER indicator light does not illuminate.
• When the on-board diagnostics is performed, POWER indicator light remains illuminated.
AT-28
WIRING DIAGRAM:
LHD MODEL
IGNITION
SWITCH No.13
BATTERY SBF-1 SBF-4
COMBINATION
A: i10
METER
B: i11
i1 B36
A7 23
POWER
E B16 5
INHIBITOR SWITCH
P R N D 3 2 1
9 3
8 2
10 1
3 8
11 7
4 6
6 5
5 4
T7 T3 B12
C11
B14
B4
B6
B3
B7
B5
B1
TRANSMISSION
B: B55 C: B56
CONTROL MODULE
E
T7 B12 B36 B55
1 2 3 4 5 6 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 8 9
1 2 3 4 5 6 7
7 8 9 10 11 12 5 6 7 8 12 13 14 15 16 17 18 19 20 21 22 23 24 10 11 12 13 14 15 16 17 18
9 10 11 12
19 20 21 22 23 24
B56 A: i10 B: i11
1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10 11 12 13 14
7 8 9 10
10 11 12 13 14 15 16 17 18 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
19 20 21 22 23 24
TR0400
AT-29
RHD MODEL
IGNITION
SWITCH
SBF-1 SBF-4 No.13
BATTERY
COMBINATION
A: i10
METER
B: i11
i3 B38
A7 22
POWER
E B16 3
INHIBITOR SWITCH
P R N D 3 2 1
9 3
8 2
10 1
3 8
11 7
4 6
6 5
5 4
T7 T3 B12
C11
B14
B4
B6
B3
B7
B5
B1
TRANSMISSION
B: B55 C: B56
CONTROL MODULE
E
T7 B12 B55 B56
1 2 3 4 5 6 1 2 3 4 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9
7 8 9 10 11 12 5 6 7 8 10 11 12 13 14 15 16 17 18 10 11 12 13 14 15 16 17 18
9 10 11 12 19 20 21 22 23 24 19 20 21 22 23 24
A: i10 B: i11 i3
1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14
11 12 13 14 15 16 17 18 19 20 21 22
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
TR0401
AT-30
Step Check Yes No

1 CHECK POWER INDICATOR LIGHT. Does the POWER indicator Go to step 3. Go to step 2.
Turn the ignition switch to ON (engine OFF). light illuminate?
2 CHECK POWER INDICATOR LIGHT. Is the POWER indicator light Go to step 4. Replace the
1)Turn the ignition switch to OFF. bulb OK? POWER indicator
2)Remove the combination meter. light bulb.
3)Remove the POWER indicator light bulb
from combination meter.
3 CHECK POWER INDICATOR LIGHT. Does the POWER indicator A temporary poor Go to step 9.
Perform “Read Diagnostic Trouble Code light blink? contact of the con-
(DTC)”. <Ref. to AT-22, Read Diagnostic Trou- nector or harness
ble Code (DTC).> may be the cause.
Repair the har-
ness or connector
in TCM, inhibitor
switch and combi-
nation meter.
4 CHECK FUSE (No. 13). Is the fuse (No. 13) blown out? Replace the fuse Go to step 5.
Remove the fuse (No. 13). (No. 13). If
replaced fuse (No.
13) is blown out
easily, repair short
circuit in harness
between fuse (No.
13) and combina-
tion meter.
5 CHECK HARNESS CONNECTOR BETWEEN Is the voltage more than 9 V? Go to step 6. Repair the open
COMBINATION METER AND IGNITION circuit in harness
SWITCH. between combina-
1)Turn the ignition switch to ON (engine OFF). tion meter and bat-
2)Measure the voltage between combination tery.
meter connector and chassis ground.
(i10) No. 7 (+) — Chassis ground (−):
6 CHECK COMBINATION METER. Is the voltage less than 1 V? Repair the combi- Go to step 7.
Measure the voltage between combination nation meter.
meter connector and chassis ground. <Ref. to IDI-15,
Connector & terminal Combination
(i11) No. 16 (+) — Chassis ground (−): Meter Assembly.>
7 CHECK OPEN CIRCUIT OF HARNESS. Is the resistance less than 1 Go to step 8. Repair the open
2)Disconnect the connector from combination between TCM and
meter connector. combination
3)Measure the resistance of harness between meter, and poor
combination meter. contact in cou-
Connector & terminal pling connector.
(B56) No. 11 — (i11) No. 16:
8 CHECK INPUT SIGNAL FOR TCM. Is the voltage less than 1 V? Even if the Replace the TCM.
1)Connect the connector to TCM and combina- POWER indicator <Ref. to AT-46,
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
(B56) No. 11 (+) — Chassis ground (−): contact of the con-
nector or harness
may be the cause.
Repair the har-
ness or connector
in TCM.
AT-31
Step Check Yes No

9 CHECK INHIBITOR SWITCH. When each range is selected, Go to step 10. Check the inhibi-
1)Connect the Subaru Select Monitor to data does the LED of Subaru Select tor switch circuit.
link connector. Monitor light up? <Ref. to AT-119,
2)Turn the ignition switch to ON. CHECK INHIBI-
3)Turn the 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 ⇔ OFF. nostic Trouble
Code (DTC).>
10 CHECK SHORT CIRCUIT OF HARNESS. Is the resistance less than 1 Replace the TCM. Repair the short
1)Disconnect the connector from TCM. MΩ? <Ref. to AT-46, circuit 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 & terminal/specified resistance
AT-32
AT-33
B: CHECK POWER SUPPLY AND GROUND LINE

WIRING DIAGRAM:
BATTERY
SBF-1
SBF-5
RHD
LHD
E
NO.4
GENERATOR F44
2
SBF-4
B61
RHD
RHD B40
LHD
LHD 1
10
IGNITION DATA LINK
6
F45 SWITCH CONNECTOR
21
12
B62 13
B300
LINE END
4
NO.11
CHECK
2
LHD
CONNECTOR
RHD B22
16
E3
C15
C24
A23
A24
C1
A: B54 C: B56 TCM
E
C19
A21
B11
16
T4
LHD : LHD MODEL
RHD : RHD MODEL

TRANSMISSION
E
B11 B40 B54 B56
1 2 3 4 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8
5 6 7 8 10 11 12 13 14 15 16 17 18 10 11 12 13 14 15 16 17 18
9 10 11 12 9 10 11 12 13 14 15 16 19 20 21 22 23 24 19 20 21 22 23 24
13 14 15 16
17 18 19 20
F45 B22 F44 B300
1 2 3 4 1 2 3 4 1 2 3
1 2 3 4 5 6 7 8 9 10 11
5 6 7 8 5 6 7 8 4 5 6
12 13 14 15 16 17 18 19 20 21 22 23 24
9 10 11 12
13 14 15 16
TR0914
AT-34
Step Check Yes No

1 CHECK IGNITION SWITCH. Is the ignition switch turned to Go to step 2. Turn the ignition
ON? switch to 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)Idle the engine. 14, Generator.>
3)Measure the voltage between generator and
chassis ground.
Terminal
ground (−):
3 CHECK BATTERY TERMINAL. Is there poor contact at battery Repair or tighten Go to step 4.
Turn the ignition switch to OFF. terminal? the battery termi-
nal.
4 CHECK POWER SUPPLY OF TCM. Is the voltage between 10 and Go to step 6. Go to step 5.
1)Disconnect the connector from TCM. 13 V?
3)Measure the voltage between TCM connec-
5 CHECK FUSE (NO. 4). Is the fuse (No. 4) blown out? Replace the fuse Repair the open
Remove the fuse (No. 4). (No. 4). If replaced circuit in harness
fuse (No. 4) has between fuse (No.
blown out easily, 4) and TCM, or
repair short circuit fuse (No. 4) and
in harness battery, and poor
between fuse (No. contact in cou-
4) and TCM. pling connector.
6 CHECK IGNITION POWER SUPPLY CIR- Is the voltage between 10 and Go to step 8. Go to step 7.
CUIT. 13 V?
1)Turn the ignition switch to ON (engine OFF).
2)Measure the ignition power supply voltage
between TCM connector and chassis ground.
7 CHECK FUSE (NO. 11). Is the fuse (No. 11) blown out? Replace the fuse Repair the open
Remove the fuse (No. 11). (No. 11). If circuit in harness
replaced fuse (No. between fuse (No.
11) has blown out 4) and TCM, or
easily, repair short fuse (No. 4) and
circuit in harness battery, and poor
between fuse (No. contact in cou-
11) and TCM. pling connector.
8 CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 Go to step 9. Repair the open
TCM AND TRANSMISSION. Ω? circuit in harness
1)Turn the ignition switch to OFF. between TCM,
2)Disconnect the connector from TCM and transmission har-
transmission. ness connector,
3)Measure the resistance of harness between and poor contact
TCM and transmission connector. in coupling con-
(B56) No. 19 — (B11) No. 16:
(B54) No. 21 — (B11) No. 16:
AT-35
Step Check Yes No

TRANSMISSION AND TRANSMISSION Ω? circuit in harness
GROUND. between transmis-
Measure the resistance of harness between sion and transmis-
transmission and transmission ground. sion ground.
(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 nector. <Ref. to AT-46,
line and data link connector? Transmission Con-
trol Module
(TCM).>
AT-36
DIAGNOSTIC PROCEDURE FOR SELECT MONITOR COMMUNICATION
13.Diagnostic Procedure for Select Monitor Communication

A: COMMUNICATION FOR INITIALIZING IMPOSSIBLE
DIAGNOSIS:
• Faulty harness connector
TROUBLE SYMPTOM:
• Select monitor communication failure
AT-37
WIRING DIAGRAM:
BATTERY
SBF-1 SBF-5
RHD
LHD
E
NO.4
GENERATOR F44
2
SBF-4
B61
RHD
RHD B40
LHD
LHD 1
10
IGNITION DATA LINK
6
F45 SWITCH CONNECTOR
21
12
B62 13
B300
LINE END
4
NO.11
CHECK
2
LHD
CONNECTOR
RHD B22
16
E3
C15
C24
A23
A24
C1
A: B54 C: B56 TCM
E
C19
A21
B11
16
T4
LHD : LHD MODEL
RHD : RHD MODEL

TRANSMISSION
E
B11 B40 B54 B56
1 2 3 4 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8
5 6 7 8 10 11 12 13 14 15 16 17 18 10 11 12 13 14 15 16 17 18
9 10 11 12 9 10 11 12 13 14 15 16 19 20 21 22 23 24 19 20 21 22 23 24
13 14 15 16
17 18 19 20
F45 B22 F44 B300
1 2 3 4 1 2 3 4 1 2 3
1 2 3 4 5 6 7 8 9 10 11
5 6 7 8 5 6 7 8 4 5 6
12 13 14 15 16 17 18 19 20 21 22 23 24
9 10 11 12
13 14 15 16
TR0914
AT-38
Step Check Yes No

1 CHECK SUBARU SELECT MONITOR POW- Is the voltage more than 10V? Go to step 2. Repair the har-
ER SUPPLY CIRCUIT. ness and connec-
Measure the voltage between data link con- tor between
nector and chassis ground. battery and data
Connector & terminal link connector, and
(B40) No. 1 (+) — Chassis ground (−): poor contact in
coupling connec-
tor.
2 CHECK SUBARU SELECT MONITOR Is the resistance less than 1Ω? Go to step 3. Repair the open
GROUND CIRCUIT. circuit in harness
Measure the resistance of harness between between data link
data link connector and chassis ground. connector and
Connector & terminal ground terminal,
(B40) No. 12 — Chassis ground: and poor contact
(B40) No. 13 — Chassis ground: in coupling con-
nector.
3 CHECK COMMUNICATION OF SELECT Are the name and year of sys- Go to step 8. Go to step 4.
MONITOR. tem displayed on Subaru
1)Turn the ignition switch to ON. Select Monitor?
2)Using the Subaru Select Monitor, check
whether communication to engine systems can
be executed normally.
4 CHECK COMMUNICATION OF SELECT Are the name and year of sys- Go to step 6. Go to step 5.
1)Turn the ignition switch to OFF. Select Monitor?
2)Disconnect the TCM connector.
3)Check whether communication to engine
systems can be executed normally.
5 CHECK COMMUNICATION OF SELECT Are the name and year of sys- Inspect the ECM. Go to step 6.
1)Turn the ignition switch to OFF. Select Monitor?
2)Connect the TCM connector.
3)Disconnect the ECM connector.
4)Check whether communication to transmis-
sion systems can be executed normally.
6 CHECK HARNESS CONNECTOR BETWEEN Is the resistance more than 1M Go to step 7. Repair the har-
EACH CONTROL MODULE AND DATA LINK Ω? ness and connec-
CONNECTOR. tor between each
1)Turn the ignition switch to OFF. control module
2)Disconnect the TCM, ECM, ABSCM&H/U, and data link con-
cruise control module and immobilizer control nector.
module connectors.
3)Measure the resistance between TCM con-
nector and chassis ground.
7 CHECK OUTPUT SIGNAL FOR TCM. Is the voltage more than 1 V? Repair the har- Go to step 8.
1)Turn the ignition switch to ON. ness and connec-
2)Measure the voltage between TCM and tor between each
chassis ground. control module
Connector & terminal and data link con-
(B40) No. 10 (+) — Chassis ground (−): nector.
8 CHECK HARNESS/CONNECTOR BETWEEN Is the resistance less than 0.5 Go to step 9. Repair the har-
TCM AND DATA LINK CONNECTOR. Ω? ness and connec-
Measure the resistance between TCM connector between TCM
tor and data link connector. and data link con-
(B56) No. 15 — (B40) No. 10:
AT-39
Step Check Yes No

9 CHECK HARNESS/CONNECTOR BETWEEN Is the resistance more than 1M Go to step 10. Repair the har-
TCM AND DATA LINK CONNECTOR. Ω? ness and connec-
Measure the resistance between TCM and tor between TCM
data link connector. and data link con-
(B56) No. 24 — (B40) No. 6:
10 CHECK INSTALLATION OF TCM CONNEC- Is the TCM connector inserted Go to step 11. Insert the TCM
TOR. into TCM? connector into
Turn the ignition switch to OFF. TCM.
11 CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in control Repair the poor Replace the TCM.
module and data link connec- contact. <Ref. to AT-46,
tor? Transmission Con-
trol Module
(TCM).>
AT-40
AT-41

A: DTC 11 ENGINE SPEED SIGNAL
DIAGNOSIS:
The engine speed input signal circuit is open or shorted.
TROUBLE SYMPTOM:
• No lock-up (after engine warm-up).
• The POWER indicator light remains on when vehicle speed is “0”.
WIRING DIAGRAM:
B55 TCM
17
19
NA TB
30
NA : B134 ECM NA : NON TURBO MODEL
TB : TURBO MODEL
TB : B136
B136 : TB
B55 B134 : NA
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7
1 2 3 4 5 6 7 8 9
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 8 9 10 11 12 13 14 15 16
10 11 12 13 14 15 16 17 18
24 25 26 27 28 29 30 31 32 33 34 35 17 18 19 20 21 22 23 24
19 20 21 22 23 24
TR0915
AT-42
Step Check Yes No

TCM AND ECM. Ω? circuit in harness
2)Disconnect the connectors from TCM and ECM connector.
ECM.
TCM and ECM connector.
Non-turbo model
(B55) No. 17 — (B134) No. 30:
Turbo model
(B55) No. 17 — (B136) No. 9:
2 CHECK HARNESS CONNECTOR BETWEEN Is the resistance more than 1 Go to step 3. Repair the short
TCM AND ECM. MΩ? circuit in harness
TCM connector and chassis ground. ECM connector.
3 PREPARE SUBARU SELECT MONITOR. Do you have a Subaru Select Go to step 5. Go to step 4.
Monitor?
4 CHECK INPUT SIGNAL FOR TCM. Is the voltage more than 10.5
Even if the Go to step 6.
1)Connect the connectors to TCM and ECM. V? POWER indicator
2)Turn the ignition switch to ON (engine OFF). lights up, the cir-
3)Measure the voltage between TCM connec- cuit has returned
tor and chassis ground. to a normal condi-
Connector & terminal tion at this time. A
(B55) No. 17 (+) — Chassis ground (−): temporary poor
contact of the con-
nector or harness
may be the cause.
Repair the har-
ness or connector
in TCM and ECM.
5 CHECK INPUT SIGNAL FOR TCM USING Is the revolution value same as Even if the Go to step 6.
SUBARU SELECT MONITOR. tachometer reading shown on POWER indicator
1)Connect the connectors to TCM and ECM. combination meter? lights up, the cir-
2)Connect the Subaru Select Monitor to data cuit has returned
link connector. to a normal condi-
3)Start the engine and turn Subaru Select tion at this time. A
Monitor switch to ON. temporary poor
4)Warm-up the engine until engine coolant contact of the con-
temperature is above 80°C (176°F). nector or harness
5)Idle the engine. may be the cause.
6)Read the data of engine speed using Subaru Repair the har-
Select Monitor. ness or connector
•Display shows the engine speed signal value in TCM and ECM.
sent from ECM.
6 CHECK POOR CONTACT. Is there poor contact in engine Repair the poor Go to step 7.
speed signal circuit? contact.
7 CONFIRM DTC 11. Replace the ECM with a new Replace the TCM. Replace the ECM.
one. Does the DTC appear <Ref. to AT-46,
again, after memory has been Transmission Con-
cleared? trol Module
(TCM).>
AT-43
B: DTC 23 MASS AIR FLOW SIGNAL (TURBO MODEL)

DIAGNOSIS:
The input signal circuit of TCM from ECM is open or shorted.
TROUBLE SYMPTOM:
Excessive shift shock.
WIRING DIAGRAM:
B135 ECM
28 1
B54 TCM
B54 B135
1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 10 11 12 13 14 15 16 17 18 19
19 20 21 22 23 24 20 21 22 23 24 25 26 27 28
TR0573
Step Check Yes No

1 CHECK ENGINE GROUND TERMINALS AND Is there any trouble? Repair the ground Go to step 2.
GROUND CIRCUIT OF ECM. terminal and/or
<Ref. to AT-50, DTC 31 THROTTLE POSI- ground circuit of
TION SENSOR, Diagnostic Procedure with ECM.
ECM.
(B54) No. 1 — (B135) No. 28:
Monitor?
AT-44
Step Check Yes No

5 CHECK INPUT SIGNAL FOR TCM. Is the voltage between 0.9 and Even if the AT OIL Go to step 7.
1)Connect the connectors to TCM and ECM. 1.4 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 ATF reaches its operating contact of the con-
temperature. nector or harness
4)Measure the voltage between TCM connec- Repair harness or
tor and chassis ground. connector in the
Connector & terminal TCM and ECM.
6 CHECK INPUT SIGNAL FOR TCM USING Is the value voltage between Even if the AT OIL Go to step 7.
SUBARU SELECT MONITOR. 0.9 and 1.4 V? TEMP warning
1)Connect the connectors to TCM and ECM. lights up, the cir-
3)Start the engine and turn the Subaru Select tion at this time. A
6)Read the data of mass air flow sensor signal Repair harness or
using Subaru Select Monitor. connector in the
•Display shows the mass air flow sensor signal TCM and ECM.
value sent from ECM.
7 CHECK POOR CONTACT. Is there poor contact in intake Repair the poor Replace the TCM.
manifold pressure signal cir- contact. <Ref. to AT-46,
cuit? Transmission Con-
trol Module
(TCM).>
AT-45
C: DTC 27 ATF TEMPERATURE SENSOR

DIAGNOSIS:
The input signal circuit of TCM to ATF temperature sensor is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B54 TCM
11
20
B11
11
12
T4
AT1
2
1
ATF TEMPERATURE
SENSOR
TRANSMISSION
AT1 B11 B54
2 1 1 2 3 4
1 2 3 4 5 6 7 8 9
5 6 7 8
10 11 12 13 14 15 16 17 18
9 10 11 12
19 20 21 22 23 24
13 14 15 16
17 18 19 20
S3M0626
Step Check Yes No

TCM AND ATF TEMPERATURE SENSOR. Ω? circuit in harness
2)Disconnect the connector from transmission transmission con-
and TCM. nector.
TCM and transmission connector.
(B54) No. 20 — (B11) No. 12:
AT-46
Step Check Yes No

TCM AND ATF TEMPERATURE SENSOR. Ω? circuit in harness
TCM and transmission connector. transmission con-
(B54) No. 11 — (B11) No. 11:
TCM AND ATF TEMPERATURE SENSOR. MΩ? circuit in harness
TCM connector and chassis ground. transmission con-
TCM AND ATF TEMPERATURE SENSOR. MΩ? circuit in harness
5 CHECK ATF TEMPERATURE SENSOR. Is the resistance between 275 Go to step 6. Go to step 11.
1)Turn the ignition switch to OFF. and 375 Ω?
2)Connect the connectors to transmission and
TCM.
3)Turn the ignition switch to ON and start
engine.
4)Warm-up the transmission until ATF temper-
ature reaches to 80°C (176°F).
NOTE:
If ambient temperature is below 0°C (32°F),
drive the vehicle until ATF reaches its operating
temperature.
5)Disconnect the connector from transmission.
sion connector terminals.
(T4) No. 11 — No. 12:
6 CHECK ATF TEMPERATURE SENSOR. Does the resistance value Go to step 7. Go to step 11.
1)Turn the ignition switch to ON (engine OFF). increase while ATF tempera-
2)Measure the resistance between transmis- ture decreases?
sion connector terminals.
(T4) No. 11 — No. 12:
Monitor?
8 CHECK INPUT SIGNAL FOR TCM. Is the voltage between 0.4 and Even if the Go to step 10.
1)Connect the connector to transmission. 0.9 V? POWER indicator
2)Warm-up the transmission until ATF temper- lights up, the cir-
ature 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 ATF reaches its operating Temporary poor
temperature. contact of the con-
3)Measure the voltage between TCM connec- nector or harness
tor terminal. may be the cause.
Connector & terminal Repair the har-
(B54) No. 11 (+) — No. 20 (−): ness or contact in
ATF temperature
sensor and trans-
mission connector.
AT-47
Step Check Yes No

9 CHECK INPUT SIGNAL FOR TCM USING Does the ATF temperature Even if the Go to step 10.
SUBARU SELECT MONITOR. gradually decrease? POWER indicator
1)Connect the connector to transmission. lights up, the cir-
2)Turn the ignition switch to ON (engine OFF). cuit has returned
to a normal condi-
tion at this time.
Temporary poor
contact of the con-
nector or harness
may be the cause.
Repair the har-
ness or contact in
ATF temperature
sensor and trans-
mission connector.
10 CHECK POOR CONTACT. Is there poor contact in ATF Repair the poor Replace the TCM.
temperature sensor circuit? contact. <Ref. to AT-46,
Transmission Con-
trol Module
(TCM).>
TRANSMISSION AND ATF TEMPERATURE Ω? circuit in harness
SENSOR. between ATF tem-
1)Turn the ignition switch to OFF. perature sensor
2)Disconnect the connector from transmission. and transmission
3)Remove the transmission connector from connector.
bracket.
4)Lift-up the vehicle and place safety stand.
NOTE:
On AWD models, raise all wheels off ground.
5)Drain the ATF.
CAUTION:
Do not drain the ATF until it cools down.
6)Remove the oil pan, and disconnect the con-
nector from ATF temperature sensor connec-
tor.
ATF temperature sensor and transmission
connector.
(T4) No. 11 — (AT1) No. 2:
TRANSMISSION AND ATF TEMPERATURE Ω? circuit in harness
Measure the resistance of harness between perature sensor
ATF temperature sensor and transmission and transmission
connector. connector.
(T4) No. 12 — (AT1) No. 1:
TRANSMISSION AND ATF TEMPERATURE MΩ? circuit in harness
Measure the resistance of harness between perature sensor
transmission connector and transmission and transmission
ground. connector.
(T4) No. 11 — Transmission ground:
AT-48
Step Check Yes No

14 CHECK HARNESS CONNECTOR BETWEEN Is the resistance more than 1 Replace the ATF Repair the short
TRANSMISSION AND ATF TEMPERATURE MΩ? temperature sen- circuit in harness
SENSOR. sor. <Ref. to AT- between ATF tem-
Measure the resistance of harness between 40, Shift Sole- perature sensor
transmission connector and transmission noids, Duty Sole- and transmission
ground. noids and ATF connector.
Connector & terminal Temperature Sen-
(T4) No. 12 — Transmission ground: sor.>
AT-49
D: DTC 31 THROTTLE POSITION SENSOR

DIAGNOSIS:
The input signal circuit of throttle position sensor is open or shorted.
TROUBLE SYMPTOM:
Shift point too high or too low; excessive shift shock; excessive tight corner “braking”.
AT-50
WIRING DIAGRAM:
NON-TURBO MODEL
A: B134 B: B135 C: B136 ECM

B54 TCM
C21 C21
C22 C22
A27 A27
C17 C17
C15 C15
C16 C16
WO OO
A8 A8
A7 A7
B6 B6
A34
A35
2
3
B21 B22
RHD
12
11
9
14
13
16
15
8
LHD
E2 E3
RHD WO
OO
LHD
E13
WO : WITH OBD MODEL
4
3
2
OO WO
WO OO
4
5
1
3
OO : WITHOUT OBD MODEL B83 B122

E E
1
2
1
4
SHIELD AND SHIELD AND

THROTTLE SENSOR GROUND SENSOR GROUND
POSITION SENSOR JOINT CONNECTOR JOINT CONNECTOR
B83 : WO
E13 B83 : OO B22 B21 B54 B122
1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 1 2 3 4 1 2 3 4 5 6 7 8 9 1 2 3
5 6 7 8 5 6 7 8 10 11 12 13 14 15 16 17 18 4 5 6
9 10 11 12 9 10 11 12 19 20 21 22 23 24
13 14 15 16 13 14 15 16
17 18 19 20
B136 B134 B135
1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19 20 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 8 9 10 11 12 13 14 15 16 17 18 19
21 22 23 24 25 26 27 28 29 30 24 25 26 27 28 29 30 31 32 33 34 35 20 21 22 23 24 25 26 27 28
TR0916
AT-51
TURBO MODEL
A: B134 B: B135 E: B84

ECM
B54 TCM C: B136 D: B137
A15
C18
C17
B19
A22
E1
D8
D9
A7
C8
B7
B9
2
3
B22
15
13
16
14
3
E3
B21
20
18
19
E2
E13
1
2
3
B83
E E
1
3
SHIELD AND
THROTTLE SENSOR GROUND
POSITION SENSOR JOINT CONNECTOR
E13 B134 B136 B137 B84
1 2 3 1 2 3 4 5 6 7 1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6
8 9 10 11 12 13 14 15 8 9 10 11 12 13 14 15 16 10 11 12 13 14 15 16 17 18 19 20 21 7 8 9 10 11 12
16 17 18 19 20 21 22 17 18 19 20 21 22 23 24 22 23 24 25 26 27 28 29 30 31 13 14 15 16 17
B83 B22 B21 B54 B135
1 2 3 4 5 6 1 2 3 4 1 2 3 4 8 9 1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7
5 6 7 8 5 6 7 8 10 11 12 13 14 15 16 17 18 19
10 11 12 13 14 15 16 17 18
9 10 11 12 9 10 11 12 19 20 21 20 21 22 23 24 25 26 27 28
22 23 24
13 14 15 16 13 14 15 16
17 18 19 20
TR0917
AT-52
Step Check Yes No

1 CHECK ENGINE GROUND TERMINALS. Have engine ground terminals Go to step 2. Tighten the engine
been tightened? ground terminals.
2)Disconnect the connector from ECM. between ECM
3)Measure the resistance of harness between connector and
ECM and engine ground. engine grounding
Connector & terminal terminal.
NON-TURBO MODEL WITH OBD MODEL
NON-TURBO MODEL WITHOUT OBD
MODEL
TURBO MODEL
3 CHECK THROTTLE POSITION SENSOR. Is the resistance between 3.0 Go to step 4. Replace the throt-
1)Disconnect the connector from throttle posi- and 4.2 kΩ? tle 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:
4 CHECK THROTTLE POSITION SENSOR. Is the resistance between 0.35 Go to step 5. Replace the throt-
Measure the resistance between throttle posi- and 0.5 kΩ? tle position sensor.
tion sensor connector receptacle's terminals.
Terminals
No. 2 — No. 3:
TCM AND THROTTLE POSITION SENSOR. Ω? circuit in harness
1)Disconnect the connector from TCM. between TCM and
2)Measure the resistance of harness between throttle position
TCM and throttle position sensor connector. sensor connector,
Connector & terminal and poor contact
(B55) No. 3 — (E13) No. 3: in coupling con-
nector.
AT-53
Step Check Yes No

TCM AND THROTTLE POSITION SENSOR. Ω? circuit in harness
TCM and throttle position sensor connector. throttle position
Connector & terminal sensor connector,
NON-TURBO MODEL and poor contact
(B54) No. 2 — (E13) No. 4: in coupling con-
TURBO MODEL nector.
(B54) No. 2 — (E12) No. 1:
TCM AND THROTTLE POSITION SENSOR. MΩ? circuit in harness
TCM connector and chassis ground. throttle position
TCM AND THROTTLE POSITION SENSOR. MΩ? circuit in harness
TCM connector and chassis ground. throttle position
TCM and ECM connector. ECM connector.
NON-TURBO MODEL
(B54) No. 3 — (B136) No. 17:
TURBO MODEL
(B54) No. 3 — (B135) No. 7:
TCM and ECM connector. ECM connector.
NON-TURBO MODEL
(B54) No. 2 — (B136) No. 15:
TURBO MODEL
(B54) No. 2 — (B135) No. 9:
Monitor?
12 CHECK INPUT SIGNAL FOR TCM. Is the voltage between 0.2 and Go to step 13. Go to step 18.
1)Connect the connectors to TCM, throttle 1.0 V in throttle fully closed?
position sensor and ECM.
3)Close the throttle completely.
13 CHECK INPUT SIGNAL FOR TCM. Is the voltage between 4.2 and Go to step 16. Go to step 18.
1)Open the throttle completely. 4.7 V with throttle fully open?
AT-54
Step Check Yes No

14 CHECK INPUT SIGNAL FOR TCM USING Is the value voltage between Go to step 15. Go to step 18.
SUBARU SELECT MONITOR. 0.2 and 1.0 V?
1)Connect the connectors to TCM, throttle
position sensor and ECM.
2)Connect the Subaru Select Monitor to data
link connector.
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.
15 CHECK INPUT SIGNAL FOR TCM USING Is the value voltage between Go to step 18. Go to step 17.
SUBARU SELECT MONITOR. 4.2 and 4.7 V?
Throttle fully open.
NOTE:
Must be changed correspondingly with the ac-
celerator pedal operation (from “released” to
“depressed” position).
16 CHECK INPUT SIGNAL FOR TCM (THROT- Is the voltage between 4.8 and Even if the Go to step 18.
TLE POSITION SENSOR POWER SUPPLY). 5.3 V? POWER indicator
Measure the voltage between TCM connector lights up, the cir-
and chassis ground. cuit has returned
Connector & terminal to a normal condi-
(B54) No. 2 (+) — Chassis ground (−): tion at this time. A
temporary poor
contact of the con-
nector or harness
may be the cause.
Repair the har-
ness or connector
in throttle position
sensor circuit.
17 CHECK INPUT SIGNAL FOR TCM USING Is the value voltage between Even if the Go to step 18.
SUBARU SELECT MONITOR (THROTTLE 4.8 and 5.3 V? POWER indicator
POSITION SENSOR POWER SUPPLY). lights up, the cir-
Read the data of throttle position sensor power cuit has returned
supply using Subaru Select Monitor. to a normal condi-
•Throttle position sensor power supply voltage tion at this time. A
is indicated. temporary poor
contact of the con-
nector or harness
may be the cause.
Repair the har-
ness or connector
in throttle position
sensor circuit.
18 CHECK POOR CONTACT. Is there poor contact in throttle Repair the poor Replace the TCM.
position sensor circuit? contact. <Ref. to AT-46,
Transmission Con-
trol Module
(TCM).>
AT-55
AT-56
E: DTC 33 FRONT VEHICLE SPEED SENSOR

DIAGNOSIS:
• The vehicle speed signal is abnormal.
• The circuit in combination meter is faulty.
• The harness connector between TCM and vehicle speed sensor is in short or open.
TROUBLE SYMPTOM:
• Erroneous idling.
• Engine stalls.
• Poor driving performance.
AT-57
WIRING DIAGRAM:
TCM
A: B54 B: B55 C: B56
B18
C17
A10
SHIELD AND
SENSOR GROUND
JOINT CONNECTOR
RT RN LH
6 6 3
4 4 1
5 5 2
B53
LH : LHD MODEL
B37 B11
*1
18
17
RN : RHD NON-TURBO MODEL

i2
T4
RT : RHD TURBO MODEL
1 : LHD : 9
* : RHD : 7
2
COMBINATON FRONT
METER VEHICLE SPEED
SPEEDOMETER i10 SENSOR
LH
B53 : B53 : RT B11 i10 i2 : LH
RN
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11
1 2 3 4 5 6 7 8 9 10
5 6 7 8 12 13 14 15 16 17 18 19 20 21 22 23 24
9 10 11 12
13 14 15 16
17 18 19 20
RN
B54 B55 B56 i2 :
RT
1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 10 11 12 13 14 15 16 17 18 10 11 12 13 14 15 16 17 18 10 11 12 13 14 15 16 17 18 19 20 21
19 20 21 22 23 24 19 20 21 22 23 24 19 20 21 22 23 24 22 23 24 25 26 27 28 29 30 31 32
TR0918
AT-58
Step Check Yes No

2)Disconnect the connector from TCM and transmission con-
transmission. nector.
(B55) No. 18 — (B11) No. 17:
Connector & terminal nector, and poor
(B54) No. 10 — (B11) No. 18: contact in cou-
pling connector.
TCM AND TRANSMISSION. MΩ? circuit in harness
(B55) No. 18 — Chassis ground: contact in cou-
pling connector.
5 CHECK FRONT VEHICLE SPEED SENSOR. Is the resistance between 450 Go to step 6. Replace the front
Measure the resistance between transmission and 650 Ω? vehicle speed sen-
connector receptacle's terminals. sor. <Ref. to AT-
Connector & terminal 32, Front Vehicle
(T4) No. 17 — No. 18: Speed Sensor.>
6 PREPARE OSCILLOSCOPE. Do you have an oscilloscope? Go to step 9. Go to step 7.
Monitor?
8 CHECK INPUT SIGNAL FOR TCM. Is the voltage more than AC 1 Even if the Go to step 11.
1)Connect all connectors. V? POWER indicator
2)Lift-up or raise the vehicle and place safety lights up, the cir-
stands. cuit has returned
On AWD models, raise all wheels off floor. tion at this time. A
3)Start the engine and set vehicle in 20 km/h temporary poor
(12 MPH) condition. contact or har-
ness may be the
NOTE:
The speed difference between front and rear cause. Repair the
wheels may light the ABS warning light, but this harness or con-
indicates no malfunction. When AT control di- nector in the front
agnosis is finished, perform the ABS memory vehicle speed sen-
clearance procedure of on-board diagnostics sor circuit.
system. <Ref. to ABS-22, Clear Memory
Mode.>
tor terminals.
(B55) No. 18 (+) — (B54) No. 10 (−):
AT-59
Step Check Yes No

9 CHECK FRONT VEHICLE SPEED SENSOR Is the voltage more than AC 4 Even if the Go to step 11.
USING OSCILLOSCOPE. V? POWER indicator
1)Connect all connectors. lights up, the cir-
2)Lift-up the vehicle and place safety stand. cuit has returned
On AWD models, raise all wheels off ground. tion at this time. A
3)Set the oscilloscope to TCM connector termi- temporary poor
nals. contact or har-
Connector & terminal ness may be the
Positive probe; (B55) No. 18 cause. Repair the
Earth lead; (B54) No. 10 harness or con-
nector in front
1)Start the engine, and drive the wheels
vehicle speed sen-
slowly.
sor circuit.
NOTE:
wheels may light the ABS warning light, but this
indicates no malfunctions. When AT control di-
<Ref. to ABS-22, Clear Memory Mode.>
oscilloscope.
10 CHECK INPUT SIGNAL FOR TCM USING Does the speedometer indica- Even if the Go to step 11.
SUBARU SELECT MONITOR. tion increase as Subaru Select POWER indicator
1)Connect all connectors. Monitor data increases? lights up, the cir-
3)Lift-up or raise the vehicle and place safety tion at this time. A
stands. temporary poor
NOTE: connector or har-
On AWD models, raise all wheels off floor. ness may be the
4)Turn the ignition switch to ON and turn Sub- cause. Repair the
aru Select Monitor switch to ON. harness or con-
5)Start the engine. nector in front
6)Read the data of vehicle speed using Subaru vehicle speed sen-
Select Monitor. sor circuit.
•Compare the speedometer with Subaru
Select Monitor indications.
•Vehicle speed is indicated in “km/h” or “MPH”.
7)Slowly increase the vehicle speed to 60 km/h
or 37 MPH.
NOTE:
indicates no malfunction. When AT control di-
clearance procedure of on-board diagnostics
Mode.>
11 CHECK POOR CONTACT. Is there poor contact in front Repair the poor Replace the TCM.
vehicle speed sensor circuit? contact. <Ref. to AT-46,
Transmission Con-
trol Module
(TCM).>
AT-60
AT-61
F: DTC 36 TORQUE CONVERTER TURBINE SPEED SENSOR

DIAGNOSIS:
The input signal circuit of TCM is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B55 TCM
8
9
SHIELD
9 3 3
JOINT
7 1 1
8 2 2 CONNECTOR
LH RN RT
B53
B11
14
15
LH : LHD MODEL
T4
TORQUE
CONVERTER
TURBINE SPEED
SENSOR
LH
B11 B55 B53 : B53 : RT
RN
1 2 3 4 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6
5 6 7 8 10 11 12 13 14 15 16 17 18
9 10 11 12 19 20 21 22 23 24
13 14 15 16
17 18 19 20
TR0919
AT-62
Step Check Yes No

1 CHECK TORQUE CONVERTER TURBINE Is the resistance between 450 Go to step 2. Replace the tur-
SPEED SENSOR. and 650 Ω? bine speed sen-
1)Turn the ignition switch to OFF. sor. <Ref. to AT-
2)Disconnect the connector from transmission. 37, Torque Con-
3)Measure the resistance between transmis- verter Turbine
sion connector receptacle's terminals. Speed Sensor.>
(T4) No. 14 — No. 15:
1)Disconnect the connector from TCM. between TCM and
2)Measure the resistance of harness between transmission con-
TCM and transmission connector. nector.
(B55) No. 8 — (B11) No. 14:
(B55) No. 9 — (B11) No. 15: contact in cou-
pling connector.
TCM and chassis ground. transmission con-
(B55) No. 8 — Chassis ground: contact in cou-
pling connector.
Monitor?
1)Connect the connectors to TCM and trans- V? POWER indicator
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 connection at this time. A
tor terminals. temporary poor
Connector & terminal contact of the con-
(B55) No. 8 (+) — No. 9 (−): nector or harness
may be the cause.
Repair the har-
ness or connector
in TCM and trans-
mission.
AT-63
Step Check Yes No

9 CHECK INPUT SIGNAL FOR TCM USING Is the revolution value same as Even if the Go to step 11.
SUBARU SELECT MONITOR. the tachometer reading shown POWER indicator
1)Connect the connectors to TCM and trans- on 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 Sub- temporary poor
aru 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 the har-
Select Monitor. ness or connector
•Compare the tachometer with Subaru Select in TCM and trans-
Monitor indications. mission.
10 CHECK INPUT SIGNAL FOR TCM USING Is the signal voltage more than Even if the Go to step 11.
OSCILLOSCOPE. AC 1 V? POWER indicator
1)Connect the connectors to TCM and trans- lights up, the cir-
2)Set the oscilloscope to TCM connector termi- to a normal condi-
nals. tion at this time. A
Positive probe; (B55) No. 8 contact of the con-
Earth lead; (B55) No. 9 nector or harness
3)Start the engine and move select lever to “P” may be the cause.
or “N” range. Repair the har-
ness or connector
in TCM and trans-
mission.
11 CHECK POOR CONTACT. Is there poor contact in torque Repair the poor Replace the TCM.
converter turbine speed sensor contact. <Ref. to AT-46,
circuit? Transmission Con-
trol Module
(TCM).>
AT-64
AT-65
G: DTC 38 TORQUE CONTROL SIGNAL

DIAGNOSIS:
• The signal circuit is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B56 TCM
14
5
NA : NON-TURBO MODEL
TB : TURBO MODEL
TB NA
17
16
18
19
NA : B135 ECM
TB : B134
B56 B134 : TB
B135 : NA
1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 1 2 3 4 5 6 7
10 11 12 13 14 15 16 17 18 8 9 10 11 12 13 14 15 16 17 18 19 8 9 10 11 12 13 14 15
19 20 21 22 23 24 20 21 22 23 24 25 26 27 28 16 17 18 19 20 21 22
TR0920
Step Check Yes No

ECM.
NON-TURBO MODEL
(B56) No. 14 — (B135) No. 17:
(B56) No. 5 — (B135) No. 16:
TURBO MODEL
(B56) No. 14 — (B134) No. 18:
(B56) No. 5 — (B134) No. 19:
AT-66
Step Check Yes No

3 CHECK OUTPUT SIGNAL EMITTED FROM Is the voltage more than 4.8 V? Even if the Go to step 4.
TCM. POWER indicator
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
(B56) No. 5 (+) — Chassis ground (−): nector or harness
may be the cause.
Repair the har-
ness or connector
in TCM and ECM.
4 CHECK POOR CONTACT. Is there poor contact in torque Repair the poor Go to step 5.
control signal circuit? contact.
5 CHECK GROUND LINE BETWEEN TRANS- Is there any dirt or rust at the Remove dirt and Go to step 6.
MISSION AND BODY. ground line installing point? rust.
Check installing condition of the ground line in
transmission and body.
6 CHECK GROUND LINE BETWEEN TRANS- Is the tightening torque value Go to step 7. Tighten to the
MISSION AND BODY. within specification? specified torque.
Check installing condition of the ground line in
transmission and body.
Tightening torque:
13 N·m (1.3 kgf-m, 9.4 ft-lb)
7 CHECK GROUND LINE INSIDE TRANSMIS- Is the tightening torque value Go to step 9. Tighten to the
SION. within specification? specified torque.
1)Drain the ATF and remove oil pan.
2)Check the tightening torque value of ground
line installing bolt.
Tightening torque:
T: 8 N·m (0.8 kgf-m, 5.8 ft-lb)
8 CHECK GROUND CIRCUIT OF ECM. Is there any trouble? Repair the ground Go to step 9.
<Ref. to AT-50, DTC 31 THROTTLE POSI- terminal and/or
TION SENSOR, Diagnostic Procedure with ground circuit of
Diagnostic Trouble Code (DTC).> ECM.
9 RECHECK OUTPUT SIGNAL EMITTED Is each voltage more than 4 V? Replace the TCM. Replace the ECM.
FROM TCM. <Ref. to AT-46,
Measure the voltage between TCM connector Transmission Con-
and chassis ground. trol Module
Connector & terminal (TCM).>
AT-67
H: DTC 45 INTAKE MANIFOLD PRESSURE SIGNAL (NON-TURBO MODEL)

DIAGNOSIS:
The input signal circuit of TCM from ECM is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B136 ECM
11 1
B54 TCM
B54 B136
1 2 3 4 5 6 7
1 2 3 4 5 6 7 8 9
8 9 10 11 12 13 14 15 16 17 18 19 20
10 11 12 13 14 15 16 17 18
21 22 23 24 25 26 27 28 29 30
19 20 21 22 23 24
TR0921
Step Check Yes No

1 CHECK ENGINE GROUND TERMINALS AND Is there any trouble? Repair the ground Go to step 2.
GROUND CIRCUIT OF ECM terminal and/or
<Ref. to AT-50, DTC 31 THROTTLE POSI- ground circuit of
TION SENSOR, Diagnostic Procedure with ECM.
ECM.
(B54) No. 1 — (B136) No. 11:
Monitor?
AT-68
Step Check Yes No

5 CHECK INPUT SIGNAL FOR TCM. Is the voltage between 0.4 and Even if the Go to step 7.
1)Connect the connectors to TCM and ECM. 1.6 V? POWER indicator
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-
If ambient temperature is below 0°C (32°F), temporary poor
drive the vehicle until ATF reaches its operating contact of the con-
temperature. nector or harness
4)Measure the voltage between TCM connec- Repair the har-
tor and chassis ground. ness or connector
Connector & terminal in TCM and ECM.
6 CHECK INPUT SIGNAL FOR TCM USING Is the value voltage between Even if the Go to step 7.
SUBARU SELECT MONITOR. 0.4 and 1.6 V? POWER indicator
3)Start the engine, and turn Subaru Select tion at this time. A
6)Read the data of intake manifold pressure Repair the har-
signal using Subaru Select Monitor. ness or connector
•Display shows the intake manifold pressure in TCM and ECM.
signal value sent from ECM.
7 CHECK POOR CONTACT. Is there poor contact in intake Repair the poor Replace the TCM.
manifold pressure signal cir- contact. <Ref. to AT-46,
cuit? Transmission Con-
trol Module
(TCM).>
AT-69
I: DTC 71 SHIFT SOLENOID 1

DIAGNOSIS:
The output signal circuit of shift solenoid 1 is open or shorted.
TROUBLE SYMPTOM:
Does not shift.
WIRING DIAGRAM:
B54 TCM
22
B11
1
T4
AT5
SHIFT
SOLENOID 1
TRANSMISSION
B11 B54
1 2 3 4 1 2 3 4 5 6 7 8 9
5 6 7 8 10 11 12 13 14 15 16 17 18
9 10 11 12 19 20 21 22 23 24
13 14 15 16
17 18 19 20
TR0410
Step Check Yes No

TCM and shift solenoid 1 connector.
(B54) No. 22 — (B11) No. 1:
AT-70
Step Check Yes No

3 CHECK SHIFT SOLENOID 1. Is the resistance between 10 Go to step 4. Go to step 7.
Measure the resistance between transmission and 16 Ω?
connector terminals.
(T4) No. 1 — No. 16:
4 CHECK OUTPUT SIGNAL EMITTED FROM Is the voltage more than 9V? Go to step 5. Go to step 6.
TCM.
1)Connect the connectors to TCM and trans-
mission.
3)Move the select lever to “D” range.
5 CHECK OUTPUT SIGNAL EMITTED FROM Is the voltage less than 1V? Even if the Go to step 6.
1)Turn the HOLD mode switch to ON. lights up, the cir-
contact of the con-
nector or harness
may be the cause.
Repair the har-
ness or contact in
TCM.
6 CHECK POOR CONTACT. Is there poor contact in shift Repair poor con- Replace the TCM.
solenoid 1 circuit? tact. <Ref. to AT-46,
Transmission Con-
trol Module
(TCM).>
7 CHECK SHIFT SOLENOID 1 (IN TRANSMIS- Is the resistance between 10 Go to step 8. Replace the shift
SION). and 16 Ω? solenoid 1. <Ref.
1)Remove the transmission connector from to AT-40, Shift
bracket. Solenoids, Duty
2)Lift-up or raise the vehicle and support with Solenoids and
safety stand. ATF Temperature
NOTE: Sensor.>
3)Drain the ATF.
CAUTION:
4)Remove the oil pan, and disconnect connec-
tor from shift solenoid 1.
5)Measure the resistance between shift sole-
noid 1 connector and transmission ground.
Terminal
No. 1 — Transmission ground:
AT-71
Step Check Yes No

SHIFT SOLENOID 1 AND TRANSMISSION. Ω? circuit in harness
Measure the resistance of harness between between shift sole-
shift solenoid 1 and transmission connector. noid 1 and trans-
Connector & terminal mission connector.
(AT5) No. 1 — (T4) No. 1:
9 CHECK HARNESS CONNECTOR BETWEEN Is the resistance more than 1 Even if the Repair the short
SHIFT SOLENOID 1 AND TRANSMISSION. MΩ? POWER indicator circuit harness
Measure the resistance of harness between lights up, the cir- between shift sole-
shift solenoid 1 connector and transmission cuit has returned noid 1 and trans-
ground. to a normal condi- mission connector.
(T4) No. 1 — Transmission ground: temporary poor
contact of the con-
nector or harness
may be the cause.
Repair the har-
ness or connector
in shift solenoid 1
and transmission.
AT-72
AT-73
J: DTC 72 SHIFT SOLENOID 2

DIAGNOSIS:
The output signal circuit of shift solenoid 2 is open or shorted.
TROUBLE SYMPTOM:
Does not shift.
WIRING DIAGRAM:
B54 TCM
5
B11
2
T4
AT6
SHIFT
SOLENOID 2
TRANSMISSION
B11 B54
1 2 3 4 1 2 3 4 5 6 7 8 9
5 6 7 8 10 11 12 13 14 15 16 17 18
9 10 11 12 19 20 21 22 23 24
13 14 15 16
17 18 19 20
TR0411
Step Check Yes No

TCM and shift solenoid 2 connector.
(B54) No. 5 — (B11) No. 2:
AT-74
Step Check Yes No

TCM connector and transmission ground. transmission con-
3 CHECK SHIFT SOLENOID 2. Is the resistance between 10 Go to step 4. Go to step 6.
(T4) No. 2 — No. 16:
4 CHECK OUTPUT SIGNAL EMITTED FROM Is the voltage less than 1 V? Even if the Go to step 5.
2)Lift-up or raise the vehicle and support with to a normal condi-
safety stand. tion at this time. A
NOTE: temporary poor
On AWD models, raise all wheels off ground. contact of the con-
3)Start the engine and warm-up the transmis- nector or harness
sion until ATF temperature is above 80°C may be the cause.
(176°F). Repair the har-
ness or connector
NOTE:
If ambient temperature is below 0°C (32°F), in TCM and trans-
drive the vehicle until ATF reaches its operating mission.
temperature.
4)Move the selector lever to “D” range, and
MPH).
NOTE:
Mode.>
5 CHECK POOR CONTACT. Is there poor contact in shift Repair the poor Replace the TCM.
solenoid 2 circuit? contact. <Ref. to AT-46,
Transmission Con-
trol Module
(TCM).>
6 CHECK SHIFT SOLENOID 2 (IN TRANSMIS- Is the resistance between 10 Go to step 7. Replace the shift
SION). and 16 Ω? solenoid 2 assem-
1)Remove the transmission connector from bly. <Ref. to AT-
bracket. 40, Shift Sole-
2)Drain the ATF. noids, Duty Sole-
CAUTION: noids and ATF
Do not drain the ATF until it cools down. Temperature Sen-
3)Remove the oil pan, and disconnect connec- sor.>
tor from shift solenoid 2.
4)Measure the resistance between shift sole-
noid 2 connector and transmission ground.
AT-75
Step Check Yes No

SHIFT SOLENOID 2 AND TRANSMISSION. Ω? circuit 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:
SHIFT SOLENOID 2 AND TRANSMISSION. MΩ? POWER indicator circuit harness
Measure the resistance of harness between lights up, the cir- between shift sole-
shift solenoid 2 connector and transmission cuit has returned noid 2 and trans-
ground. to a normal condi- mission connector.
(T4) No. 2 — Transmission ground: temporary poor
contact of the con-
nector or harness
may be the cause.
Repair the har-
ness or connector
in shift solenoid 2
and transmission.
AT-76
AT-77
K: DTC 73 LOW CLUTCH TIMING SOLENOID

DIAGNOSIS:
The output signal circuit of low clutch timing solenoid is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B54 TCM
15
B11
3
T4
AT9
LOW CLUTCH
TIMING
SOLENOID
TRANSMISSION
B11 B54
1 2 3 4 1 2 3 4 5 6 7 8 9
5 6 7 8 10 11 12 13 14 15 16 17 18
9 10 11 12 19 20 21 22 23 24
13 14 15 16
17 18 19 20
TR0412
Step Check Yes No

(B54) No. 15 — (B11) No. 3:
AT-78
Step Check Yes No

3 CHECK LOW CLUTCH TIMING SOLENOID. Is the resistance between 10 Go to step 4. Go to step 7.
(T4) No. 3 — No. 16:
4 CHECK OUTPUT SIGNAL EMITTED FROM Is the voltage more than 9 V? Go to step 5. Go to step 6.
TCM.
mission.
3)Move the select lever to “D” range.
5 CHECK OUTPUT SIGNAL EMITTED FROM Is the voltage less than 1 V? Even if the Go to step 6.
1)Turn the HOLD mode switch to ON. lights up, the cir-
contact of the con-
nector or harness
may be the cause.
Repair the har-
ness or contact in
TCM and trans-
mission.
6 CHECK POOR CONTACT. Is there poor contact in low Repair the poor Replace the TCM.
clutch timing solenoid circuit? contact. <Ref. to AT-46,
Transmission Con-
trol Module
(TCM).>
7 CHECK LOW CLUTCH TIMING SOLENOID Is the resistance between 10 Go to step 8. Replace the low
(IN TRANSMISSION). and 16 Ω? clutch timing sole-
1)Remove the transmission connector from noid. <Ref. to AT-
2)Lift-up or raise the vehicle and support with noids, Duty Sole-
safety stand. noids and ATF
On AWD models, raise all wheels off ground. sor.>
3)Drain the ATF.
CAUTION:
tor from low clutch timing solenoid.
5)Measure the resistance between low clutch
timing solenoid connector and transmission
ground.
Terminal
AT-79
Step Check Yes No

LOW CLUTCH TIMING SOLENOID AND Ω? circuit in harness
TRANSMISSION. between low
Measure the resistance of harness between clutch timing sole-
low clutch timing solenoid and transmission noid and transmis-
connector. sion connector.
(AT9) No. 1 — (T4) No. 3:
LOW CLUTCH TIMING SOLENOID AND MΩ? POWER indicator circuit harness
TRANSMISSION. lights up, the cir- between low
Measure the resistance of harness between cuit has returned clutch timing sole-
low clutch timing solenoid connector and trans- to a normal condi- noid and transmis-
mission ground. tion at this time. A sion connector.
(T4) No. 3 — Transmission ground: contact of the con-
nector or harness
may be the cause.
Repair the har-
ness or connector
in low clutch timing
solenoid and
transmission.
AT-80
AT-81
L: DTC 74 2-4 BRAKE TIMING SOLENOID

DIAGNOSIS:
The output signal circuit of 2-4 brake timing solenoid is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B54 TCM
16
B11
4
T4
AT8
2-4 BRAKE
TIMING
SOLENOID
TRANSMISSION
B11 B54
1 2 3 4 1 2 3 4 5 6 7 8 9
5 6 7 8 10 11 12 13 14 15 16 17 18
9 10 11 12 19 20 21 22 23 24
13 14 15 16
17 18 19 20
TR0413
Step Check Yes No

(B54) No. 16 — (B11) No. 4:
AT-82
Step Check Yes No

(B54) No. 16 — Transmission ground:
3 CHECK 2-4 BRAKE TIMING SOLENOID. Is the resistance between 10 Go to step 4. Go to step 7.
(T4) No. 4 — No. 16:
4 CHECK OUTPUT SIGNAL EMITTED FROM Is the voltage less than 1 V? Go to step 5. Go to step 6.
TCM.
mission.
2)Lift-up or raise the vehicle and support with
safety stand.
NOTE:
3)Start the engine and warm-up the transmis-
sion until ATF temperature is above 80°C
(176°F).
NOTE:
temperature.
4)Move the selector lever to “1” range, and
MPH).
NOTE:
Mode.>
5 CHECK OUTPUT SIGNAL EMITTED FROM Is the voltage more than 9 V? Even if the Go to step 6.
1)Move the selector lever to “D” range, and lights up, the cir-
slowly increase vehicle speed to 65 km/h (40 cuit has returned
MPH). to a normal condi-
The speed difference between front and rear temporary poor
wheels may light the ABS warning light, but this contact of the con-
indicates no malfunction. When AT control di- nector or harness
agnosis is finished, perform the ABS memory may be the cause.
clearance procedure of on-board diagnostics Repair the har-
system. <Ref. to ABS-22, Clear Memory ness or contact in
Mode.> transmission.
AT-83
Step Check Yes No

6 CHECK POOR CONTACT. Is there poor contact in 2-4 Repair the poor Replace the TCM.
brake timing solenoid circuit? contact. <Ref. to AT-46,
Transmission Con-
trol Module
(TCM).>
7 CHECK 2-4 BRAKE TIMING SOLENOID (IN Is the resistance between 10 Go to step 8. Replace the 2-4
TRANSMISSION). and 16 Ω? brake timing sole-
2)Lift-up or raise the vehicle and support with noids, Duty Sole-
safety stand. noids and ATF
On AWD models, raise all wheels off ground. sor.>
3)Drain the ATF.
CAUTION:
tor from 2-4 brake timing solenoid.
5)Measure the resistance between 2-4 brake
timing solenoid connector and transmission
ground.
Terminal
2-4 BRAKE TIMING SOLENOID AND Ω? circuit 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.
(AT8) No. 1 — (T4) No. 4:
2-4 BRAKE TIMING SOLENOID AND MΩ? POWER indicator circuit harness
TRANSMISSION. lights up, the cir- between 2-4 brake
Measure the resistance of harness between 2- cuit has returned timing solenoid
4 brake timing solenoid connector and trans- to a normal condi- and transmission
mission ground. tion at this time. A connector.
nector or harness
may be the cause.
Repair the har-
ness or connector
in 2-4 brake tim-
ing solenoid and
transmission.
AT-84
AT-85
M: DTC 75 LINE PRESSURE DUTY SOLENOID

DIAGNOSIS:
The output signal circuit of line pressure duty solenoid is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B54 TCM
9
B11
5
T4
AT2
LINE
PRESSURE
DUTY
SOLENOID
TRANSMISSION
B11 B54
1 2 3 4 1 2 3 4 5 6 7 8 9
5 6 7 8 10 11 12 13 14 15 16 17 18
9 10 11 12 19 20 21 22 23 24
13 14 15 16
17 18 19 20
TR0414
Step Check Yes No

and TCM. nector.
(B54) No. 9 — (B11) No. 5:
TCM AND CHASSIS GROUND. MΩ? circuit in harness
3 CHECK LINE PRESSURE DUTY SOLENOID. Is the resistance between 2.0 Go to step 4. Go to step 10.
Measure the resistance between transmission and 4.5 Ω?
connector receptacle's terminals.
Terminal
(T4) No. 5 — No. 16:
Monitor?
AT-86
Step Check Yes No

5 CHECK OUTPUT SIGNAL EMITTED FROM Is the voltage between 1.5 and Go to step 6. Go to step 9.
TCM. 5.0 V with throttle fully closed?
1)Connect all connectors.
(176°F).
NOTE:
temperature.
4)Move the select lever to “N” range.
6 CHECK OUTPUT SIGNAL EMITTED FROM Is the voltage less than 1 V Even if the Go to step 9.
TCM. with throttle fully open? POWER indicator
temporary poor
contact of the con-
nector or harness
may be the cause.
Repair the har-
ness or connector
in transmission.
7 CHECK OUTPUT SIGNAL EMITTED FROM Is the value 100 %? Go to step 8. Go to step 9.
TCM USING SUBARU SELECT MONITOR.
mission.
link connector.
3)Start the engine and turn Subaru Select
Monitor switch to ON.
ature is above 80°C (176°F).
NOTE:
temperature.
ON (engine OFF).
7)Read the data of line pressure duty solenoid
•Line pressure duty solenoid is indicated in
“%”.
8)Throttle is fully closed.
AT-87
Step Check Yes No

8 CHECK OUTPUT SIGNAL EMITTED FROM Is the value less than 25 %? Even if the Go to step 9.
TCM USING SUBARU SELECT MONITOR. POWER indicator
2)Throttle is fully open. cuit has returned
to a normal condi-
tion at this time. A
temporary poor
contact of the con-
nector or harness
may be the cause.
Repair the har-
ness or connector
in transmission.
9 CHECK POOR CONTACT. Is there poor contact in line Repair the poor Replace the TCM.
pressure duty solenoid circuit? contact. <Ref. to AT-46,
Transmission Con-
trol Module
(TCM).>
10 CHECK LINE PRESSURE DUTY SOLENOID Is the resistance between 2.0 Go to step 11. Replace the line
(IN TRANSMISSION). and 4.5 Ω? pressure duty
1)Remove the transmission connector from solenoid. <Ref. to
bracket. AT-40, Shift Sole-
tor from line pressure duty solenoid.
4)Measure the resistance between line pres-
sure duty solenoid connector and transmission
ground.
Terminal
TRANSMISSION AND LINE PRESSURE Ω? circuit in harness
DUTY SOLENOID. between line pres-
Measure the resistance of harness between sure duty solenoid
line pressure duty solenoid and transmission and transmission
connector. connector.
(T4) No. 5 — (AT2) No. 1:
TRANSMISSION AND LINE PRESSURE MΩ? POWER indicator circuit in harness
DUTY SOLENOID. lights up, the cir- between line pres-
Measure the resistance of harness between cuit has returned sure duty solenoid
transmission connector and transmission to a normal condi- and transmission
ground. tion at this time. A connector.
nector or harness
may be the cause.
Repair the har-
ness or connector
in line pressure
duty solenoid and
transmission.
AT-88
AT-89
N: DTC 76 2-4 BRAKE DUTY SOLENOID

DIAGNOSIS:
The output signal circuit of 2-4 brake duty solenoid is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B54 TCM
18
B11
9
T4
AT7
2-4
BRAKE DUTY
SOLENOID
TRANSMISSION
B11 B54
1 2 3 4 1 2 3 4 5 6 7 8 9
5 6 7 8 10 11 12 13 14 15 16 17 18
9 10 11 12 19 20 21 22 23 24
13 14 15 16
17 18 19 20
TR0415
Step Check Yes No

and TCM. nector.
(B54) No. 18 — (B11) No. 9:
TCM AND CHASSIS GROUND. MΩ? circuit in harness
3 CHECK 2-4 BRAKE DUTY SOLENOID. Is the resistance between 2.0 Go to step 4. Go to step 10.
Measure the resistance between transmission and 4.5 Ω?
Terminal
(T4) No. 16 — No. 9:
Monitor?
AT-90
Step Check Yes No

5 CHECK OUTPUT SIGNAL EMITTED FROM Is the voltage between 1.5 and Go to step 6. Go to step 9.
TCM. 5.0 V with throttle fully closed?
(176°F).
NOTE:
temperature.
6 CHECK OUTPUT SIGNAL EMITTED FROM Is the voltage less than 1 V Even if the Go to step 9.
TCM. with throttle fully open? POWER indicator
temporary poor
contact of the con-
nector or harness
may be the cause.
Repair the har-
ness or connector
in TCM and trans-
mission.
link connector.
ature is above 80°C (176°F).
NOTE:
temperature.
ON (engine OFF).
7)Read the data of 2-4 brake duty solenoid
•2-4 brake duty solenoid is indicated in “%”.
AT-91
Step Check Yes No

8 CHECK OUTPUT SIGNAL EMITTED FROM Is the value less than 25 %? Even if the Go to step 9.
2)Throttle is fully open. cuit has returned
to a normal condi-
tion at this time. A
temporary poor
contact of the con-
nector or harness
may be the cause.
Repair the har-
ness or connector
in TCM and trans-
mission.
9 CHECK POOR CONTACT. Is there poor contact in 2-4 Repair the poor Replace the TCM.
brake duty solenoid circuit? contact. <Ref. to AT-46,
Transmission Con-
trol Module
(TCM).>
10 CHECK 2-4 BRAKE DUTY SOLENOID (IN Is the resistance between 2.0 Go to step 11. Replace the 2-4
TRANSMISSION). and 4.5 Ω? brake duty sole-
tor from 2-4 brake duty solenoid.
4)Measure the resistance between 2-4 brake
duty solenoid connector and transmission
ground.
Terminal
TRANSMISSION AND 2-4 BRAKE DUTY SO- Ω? circuit 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.
(T4) No. 9 — (AT7) No. 1:
TRANSMISSION AND 2-4 BRAKE DUTY SO- MΩ? POWER indicator circuit in harness
LENOID. lights up, the cir- between 2-4 brake
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.
nector or harness
may be the cause.
Repair the har-
ness or connector
in line pressure
duty solenoid and
transmission.
AT-92
AT-93
O: DTC 77 LOCK-UP DUTY SOLENOID

DIAGNOSIS:
The output signal circuit of lock-up duty solenoid is open or shorted.
TROUBLE SYMPTOM:
No “lock-up” (after engine warm-up).
WIRING DIAGRAM:
B54 TCM
7
B11
13
T4
AT3
LOCK-UP
DUTY
SOLENOID
TRANSMISSION
B11 B54
1 2 3 4 1 2 3 4 5 6 7 8 9
5 6 7 8 10 11 12 13 14 15 16 17 18
9 10 11 12 19 20 21 22 23 24
13 14 15 16
17 18 19 20
TR0416
Step Check Yes No

1 CHECK DIAGNOSTIC TROUBLE CODE Do multiple DTCs appear in Go to another Go to step 2.
(DTC). the on-board diagnostics test DTC.
mode?
AT-94
Step Check Yes No

(B54) No. 7 — (B11) No. 13:
Measure the resistance of harness connector between TCM and
between TCM and chassis ground. transmission con-
4 CHECK LOCK-UP DUTY SOLENOID. Is the resistance between 10 Go to step 5. Go to step 11.
(T4) No. 13 — No. 16:
Monitor?
6 CHECK OUTPUT SIGNAL EMITTED FROM Is the voltage more than 8.5 V? Go to step 7. Go to step 10.
TCM.
mission.
NOTE:
(176°F).
NOTE:
temperature.
MPH). Wheels will lock-up.
NOTE:
Mode.>
AT-95
Step Check Yes No

7 CHECK OUTPUT SIGNAL EMITTED FROM Is the voltage less than 0.5 V? Even if the Go to step 10.
1)Return the engine to idling speed and move lights up, the cir-
select lever to “N” range. cuit has returned
2)Measure the voltage between TCM connec- to a normal condi-
tor and chassis ground. tion at this time. A
nector or harness
may be the cause.
Repair the har-
ness or connector
in TCM and trans-
mission.
mission.
NOTE:
link connector.
(176°F).
NOTE:
temperature.
6)Read the data of lock-up duty solenoid using
Subaru Select Monitor.
•Lock-up duty solenoid is indicated in “%”.
MPH). Wheels will lock-up.
NOTE:
Mode.>
9 CHECK OUTPUT SIGNAL EMITTED FROM Is the value 5 %? Even if the Go to step 10.
Return the engine to idling speed and move lights up, the cir-
selector lever to “N” range. cuit has returned
The speed difference between front and rear 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 memory nector or harness
clearance procedure of on-board diagnostics may be the cause.
system. <Ref. to ABS-22, Clear Memory Repair the har-
Mode.> ness or connector
in TCM and trans-
mission.
AT-96
Step Check Yes No

10 CHECK POOR CONTACT. Is there poor contact in lock-up Repair poor con- Replace the TCM.
duty solenoid circuit? tact. <Ref. to AT-46,
Transmission Con-
trol Module
(TCM).>
11 CHECK LOCK-UP DUTY SOLENOID (IN Is the resistance between 10 Go to step 12. Replace the lock-
TRANSMISSION). and 17 Ω? up duty solenoid.
1)Remove the transmission connector from <Ref. to AT-40,
bracket. Shift Solenoids,
2)Drain the ATF. Duty Solenoids
CAUTION: and ATF Temper-
Do not drain the ATF until it cools down. ature Sensor.>
3)Remove the oil pan and disconnect connec-
tor from lock-up duty solenoid.
4)Measure the resistance between lock-up
ground.
Terminal
LOCK-UP DUTY SOLENOID AND TRANS- Ω? circuit in harness
MISSION. between TCM and
Measure the resistance of harness between transmission con-
lock-up duty solenoid and transmission connector.
nector.
(T4) No. 13 — (AT3) No. 1:
LOCK-UP DUTY SOLENOID AND TRANS- MΩ? POWER indicator circuit in harness
MISSION. lights up, the cir- between lock-up
nector or harness
may be the cause.
Repair the har-
ness or connector
in lock-up duty
solenoid and
transmission.
AT-97
P: DTC 79 TRANSFER DUTY SOLENOID

DIAGNOSIS:
The output signal circuit of transfer duty solenoid is open or shorted.
TROUBLE SYMPTOM:
Excessive “braking” in tight corners.
WIRING DIAGRAM:
B54 TCM
6 6 B11
T4
AT4
TRANSFER
DUTY
SOLENOID
TRANSMISSION
B11 B54
1 2 3 4 1 2 3 4 5 6 7 8 9
5 6 7 8 10 11 12 13 14 15 16 17 18
9 10 11 12 19 20 21 22 23 24
13 14 15 16
17 18 19 20
TR0417
Step Check Yes No

(B54) No. 6 — (B11) No. 6:
AT-98
Step Check Yes No

Measure the resistance harness connector between TCM and
between TCM and chassis ground. transmission con-
3 CHECK TRANSFER DUTY SOLENOID. Is the resistance between 10 Go to step 4. Go to step 13.
connector and transmission terminals.
(T4) No. 6 — No. 16:
Monitor?
5 CHECK OUTPUT SIGNAL EMITTED FROM Is the voltage less than 1 V in Go to step 6. Go to step 12.
TCM. “P” range?
mission.
6 CHECK OUTPUT SIGNAL EMITTED FROM Is the voltage more than 8.5 V Even if the Go to step 12.
TCM. in “D” range? POWER indicator
temporary poor
contact of the con-
nector or harness
may be the cause.
Repair the har-
ness or connector
in TCM and trans-
mission.
7 CHECK VEHICLE Is the target Non-turbo vehi- Go to step 8. Go to step 10.
cle?
8 CHECK OUTPUT SIGNAL EMITTED FROM Is the value between 5 and 10 Go to step 9. Go to step 12.
TCM USING SUBARU SELECT MONITOR. %?
mission.
link connector.
3)Turn the ignition switch to ON (engine OFF)
and turn Subaru Select Monitor switch to ON.
4)Move the select lever to “D” range with throt-
tle fully open (vehicle speed 0 km/h or 0 MPH).
5)Read data of transfer duty solenoid using
•Transfer duty solenoid is indicated in “%”.
AT-99
Step Check Yes No

9 CHECK OUTPUT SIGNAL EMITTED FROM Is the value between approx. Even if the Go to step 12.
TCM USING SUBARU SELECT MONITOR. 60 % and approx. 70 %? POWER indicator
1)Move the select lever to “N” range with throt- lights up, the cir-
tle fully closed (vehicle speed 0 km/h or 0 cuit has returned
MPH). to a normal condi-
2)Read the data of transfer duty solenoid using tion at this time. A
Subaru Select Monitor. temporary poor
•Transfer duty solenoid is indicated in “%”. contact of the con-
nector or harness
may be the cause.
Repair the har-
ness or connector
in TCM and trans-
mission.
10 CHECK OUTPUT SIGNAL EMITTED FROM Is the value between 80 and 95 Go to step 11. Go to step 12.
TCM USING SUBARU SELECT MONITOR. %?
mission.
link connector.
3)Turn the ignition switch to ON (engine OFF)
and turn Subaru Select Monitor switch to ON.
4)Move the select lever to “D” range with throt-
tle fully open (vehicle speed 0 km/h or 0 MPH).
5)Read the data of transfer duty solenoid using
•Transfer duty solenoid is indicated in “%”.
11 CHECK OUTPUT SIGNAL EMITTED FROM Is the value approx. 40 %? Even if the AT OIL Go to step 12.
TCM USING SUBARU SELECT MONITOR. TEMP warning
1)Move the select lever to “N” range with throt- lights up, the cir-
tle fully close (vehicle speed 0 km/h or 0 MPH). cuit has returned
2)Read 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 the har-
ness or connector
in transfer duty
solenoid and TCM
connector.
12 CHECK POOR CONTACT. Is there poor contact in transfer Repair the poor Replace the TCM.
duty solenoid circuit? contact. <Ref. to AT-46,
Transmission Con-
trol Module
(TCM).>
AT-100
Step Check Yes No

13 CHECK TRANSFER DUTY SOLENOID (IN Is the resistance between 10 Go to step 14. Replace the trans-
TRANSMISSION). and 17 Ω? fer duty solenoid.
NOTE:
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
connector from transfer duty solenoid.
4)Measure the resistance between transfer
ground.
(AT4) No. 1 — Transmission ground:
TRANSFER DUTY SOLENOID AND TRANS- Ω? circuit in harness
MISSION. between transfer
Measure the resistance of harness between duty solenoid and
transfer duty solenoid and transmission con- transmission con-
nector. nector.
(T4) No. 6 — (AT4) No. 1:
TRANSFER DUTY SOLENOID AND TRANS- MΩ? POWER indicator circuit in harness
MISSION. lights up, the cir- between transfer
nector or harness
may be the cause.
Repair the har-
ness or contact in
transfer duty sole-
noid and transmis-
sion.
AT-101
Q: DTC 93 REAR VEHICLE SPEED SENSOR

DIAGNOSIS:
The input signal circuit of TCM is open or shorted.
TROUBLE SYMPTOM:
No lock-up or excessive tight corner “braking”.
WIRING DIAGRAM:
A: B54
TCM
B: B55
B24
A19
SHIELD AND
SENSOR GROUND
JOINT CONNECTOR
6 9 3
4 7 1
5 8 2
LH RN RT
B53
B11
20
19
T4
LH : LHD MODEL
REAR VEHICLE
SPEED SENSOR
LH
B53 : B11 B55 B54
RN
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9
5 6 7 8 10 11 12 13 14 15 16 17 18 10 11 12 13 14 15 16 17 18
9 10 11 12 19 20 21 22 23 24 19 20 21 22 23 24
B53 : RT
13 14 15 16
17 18 19 20
1 2 3 4 5 6
TR0922
AT-102
Step Check Yes No

(B55) No. 24 — (B11) No. 19:
TCM and transmission connector. transmission, and
Connector & terminal poor contact in
(B54) No. 19 — (B11) No. 20: coupling connec-
tor.
5 CHECK REAR VEHICLE SPEED SENSOR. Is the resistance between 450 Go to step 6. Replace the rear
Measure the resistance between transmission and 650 Ω? vehicle speed sen-
connector receptacle's terminals. sor. <Ref. to AT-
Connector & terminal 36, Rear Vehicle
(T4) No. 19 — No. 20: Speed Sensor.>
Monitor?
1)Connect the connectors to TCM and trans- V? POWER indicator
mission. lights up, the cir-
2)Lift-up or raise the vehicle and place safety cuit has returned
stands. to a normal condi-
On AWD models, raise all wheels off floor. temporary poor
3)Start the engine and set vehicle in 20 km/h contact of the con-
(12 MPH) condition. nector or harness
may be the cause.
NOTE:
The speed difference between front and rear Repair the har-
wheels may light the ABS warning light, but this ness or connector
indicates no malfunction. When AT control di- in TCM and trans-
agnosis is finished, perform the ABS memory mission.
Mode.>
tor terminals.
(B55) No. 24 (+) — (B54) No. 19 (−):
AT-103
Step Check Yes No

9 CHECK INPUT SIGNAL FOR TCM USING Does the speedometer indica- Even if the Go to step 11.
SUBARU SELECT MONITOR. tion increase as the Subaru POWER indicator
1)Connect the connectors to TCM and trans- Select Monitor data increases? lights up, the cir-
2)Connect the Subaru Select Monitor to data to a normal condi-
link connector. tion at this time. A
3)Lift-up or raise the vehicle and place safety temporary poor
stands. contact of the con-
NOTE: nector or harness
On AWD models, raise all wheels off floor. may be the cause.
4)Turn the ignition switch to ON and turn Sub- Repair the har-
aru Select Monitor switch to ON. ness or connector
5)Start the engine. in TCM and trans-
6)Read the data of vehicle speed using Subaru mission.
Select Monitor.
•Compare the speedometer with Subaru
Select Monitor indications.
•Vehicle speed is indicated in “km/h” or “MPH”.
7)Slowly increase the vehicle speed to 60 km/h
or 37 MPH.
NOTE:
Mode.>
10 CHECK INPUT SIGNAL FOR TCM USING Is the signal voltage more than Even if the Go to step 11.
OSCILLOSCOPE. AC 1 V? POWER indicator
2)Lift-up or raise the vehicle and place safety to a normal condi-
stands. tion at this time. A
NOTE: temporary poor
On AWD models, raise all wheels off floor. contact of the con-
3)Set the oscilloscope to TCM connector termi- nector or harness
nals. may be the cause.
Connector & terminal Repair the har-
Positive probe; (B55) No. 24 ness or connector
Earth lead; (B54) No. 19 in TCM and trans-
mission.
4)Start the engine and set vehicle in 20 km/h
(12 MPH) condition.
NOTE:
Mode.>
oscilloscope.
11 CHECK POOR CONTACT. Is there poor contact in rear Repair the poor Replace the TCM.
vehicle speed sensor circuit? contact. <Ref. to AT-46,
Transmission Con-
trol Module
(TCM).>
AT-104
DIAGNOSTIC PROCEDURE FOR NO-DIAGNOSTIC TROUBLE CODE (DTC)
15.Diagnostic Procedure for No-diagnostic Trouble Code (DTC)

A: CHECK GEAR POSITION.
Step Check Yes No
1 CHECK GEAR POSITION. Does the transmission gear Go to step 2. Check the shift
1)Lift-up the vehicle and place safety stand. correspond to the gear which solenoid 1 and
NOTE: is shown on display? shift solenoid 2
On AWD models, raise all wheels off ground. signal circuit.
2)Start the engine. <Ref. to AT-70,
3)Move the select lever to “D” range and drive DTC 71 SHIFT
vehicle. SOLENOID 1,
4)Read the data of gear position using Subaru Diagnostic Proce-
Select Monitor. dure with Diagnos-
•Gear position is indicated. tic Trouble Code
(DTC).> and <Ref.
NOTE:
The speed difference between front and rear to AT-74, DTC 72
wheels may light the ABS warning light, but this SHIFT SOLE-
indicates no malfunction. When AT control di- NOID 2, Diagnos-
agnosis is finished, perform the ABS memory tic Procedure with
clearance procedure of on-board diagnostics Diagnostic Trou-
system. <Ref. to ABS-22, Clear Memory ble Code (DTC).>
Mode.>
2 CHECK VEHICLE. Is the target Non-turbo vehi- Go to step CHECK Go to step CHECK
cle? FWD BRAKE SWITCH.
SWITCH.<Ref. to <Ref. to AT-110,
AT-106, CHECK CHECK BRAKE
FWD SWITCH., SWITCH., Diag-
Diagnostic Proce- nostic Procedure
dure for No-diag- for No-diagnostic
nostic Trouble Trouble Code
Code (DTC).> (DTC).>
AT-105
B: CHECK FWD SWITCH.

DIAGNOSIS:
• The LED does not come on even if FWD switch is ON.
• The FWD switch circuit is open or short.
AT-106
WIRING DIAGRAM:
LHD MODEL
BATTERY
SBF-4 SBF-1
IGNITION
SWITCH
COMBINATION
METER FWD SWITCH
No.13
A: i10
FWD
30
29
B: i11
F67
B4
A7
i1
F45
23
17
7
B36 B62
B20
C2
B: B55 C: B56 TCM

E
B56 B55 F45 B36
1 2 3 4 8 9 8 9 1 2 3 4 5 6 7 8 9 10 11
5 6 7 1 2 3 4 5 6 7
10 11 12 13 14 15 16 17 18 10 11 12 13 14 15 16 17 18 12 13 14 15 16 17 18 19 20 21 22 23 24
19 20 21 22 23 24 19 20 21 22 23 24
B: i11 A: i10
1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
TR0419
AT-107
RHD MODEL
BATTERY
SBF-4 SBF-1
IGNITION
SWITCH
E
COMBINATION
FWD SWITCH
METER
No.13
A: i10
FWD
30
29
B: i11 F67
B4
A7
i3
F45
22
1
15
B38 B62
B20
C2
B: B55 C: B56 TCM

E
B56 B55 B: i11
1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 10 11 12 13 14
10 11 12 13 14 15 16 17 18 10 11 12 13 14 15 16 17 18 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
19 20 21 22 23 24 19 20 21 22 23 24
F45 i3 A: i10
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6 7 8 9 10
9 10 11 12 13 14 15 16 17 18 11 12 13 14 15 16 17 18 19 20 21 22
TR0420
AT-108
Step Check Yes No

1 CHECK FWD SWITCH. When the fuse is inserted to Go to step CHECK Go to step 2.
FWD switch, does LED light BRAKE
up? SWITCH.<Ref. to
AT-110, CHECK
BRAKE SWITCH.,
Diagnostic Proce-
dure for No-diag-
nostic Trouble
Code (DTC).>
2 CHECK FWD INDICATOR LIGHT. Is the FWD indicator light bulb Go to step 3. Replace the FWD
1)Turn the ignition switch to OFF. OK? indicator light bulb.
2)Remove the combination meter. <Ref. to IDI-15,
3)Remove the FWD indicator light bulb from Combination
combination meter. Meter Assembly.>
TCM AND FWD SWITCH. Ω? circuit in harness
2)Disconnect the connector from TCM and FWD switch con-
FWD switch. nector.
TCM and FWD switch connector.
(B55) No. 20 — (F67) No. 30:
FWD SWITCH AND CHASSIS GROUND. Ω? circuit 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.
TCM AND FWD SWITCH. MΩ? circuit in harness
between TCM and body to make sure that cir- FWD switch con-
cuit does not short. nector.
6 CHECK INPUT SIGNAL FOR TCM. Is the voltage less than 1 V in Go to step 7. Go to step 11.
1)Turn the ignition switch to OFF. FWD switch while installing?
2)Connect the connector to TCM and FWD
switch.
4)Measure the signal voltage for TCM while
installing the fuse to FWD switch connector.
7 CHECK INPUT SIGNAL FOR TCM. Is the voltage between 6 and Go to step 8. Replace the TCM.
Measure the signal voltage for TCM while 9.1 V in FWD switch while <Ref. to AT-46,
removing the fuse from FWD switch connector. removing? Transmission Con-
Connector & terminal trol Module
(B55) No. 20 (+) — Chassis ground (−): (TCM).>
TCM AND COMBINATION METER. Ω? circuit in harness
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.
(B56) No. 2 — (i11) No. 4:
AT-109
Step Check Yes No

TCM AND COMBINATION METER. MΩ? circuit in harness
between TCM and chassis ground to make combination meter
sure that circuit does not short. connector.
10 CHECK OUTPUT SIGNAL EMITTED FROM Is the voltage less than 1 V in Go to step 11. Go to step 12.
TCM. FWD switch while installing?
2)Connect the connector to TCM and combina-
tion meter.
4)Measure the signal voltage for TCM while
installing and removing the fuse to FWD switch
connector.
11 CHECK OUTPUT SIGNAL EMITTED FROM Is the voltage between 6 and Go to step 12. Replace the TCM.
TCM. 9.1 V in FWD switch while <Ref. to AT-46,
Measure the signal voltage for TCM while removing? Transmission Con-
removing the fuse from FWD switch connector. trol Module
Connector & terminal (TCM).>
12 CHECK POOR CONTACT. Is there poor contact in FWD Repair the poor Replace the TCM.
switch circuit? contact. <Ref. to AT-46,
Transmission Con-
trol Module
(TCM).>
C: CHECK BRAKE SWITCH.

Step Check Yes No
1 CHECK BRAKE SWITCH. When the brake pedal is Go to step CHECK Check the brake
depressed, does LED light up? ABS SWITCH. switch circuit.
<Ref. to AT-111, <Ref. to EN-224,
CHECK ABS DTC P0703 —
SWITCH., Diag- BRAKE SWITCH
nostic Procedure INPUT MAL-
for No-diagnostic FUNCTION —,
Trouble Code Diagnostic Proce-
(DTC).> dure with Diagnos-
tic Trouble Code
(DTC).>
AT-110
D: CHECK ABS SWITCH.

Step Check Yes No
1 CHECK ABS SWITCH. Does the LED of ABS switch Check the ABS Go to step CHECK
light up? switch circuit. CRUISE CON-
<Ref. to ABS-136, TROL SWITCH.
DTC 44 — ABS- <Ref. to AT-111,
AT CONTROL CHECK CRUISE
(NON CON- CONTROL
TROLLED) —, SWITCH., Diag-
Diagnostics Chart nostic Procedure
with Subaru Select for No-diagnostic
Monitor.> and Trouble Code
<Ref. to ABS-138, (DTC).>
DTC 44 — ABS-
AT CONTROL
(CONTROLLED)
—, Diagnostics
Chart with Subaru
Select Monitor.>
E: CHECK CRUISE CONTROL SWITCH.

Step Check Yes No
1 CHECK CRUISE CONTROL SWITCH. When the cruise control is set, Go to step CHECK Check the cruise
does LED light up? KICK-DOWN control. <Ref. to
SWITCH. <Ref. to CC-29, Diagnos-
AT-112, CHECK tics Chart with
KICK–DOWN Trouble Code.>
SWITCH., Diag-
nostic Procedure
for No-diagnostic
Trouble Code
(DTC).>
AT-111
F: CHECK KICK–DOWN SWITCH.

DIAGNOSIS:
• The kick-down switch is ON when the throttle is fully opened, but is OFF when the throttle is partially open
or fully closed.
TROUBLE SYMPTOM:
No kick-down occurs (when the throttle is fully opened).
WIRING DIAGRAM:
B3M2169
AT-112
Step Check Yes No

1 CHECK KICK-DOWN SWITCH OPERATION. When the accelerator pedal is Go to step CHECK Go to step 2.
depressed, does “ON” dis- POWER MODE
played? SWITCH. <Ref. to
AT-115, CHECK
POWER MODE
SWITCH., Diag-
nostic Procedure
for No-diagnostic
Trouble Code
(DTC).>
2 CHECK KICK-DOWN SWITCH GROUND Is the resistance less than 1 Go to step 3. Repair the open
LINE. Ω? circuit in harness
1)Disconnect the connector from kick-down between kick-
switch. down switch and
2)Measure the resistance of harness connec- TCM.
tor between kick-down switch and chassis
ground.
3 CHECK KICK-DOWN SWITCH. Is the resistance less than 1 Go to step 4. Replace the kick-
Measure the resistance for kick-down switch Ω? down switch. <Ref.
when depressing the accelerator pedal. to SP-4, Accelera-
Terminals tor Pedal.>
No. 1 — No. 2:
4 CHECK KICK-DOWN SWITCH. Is the resistance more than 1 Go to step 5. Replace the kick-
Measure the resistance for kick-down switch MΩ? down switch.
when pressing the accelerator pedal.
Terminals
No. 1 — No. 2:
TCM AND KICK-DOWN SWITCH. Ω? circuit in harness
2)Disconnect the connectors from kick-down kick-down switch.
switch.
3)Measure the resistance of harness connec-
tor between TCM and kick-down switch.
(B55) No. 11 — (B129) No. 2:
TCM AND KICK-DOWN SWITCH. MΩ? circuit in harness
between TCM and chassis ground. chassis ground.
7 CHECK INPUT SIGNAL FOR TCM. Is the voltage less than 1 V? Go to step 8. Go to step 9.
2)Connect the connector to kick-down switch.
4)Measure the signal voltage for TCM when
depressing the accelerator pedal.
8 CHECK INPUT SIGNAL FOR TCM. Is the voltage more than 6.5 V? A temporary poor Go to step 9.
Measure the signal voltage for TCM when contact of the con-
pressing the accelerator pedal. nector and har-
Connector & terminal ness may be the
(B55) No. 11 (+) — Chassis ground (−): cause. Repair the
harness and con-
nector in TCM.
AT-113
Step Check Yes No

9 CHECK POOR CONTACT. Is there poor contact? Repair the poor Replace the TCM.
contact. <Ref. to AT-46,
Transmission Con-
trol Module
(TCM).>
AT-114
G: CHECK POWER MODE SWITCH.

DIAGNOSIS:
• The LED does not come on when power switch is ON.
• The power switch circuit is open or shorted.
TROUBLE SYMPTOM:
No power mode occurs.
WIRING DIAGRAM:
LHD MODEL
IGNITION
SWITCH BATTERY
SBF-4 SBF-1
E
A: i10
COMBINATION
METER B: i11
C11
B: B55 C: B56
POWER TCM
No.13
B23
B16
B15
A7
i1
23
1
POWER MODE AND

B36
SNOW HOLD MODE SWITCH
SNOW
POWER OFF
HOLD
2
5
4
B133
B133 B55 B56
1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9
1 2 3
10 11 12 13 14 15 16 17 18 10 11 12 13 14 15 16 17 18
4 5 6
19 20 21 22 23 24 19 20 21 22 23 24
i11 B36
i10
1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11
1 2 3 4 5 6 7 8 9 10
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 12 13 14 15 16 17 18 19 20 21 22 23 24
TR0923
AT-115
RHD MODEL
IGNITION
SWITCH BATTERY
SBF-4 SBF-1
E
A: i10
COMBINATION
METER B: i11
C11
B: B53 C: B56
TCM
POWER
No.13
B23
B16
B15
A7
i3
22
2
B38 POWER MODE AND

SNOW
POWER OFF
HOLD
2
5
4
B133
B133 B55 B56 i3
1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 10
1 2 3
4 5 6 10 11 12 13 14 15 16 17 18 10 11 12 13 14 15 16 17 18 11 12 13 14 15 16 17 18 19 20 21 22
19 20 21 22 23 24 19 20 21 22 23 24
i10 i11
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
TR0924
AT-116
Step Check Yes No

1 CHECK POWER SWITCH OPERATION. When the power switch is Go to step 5. Go to step 2.
turned to OFF, does LED light
up?
2 CHECK POWER SWITCH OPERATION. When the power switch is Go to step CHECK Go to step 3.
turned to ON, does LED light INHIBITOR
up? SWITCH. <Ref. to
AT-119, CHECK
INHIBITOR
SWITCH., Diag-
nostic Procedure
for No-diagnostic
Trouble Code
(DTC).>
3 CHECK POWER INDICATOR LIGHT. Is the POWER indicator light Go to step 4. Replace the
1)Turn the ignition switch to OFF. bulb OK? POWER indicator
2)Remove the combination meter. light bulb. <Ref. to
3)Remove the POWER indicator light bulb IDI-15, Combina-
from combination meter. tion Meter Assem-
bly.>
4 CHECK POWER SWITCH GROUND LINE. Is the resistance less than 1 Go to step 5. Repair the open
2)Disconnect the connector from power switch. between power
3)Measure the resistance of harness connec- switch and chassis
tor between power switch and chassis ground. ground.
5 CHECK POWER SWITCH. Is the resistance less than 1 Go to step 6. Repair the power
1)Turn the power switch to ON. Ω? switch.
2)Measure the resistance between terminals of
power switch.
Terminals
No. 5 — No. 4:
6 CHECK POWER SWITCH. Is the resistance more than 1 Go to step 7. Repair the power
1)Turn the power switch to OFF. MΩ? switch.
power switch.
Terminals
No. 5 — No. 4:
TCM AND POWER SWITCH. Ω? circuit in harness
between TCM and power switch. power switch con-
(B55) No. 23 — (B133) No. 3:
TCM AND POWER SWITCH. MΩ? circuit in harness
between TCM and chassis ground. power switch con-
9 CHECK INPUT SIGNAL FOR TCM. Is the voltage more than 10 V? Go to step 10. Replace the TCM.
1)Connect the connectors to TCM and power <Ref. to AT-46,
switch. Transmission Con-
2)Turn the ignition switch to ON (engine OFF). trol Module
3)Measure the signal voltage for TCM while (TCM).>
turning power switch to OFF.
AT-117
Step Check Yes No

10 CHECK INPUT SIGNAL FOR TCM. Is the voltage less than 1 V? Go to step 11. Replace the TCM.
Measure the signal voltage for TCM while turn- <Ref. to AT-46,
ing power switch to ON. Transmission Con-
(B55) No. 23 (+) — Chassis ground (–): (TCM).>
11 CHECK POOR CONTACT. Is there poor contact? Repair the poor A temporary poor
contact. contact of the con-
nector or harness
or connector in
power switch cir-
cuit.
AT-118
H: CHECK INHIBITOR SWITCH.

DIAGNOSIS:
The input signal circuit of inhibitor switch is open or shorted.
TROUBLE SYMPTOM:
• Shift characteristics are erroneous.
• Engine brake is not effected when selector lever is in “3” range.
AT-119
WIRING DIAGRAM:
LHD MODEL
SBF-1 SBF-4
BATTERY
IGNITION
SWITCH ILLUMINATION CONTROL CIRCUIT
COMBINATION
METER
A: i10
P R N D 3 2 1 C: i12
No.13
C13
C14
C12
C11
C10
C5
A7
C4
i1
16
18
15
23
19
14
3
4
B36
INHIBITOR SWITCH
P R N D 3 2 1
9 3
8 2
10 1
3 8
11 7
4 6
6 5
5 4
T7 T3 B12
14
7
3
6
1
TRANSMISSION
B55
CONTROL MODULE
E
T7 B12 C: i12 A: i10
1 2 3 4 5 6 1 2 3 4 1 2 3 4 5 6
1 2 3 4 5 6 7 8 9 10
7 8 9 10 11 12 5 6 7 8 1 2 3 10 11 12 13 14
9 10 11 12
B55 B36
1 2 3 4 7 8 9 1 2 3 4 5 6 7 8 9 10 11
5 6
10 11 12 13 14 15 16 17 18 12 13 14 15 16 17 18 19 20 21 22 23 24
19 20 21 22 23 24
TR0424
AT-120
RHD MODEL
SBF-1 SBF-4
BATTERY
IGNITION COMBINATION
SWITCH ILLUMINATION CONTROL CIRCUIT METER
A: i10
C: i12
No.13 P R N D 3 2 1
E
C13
C14
C10
C12
C11
C5
A7
C4
i3
10
22
6
7
4
5
B38
INHIBITOR SWITCH
P R N D 3 2 1
9 3
8 2
10 1
3 8
11 7
4 6
6 5
5 4
T7 T3 B12
14
7
4
3
6
1
TRANSMISSION
B55
CONTROL MODULE
E
T7 B12 C: i12 A: i10
1 2 3 4 5 6 1 2 3 4 1 2 3 4 5 6
1 2 3 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10
7 8 9 10 11 12 5 6 7 8
9 10 11 12
i3
B55
1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6 7 8 9
11 12 13 14 15 16 17 18 19 20 21 22
10 11 12 13 14 15 16 17 18
19 20 21 22 23 24
TR0925
AT-121
Step Check Yes No

1 CHECK “P” RANGE SWITCH. When the “P” range is Go to step 2. Go to step 22.
selected, does LED light up?
2 CHECK INDICATOR LIGHT. Does the combination meter Go to step 3. Go to step 26.
“P” range indicator illuminate?
3 CHECK “P” RANGE SWITCH. When the “R” range is Go to step 28. Go to step 4.
selected, does “P” range LED
light up?
4 CHECK “R” RANGE SWITCH. When the “R” range is Go to step 5. Go to step 29.
“R” range indicator illuminate?
6 CHECK “R” RANGE SWITCH. When the “N” range is Go to step 34. Go to step 7.
selected, does “R” range LED
light up?
7 CHECK “N” RANGE SWITCH. When the “N” range is Go to step 8. Go to step 35.
“N” range indicator illuminate?
9 CHECK “N” RANGE SWITCH. When the “D” range is Go to step 40. Go to step 10.
selected, does “N” range LED
light up?
10 CHECK “D” RANGE SWITCH. When the “D” range is Go to step 11. Go to step 41.
“D” range indicator illuminate?
12 CHECK “D” RANGE SWITCH. When the “3” range is Go to step 46. Go to step 13.
selected, does “D” range LED
light up?
13 CHECK “3” RANGE SWITCH. When the “3” range is Go to step 14. Go to step 47.
“3” range indicator illuminate?
selected, does “3” range LED
light up?
selected, does “2” range LED
light up?
21 CHECK “1” RANGE SWITCH. When the “P” range is Go to step 64. Go to step CHECK
selected, does “1” range LED HOLD SWITCH.
light UP? <Ref. to AT-129,
CHECK HOLD
SWITCH., Diag-
nostic Procedure
for No-diagnostic
Trouble Code
(DTC).>
AT-122
Step Check Yes No

INHIBITOR SWITCH AND CHASSIS Ω? circuit 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.
(T7) No. 5 — Chassis ground:
TCM AND INHIBITOR SWITCH. Ω? circuit in harness
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.
(B55) No. 1 — (T7) No. 9
1)Turn the ignition switch to OFF. “P” range?
2)Connect the connector to TCM and inhibitor
switch.
chassis ground.
25 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- other ranges? <Ref. to AT-46,
sis ground. Transmission Con-
26 CHECK “P” RANGE INDICATOR LIGHT Is the “P” range indicator light Go to step 27. Replace the “P”
BULB. bulb OK? range indicator
1)Turn the ignition switch to OFF. light bulb. <Ref. to
2)Remove the combination meter. IDI-15, Combina-
3)Remove the “P” range indicator light bulb tion Meter Assem-
from combination meter. bly.>
27 CHECK HARNESS CONNECTOR BETWEEN Is the resistance more than 1 Go to step 65. Repair the open
1)Disconnect the connectors from TCM and between TCM
combination meter. connector and
2)Measure the resistance of harness between combination
TCM and combination meter. meter, and poor
Connector & terminal contact in cou-
(B55) No. 1 — (i12) No. 14: pling connector.
28 CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1 Go to step 29. Repair the ground
TCM AND INHIBITOR SWITCH. MΩ? short circuit in “P”
1)Turn the ignition switch to OFF. range circuit.
2)Disconnect the connectors from TCM, inhibi-
tor switch and combination meter.
TCM and chassis ground.
AT-123
Step Check Yes No

(B55) No. 3 — (T7) No. 8:
1)Turn the ignition switch to OFF. “R” range?
switch.
chassis ground.
32 CHECK “R” RANGE INDICATOR LIGHT Is “R” range indicator light bulb Go to step 33. Replace the “R”
BULB. OK? range indicator
3)Remove the “R” range indicator light bulb tion Meter Assem-
Connector & terminal contact in TCM
(B55) No. 3 — (i12) No. 13: connector.
TCM AND INHIBITOR SWITCH. MΩ? short circuit in “R”
(B55) No. 14 — (T7) No. 10:
AT-124
Step Check Yes No

1)Turn the ignition switch to OFF. “N” range?
switch.
chassis ground.
38 CHECK “N” RANGE INDICATOR LIGHT Is the “N” range indicator light Go to step 39. Replace the “N”
3)Remove the “N” range indicator light bulb tion Meter Assem-
TCM AND INHIBITOR SWITCH. MΩ? short circuit in “N”
(B55) No. 4 — (T7) No. 3:
1)Turn the ignition switch to OFF. “D” range?
switch.
chassis ground.
AT-125
Step Check Yes No

44 CHECK “D” RANGE INDICATOR LIGHT Is the “D” range indicator light Go to step 45. Replace the “D”
3)Remove the “D” range indicator light bulb tion Meter Assem-
TCM and combination meter. meter, and TCM
(B55) No. 4 — (i12) No. 11:
TCM AND INHIBITOR SWITCH. MΩ? short circuit in “D”
2)Disconnect the connector from TCM and inhibitor switch
(B55) No. 5 — (T7) No. 11:
1)Turn the ignition switch to OFF. “3” range?
switch.
chassis ground.
50 CHECK “3” RANGE INDICATOR LIGHT Is the “3” range indicator light Go to step 51. Replace the “3”
3)Remove the “3” range indicator light bulb tion Meter Assem-
51 CHECK HARNESS CONNECTOR BETWEEN Is the resistance more than 1 Go to step 65. Repair the open
AT-126
Step Check Yes No

TCM AND INHIBITOR SWITCH. MΩ? short circuit in “3”
2)Disconnect the connector from TCM and inhibitor switch
(B55) No. 6 — (T7) No. 4:
switch.
chassis ground.
1)Disconnect the connectors from TCM and between TCM and
combination meter. combination
2)Measure the resistance of harness between meter, and poor
TCM and combination meter. contact in TCM
(B55) No. 6 — (i12) No. 4:
AT-127
Step Check Yes No

(B55) No. 7 — (T7) No. 6:
switch.
chassis ground.
63 CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1Ω? Go to step 65. Repair the open
TCM AND COMBINATION METER. circuit in harness
1)Disconnect the connectors from TCM and between TCM and
combination meter. combination
2)Measure the resistance of harness between meter, poor con-
TCM and combination meter. tact in TCM con-
(B55) No. 7 — (i12) No. 5:
65 CHECK POOR CONTACT. Is there poor contact in inhibi- Repair the poor Adjust the inhibi-
tor switch circuit? contact. tor switch and
select cable. <Ref.
to AT-28,
ADJUSTMENT,
Inhibitor Switch.>
and <Ref. to CS-9,
Select Cable.>
AT-128
I: CHECK HOLD SWITCH.

DIAGNOSIS:
• The LED does not come on when hold switch is ON.
• The hold switch circuit is open or shorted.
TROUBLE SYMPTOM:
• The 2nd gear is not held.
• Failure of vehicle to start in 2nd gear except 1st range.
WIRING DIAGRAM:
LHD MODEL
IGNITION
SWITCH BATTERY
SBF-4 SBF-1
E
A: i10
COMBINATION
METER B: i11
HOLD
B: B55
TCM
No.13
B23
B16
B15
A7
i1
23
6
POWER MODE AND

B36
SNOW
POWER OFF
HOLD
2
5
4
B133
B133 B55 B36
1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 10 11
1 2 3
10 11 12 13 14 15 16 17 18 12 13 14 15 16 17 18 19 20 21 22 23 24
4 5 6
19 20 21 22 23 24
B: i11 A: i10
1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
TR0926
AT-129
RHD MODEL
IGNITION
SWITCH BATTERY
SBF-4 SBF-1
E
A: i10
COMBINATION
METER B: i11
HOLD
B55
TCM
No.13
23
16
B15
A7
i3
22
2
POWER MODE AND

B38 SNOW HOLD MODE SWITCH
SNOW
POWER OFF
HOLD
2
5
4
B133
B133 B55 B36
1 2 3 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 10 11
4 5 6 10 11 12 13 14 15 16 17 18 12 13 14 15 16 17 18 19 20 21 22 23 24
19 20 21 22 23 24
i11 i10 i3
1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
TR0927
Step Check Yes No

1 CHECK HOLD SWITCH OPERATION. When the hold switch is turned Go to step 5. Go to step 2.
to OFF, does LED light up?
AT-130
Step Check Yes No

2 CHECK HOLD SWITCH OPERATION. When the hold switch is turned Go to step Symp- Go to step 3.
to ON, does LED light up? tom Related Diag-
nostic. <Ref. to
AT-133, Symptom
Related Diagnos-
tic.>
3 CHECK HOLD INDICATOR LIGHT. Is the HOLD indicator light bulb Go to step 4. Replace the HOLD
1)Turn the ignition switch to OFF. OK? indicator light bulb.
2)Remove the combination meter. <Ref. to IDI-15,
3)Remove the HOLD indicator light bulb from Combination
combination meter. Meter Assembly.>
4 CHECK HOLD SWITCH GROUND LINE. Is the resistance less than 1 Go to step 5. Repair the open
2)Disconnect the connector from hold switch. between hold
3)Measure the resistance of harness connec- switch and chassis
tor between hold switch and chassis ground. ground.
5 CHECK HOLD SWITCH. Is the resistance less than 1 Go to step 6. Repair the hold
1)Turn the hold switch to ON. Ω? switch.
hold switch.
Terminals
No. 4 — No. 2:
6 CHECK HOLD SWITCH. Is the resistance more than 1 Go to step 7. Repair the hold
1)Turn the hold switch to OFF. MΩ? switch.
hold switch.
Terminals
No. 4 — No. 2:
TCM AND HOLD SWITCH. Ω? circuit in harness
1)Disconnect the connector TCM and combi- between TCM and
nation meter. hold switch con-
2)Measure the resistance of harness connec- nector and poor
tor between TCM and hold switch. contact in cou-
Connector & terminal pling connector.
(B55) No. 16 — (B133) No. 2:
TCM and combination meter. combination
Connector & terminal meter, and poor
(B55) No. 16 — (i11) No. 15: contact in cou-
pling connector.
TCM AND HOLD SWITCH. MΩ? circuit in harness
between TCM and chassis ground to make hold switch con-
sure that circuit does not short. nector.
AT-131
Step Check Yes No

10 CHECK INPUT SIGNAL FOR TCM. Is the voltage more than 8 V? Go to step 11. Replace the TCM.
1)Connect the connectors to TCM and hold <Ref. to AT-46,
switch. Transmission Con-
2)Turn the ignition switch to ON (engine OFF). trol Module
3)Measure the signal voltage for TCM while (TCM).>
turning hold switch to OFF.
11 CHECK INPUT SIGNAL FOR TCM. Is the voltage less than 1 V? Go to step 12. Replace the TCM.
Measure the signal voltage for TCM while turn- <Ref. to AT-46,
ing hold switch to ON. Transmission Con-
12 CHECK POOR CONTACT. Is there poor contact? Repair the poor A temporary poor
contact. contact of the con-
nector or harness
or connector in
hold switch circuit.
AT-132
SYMPTOM RELATED DIAGNOSTIC
16.Symptom Related Diagnostic

A: INSPECTION
• Inhibitor switch
Starter does not rotate when select lever is in “P” or “N” range; • Select cable
starter rotates when select lever is in “R”, “D”, “3” or “2” range. • Select lever
• Starter motor and harness
• Strainer
• Transfer duty solenoid
Abnormal noise when select lever is in “P” or “N” range. • Oil pump
• Drive plate
• ATF level too high or too low
• Strainer
Hissing noise occurs during standing start.
• ATF level too high or too low
Noise occurs while driving in “D1”. • Final gear
• Planetary gear
Noise occurs while driving in “D2”. • Reduction gear
• Differential gear oil level too high or too low
• Final gear
• Low & reverse brake
Noise occurs while driving in “D3”.
• Reduction gear
• Final gear
Noise occurs while driving in “D4”. • Planetary gear
• Reduction gear
• Control valve
• Lock-up damper
Engine stalls while shifting from one range to another.
• Engine performance
• Input shaft
• TCM
Vehicle moves when select lever is in “N” range.
• Low clutch
• TCM
• Harness
Shock occurs when select lever is moved from “N” to “D” range.
• Control valve
• ATF deterioration
• Control valve
• Low clutch
Excessive time lag occurs when select lever is moved from “N”
• Line pressure duty solenoid
to “D” range.
• Seal ring
• Front gasket transmission case
• TCM
• Harness
Shock occurs when select lever is moved from “N” to “R” range.
• Control valve
• Control valve
• Low & reverse clutch
Excessive time lag occurs when select lever is moved from “N” • Reverse clutch
to “R” range. • Line pressure duty solenoid
• Seal ring
• Parking brake mechanism
Vehicle does not start in any shift range (engine stalls).
• Planetary gear
AT-133

• Strainer
• Control valve
• Drive pinion
• Hypoid gear
• Axle shaft
• Differential gear
Vehicle does not start in any shift range (engine revving up).
• Oil pump
• Input shaft
• Output shaft
• Planetary gear
• Drive plate
• ATF level too low
• Select cable
• Select lever
Vehicle does not start in “R” range only (engine revving up). • Control valve
• Reverse clutch
• Low clutch
• 2-4 brake
Vehicle does not start in “R” range only (engine stalls).
• Planetary gear
• Parking brake mechanism
• Low clutch
Vehicle does not start in “D”, “3” range only (engine revving up).
• One-way clutch
Vehicle does not start in “D”, “3” or “2” range only (engine rev- • Low clutch
ving up).
Vehicle does not start in “D”, “3” or “2” range only (engine • Reverse clutch
stalls).
Vehicle starts in “R” range only (engine revving up). • Control valve
• Control valve
• Low clutch
• Reverse clutch
Acceleration during standing starts is poor (high stall rpm).
• ATF level too low
• Oil pump
Acceleration during standing starts is poor (low stall rpm). • Torque converter one-way clutch
• TCM
• Control valve
Acceleration is poor when select lever is in “D”, “3” or “2” range
• High clutch
(normal stall rpm).
• 2-4 brake
• Planetary gear
• Control valve
Acceleration is poor when select lever is in “R” (normal stall • High clutch
rpm). • 2-4 brake
• Planetary gear
• TCM
• 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
AT-134

• TCM
No shift occurs from 3rd to 4th gear. • ATF temperature sensor
• Control valve
• 2-4 brake
• TCM
Engine brake is not effected when select lever is in “3” range.
• Throttle position sensor
• Control valve
Engine brake is not effected when select lever is in “3” or “2” • Control valve
range.
• Control valve
Engine brake is not effected when select lever is in “1” range.
• TCM
Shift characteristics are erroneous. • Rear vehicle speed sensor
• Control valve
• Ground earth
• TCM
• ATF temperature sensor
No lock-up occurs.
• Control valve
• Lock-up facing
• Engine speed signal
Parking brake is not effected. • Select cable
• Select lever
Shift lever cannot be moved or is hard to move from “P” range. • Parking mechanism
ATF spurts out. • ATF level too high
Differential oil spurts out. • Differential gear oil too high
• Seal pipe
Differential oil level changes excessively.
• Double oil seal
• High clutch
• 2-4 brake
Odor is produced from ATF supply pipe.
• Reverse clutch
• Lock-up facing
• TCM
• 2-4 brake duty solenoid
Shock occurs from 1st to 2nd gear.
• Control valve
• 2-4 brake
• 2-4 brake timing solenoid
• TCM
Slippage occurs from 1st to 2nd gear. • Line pressure duty solenoid
• Control valve
• 2-4 brake
• High clutch
AT-135

• TCM
Shock occurs from 2nd to 3rd gear. • Control valve
• High clutch
• 2-4 brake
• TCM
Slippage occurs from 2nd to 3rd gear. • Line pressure duty solenoid
• Control valve
• High clutch
• 2-4 brake
• TCM
• Control valve
Shock occurs from 3rd to 4th gear.
• 2-4 brake
• Low clutch timing solenoid
• Low clutch
• TCM
Slippage occurs from 3rd to 4th gear.
• Control valve
• 2-4 brake
• TCM
Shock occurs when select lever is moved from “3” to “2” range. • Control valve
• 2-4 brake
• TCM
Shock occurs when select lever is moved from “D” to “1” range. • Control valve
AT-136

• TCM
• Control valve
Shock occurs when select lever is moved from “2” to “1” range.
• TCM
Shock occurs when accelerator pedal is released at medium • Control valve
speeds. • Lock-up damper
• TCM
• Lock-up duty solenoid
Vibration occurs during straight-forward operation.
• Lock-up facing
• Lock-up damper
• TCM
Vibration occurs during turns (tight corner “braking” phenome- • ATF temperature sensor
non). • Transfer clutch
• Transfer valve
• Harness
• TCM
• FWD switch
Front wheel slippage occurs during standing starts.
• Control valve
• Transfer clutch
• Transfer valve
• Transfer pipe
• TCM
• FWD switch
Vehicle is not set in FWD mode. • Transfer clutch
• Transfer valve
• Select cable
• Select lever
Select lever is hard to move.
• Detente spring
• Manual plate
• Detente 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. • Detente spring
• Manual plate
AT-137
AT-138
MANUAL TRANSMISSION AND
DIFFERENTIAL
MT
Page
2. Transmission Gear Oil ..............................................................................32
3. Manual Transmission Assembly ...............................................................33
4. Transmission Mounting System ................................................................40
5. Oil Seal......................................................................................................42
6. Switches and Harness ..............................................................................43
7. Vehicle Speed Sensor...............................................................................46
9. Transfer Case and Extension Case Assembly..........................................48
10. Transfer Drive Gear ..................................................................................52
11. Transfer Driven Gear ................................................................................54
12. Center Differential .....................................................................................56
13. Reverse Check Sleeve..............................................................................57
14. Transmission Case ...................................................................................61
15. Main Shaft Assembly for Single-Range ....................................................68
16. Main Shaft Assembly for Dual-Range .......................................................76
17. Input Shaft Assembly ................................................................................82
18. Drive Pinion Shaft Assembly.....................................................................86
19. Front Differential Assembly .......................................................................95
20. Speedometer Gear..................................................................................102
21. Reverse Idler Gear..................................................................................103
22. Shifter Fork and Rod ...............................................................................105
23. Counter Gear ..........................................................................................109
24. General Diagnostic..................................................................................111
GENERAL DESCRIPTION
MANUAL TRANSMISSION AND DIFFERENTIAL
A: SPECIFICATIONS
1. MANUAL TRANSMISSION AND DIFFERENTIAL
2.0L Turbo 2.5L
2.0L
Model 1.6L Except Except
Non-turbo Australia Australia
Australia Australia
5-forward speeds with synchromesh and 1-reverse
Type
5×2-forward speeds with synchromesh and 2-reverse*
1st 3.454 3.454 3.166 3.454
2nd 2.062 1.947 1.882 2.062
Transmission gear 3rd 1.448 1.366 1.296 1.448
ratio 4th 1.088 0.972 1.088
5th 0.825 0.738 0.871 0.780
Reverse 3.333
Auxiliary transmis- High 1.000 —
sion gear ratio* Low 1.447 —
Front Type of gear Hypoid
reduction Final
gear Gear ratio 4.111 3.900 3.900 4.444 3.700 4.111
Type of gear Helical
Rear Transfer
Gear ratio 1.000 1.100 1.000
reduction
gear Type of gear Hypoid
Final
Gear ratio 4.111 3.900 3.545 4.444 3.700 4.111
Front
Type and number of gear Straight bevel gear (Bevel pinion: 2, Bevel gear: 2)
differential
Center
Type and number of gear Straight bevel gear (Bevel pinion: 2, Bevel gear: 2 and viscous coupling)
differential
Transmission gear oil GL-5
3.5 2 (3.7 US qt, 3.1 lmp qt)
Transmission oil capacity
4.0 2 (4.2 US qt, 3.5 lmp qt)*
*: Dual-range model only
2. TRANSMISSION GEAR OIL
Recommended oil
B1H0024
MT-2
GENERAL DESCRIPTION
3. TRANSMISSION CASE ASSEMBLY 4. DRIVE PINION ASSEMBLY

Drive pinion shim adjustment 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-
lb)
Drive pinion shim
Thickness Thickness Adjusting washer No. 1
Part No. Part No.
mm (in) mm (in) Part No. Thickness mm (in)
0.150 0.250 803025051 3.925 (0.1545)
32295AA031 32295AA071
(0.0059) (0.0098) 803025052 3.950 (0.1555)
0.175 0.275 803025053 3.975 (0.1565)
32295AA041 32295AA081
(0.0069) (0.0108)
803025054 4.000 (0.1575)
0.200 0.300
32295AA051 32295AA091 803025055 4.025 (0.1585)
(0.0079) (0.0118)
803025056 4.050 (0.1594)
0.225 0.500
32295AA061 32295AA101 803025057 4.075 (0.1604)
(0.0089) (0.0197)
Selection of main shaft rear plate Adjusting washer No. 2

Main shaft rear plate Part No. Thickness mm (in)
Dimension “A” mm (in) Part No. Mark 803025059 3.850 (0.1516)
4.00 — 4.13 803025054 4.000 (0.1575)
32294AA041 1 803025058 4.150 (0.1634)
(0.1575 — 0.1626)
3.87 — 3.99
32294AA051 2 5. INPUT SHAFT ASSEMBLY
(0.1524 — 0.1571)
Snap ring to counter washer clearance Snap ring (Outer-28) to ball bearing clearance
0.05 — 0.35 mm (0.0020 — 0.0138 in) 0 — 0.12 mm (0 — 0.0047 in)
Snap ring (Outer-28)
Part No. Thickness mm (in)
805028050 2.48 (0.0976)
031319000 1.50 (0.0591)
805028060 2.56 (0.1008)
805019010 1.72 (0.0677)
805028070 2.64 (0.1039)
Input shaft holder adjustment
Snap ring (Inner-68) to bearing clearance
Dimension “D” mm (in) Number of shim
0 — 0.12 mm (0 — 0.0047 in)
52.50 — 53.11
— Snap ring (Inner-68)
(2.0669 — 2.0909)
52.00 — 52.49 Part No. Thickness mm (in)
1 805168020 1.84 (0.0724)
(2.0472 — 2.0665)
51.26 — 51.99 805168030 1.92 (0.0756)
2
(2.0181 — 2.0468) 805168040 2.00 (0.0787)
6. MAIN SHAFT
Snap ring (Outer-25) to synchronizer hub clear-
ance
0.060 — 0.100 mm (0.0024 — 0.0039 in)
Thickness Thickness
Part No. Part No.
mm (in) mm (in)
805025051 2.42 (0.0953) 805025055 2.62 (0.1031)
805025052 2.47 (0.0972) 805025056 2.67 (0.1051)
805025053 2.52 (0.0992) 805025057 2.72 (0.1071)
805025054 2.57 (0.1012) 805025058 2.37 (0.0933)
MT-3
GENERAL DESCRIPTION
7. REVERSE IDLER GEAR 8. SHIFTER FORK AND ROD

Adjustment of reverse idler gear position Select the suitable shifter forks so that both cou-
Reverse idler gear to transmission case (LH) wall pling sleeve and reverse driven gear are positioned
clearance in the center of their synchromesh mechanisms.
6.0 — 7.5 mm (0.236 — 0.295 in) Rod end clearance
A: 1st-2nd — 3rd-4th
Reverse shifter lever
0.4 — 1.4 mm (0.016 — 0.055 in)
Part No. Mark Remarks
B: 3rd-4th — 5th
32820AA070 7 Further from case wall
0.5 — 1.3 mm (0.020 — 0.051 in)
32820AA080 8 Standard
32820AA090 9 Closer to the case wall 1st-2nd shifter fork
After installing a suitable reverse shifter lever, ad- Approach to 1st gear
just the reverse idler gear to transmission case wall 32804AA060 1
by 0.2 mm (0.008 in)
clearance to within 0 to 0.5 mm (0 to 0.020 in) using 32804AA070 No mark Standard
washers. Approach to 2nd gear
32804AA080 3
Washer (20.5 × 26 × t) by 0.2 mm (0.008 in)
Thickness Thickness
Part No. Part No. 3rd-4th shifter fork
mm (in) mm (in)
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) — — by 0.2 mm (0.008 in)
32810AA071 No mark Standard
Approach to 3rd gear
32810AA101 3
by 0.2 mm (0.008 in)
5th shifter fork (Non-turbo)

Approach to 5th gear
32812AA201 4
by 0.2 mm (0.008 in)
Become distant from
32812AA221 6 5th gear by 0.2 mm
(0.008 in)
5th shifter fork (Turbo)

32812AA231 7
by 0.2 mm (0.008 in)
32812AA241 No mark Standard
Become distant from
32812AA251 9 5th gear by 0.2 mm
(0.008 in)
MT-4
GENERAL DESCRIPTION
9. TRANSFER CASE OR REAR CASE 10.EXTENSION ASSEMBLY

Neutral position adjustment Thrust washer (50 × 61 × t) to taper roller bearing
table outer race side clearance
Adjustment shim
0.2 — 0.3 mm T (0.0008 — 0.012 in T)
32190AA000 0.15 (0.0059) NOTE:
32190AA010 0.30 (0.0118)
T: Tight
Thrust washer (50 × 61 × t)
Reverse accent shaft 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.
803050062 0.60 (0.0236)
32188AA100 0 Standard 803050063 0.65 (0.0256)
Neutral position is 803050064 0.70 (0.0276)
32188AA110 1
closer to reverse gear.
803050065 0.75 (0.0295)
Reverse check plate adjustment 803050066 0.80 (0.0315)
803050067 0.85 (0.0335)
Reverse check plate
803050068 0.90 (0.0354)
Angle
Part No. Mark Remarks 803050069 0.95 (0.0374)
θ
Arm stops closer to 803050070 1.00 (0.0394)
32189AA000 0 28° 803050071 1.05 (0.0413)
5th gear.
32189AA010 1 31°
5th gear. 803050073 1.15 (0.0453)
Arm stops in the cen- 803050074 1.20 (0.0472)
33189AA020 2 34°
ter. 803050075 1.25 (0.0492)
32189AA030 3 37°
reverse gear. 803050077 1.35 (0.0531)
32189AA040 4 40°
reverse gear.
803050079 1.45 (0.0571)
Thrust washer to center differential side clearance

0.15 — 0.35 mm (0.0059 — 0.0138 in)
Thrust washer
803036050 0.9 (0.035)
803036054 1.0 (0.039)
803036051 1.1 (0.043)
803036055 1.2 (0.047)
803036052 1.3 (0.051)
803036056 1.4 (0.055)
803036053 1.5 (0.059)
803036057 1.6 (0.063)
803036058 1.7 (0.067)
MT-5
GENERAL DESCRIPTION
11.FRONT DIFFERENTIAL
Bevel gear to pinion backlash
0.13 — 0.18 mm (0.0051 — 0.0071 in)
Washer (38.1 × 50 × t)
Thickness Thickness
Part No. Part No.
mm (in) mm (in)
0.925 — 1.025 —
0.950 1.050
803038021 803038023
(0.0364 — (0.0404 —
0.0374) 0.0413)
0.975 —
1.000
803038022 — —
(0.0384 —
0.0394)
Pinion shaft to axle drive shaft clearance

0 — 0.2 mm (0 — 0.008 in)
Thickness Thickness
Part No. Part No.
mm (in) mm (in)
805028011 1.05 (0.0413) 805028012 1.20 (0.0472)
12.TRANSFER DRIVE GEAR

Snap ring (Outer-30) to ball bearing clearance
0.01 — 0.15 mm (0.0004 — 0.0059 in)
805030041 1.53 (0.0602)
805030042 1.65 (0.0650)
805030043 1.77 (0.0697)
MT-6
GENERAL DESCRIPTION
MT-7
GENERAL DESCRIPTION
B: COMPONENT
1. TRANSMISSION CASE
(17)
(14)
(16)
(18) (11)
(13) (10) (9)

(8)
(7)
(6)
(15)
(12) (5)
(4)
(1)
(2)
(3) T
TR0906
MT-8
GENERAL DESCRIPTION
(1) Transmission case ASSY (9) Oil seal (16) High-low cable bracket A (Dual-
(2) Gasket (10) Clamp range)
(3) Drain plug (11) Pitching stopper bracket (17) High-low cable bracket B (Dual-
(4) Snap ring (Outer) (12) Clip range)
(5) Speedometer driven gear (13) Oil level gauge (Non-turbo model) (18) Oil level gauge (Turbo model)
(6) Washer (14) Oil seal (Dual-range)
(7) Speedometer shaft (15) Transmission case ASSY (Dual- Tightening torque: N·m (kgf-m, ft-lb)
(8) Snap ring (Outer) range) T: 44 (4.5, 32.5)
• Transmission case tightening torque
Tightening torque: N·m (kgf-m,

Bolt No. Bolt size
ft-lb)
<5> to <15> 8 mm 25 (2.5, 18.1)
<1> to <4>
10 mm 39 (4.0, 28.9)
<16>, <17>
B3M2243A
MT-9
GENERAL DESCRIPTION
2. DRIVE PINION ASSEMBLY
(4) (5)
(3)
(2)
(1)
(11) (18)
(8) (17)
(7) (16)
(15)
(14)
(13)
(12)
(10)
(9) (29) T3
(6) (28)
(27)
T1
(26)
(25)
(22)
(24)
(36) (23)
(35) T2
(22)
(34)
(21) (33)
(20) (32)
(19) (30)
(31)
(30)
TR0911
(1) Drive pinion shaft (16) 1st-2nd synchronizer hub (28) Lock washer
(2) Roller bearing (17) Insert key (29) Lock nut
(3) Washer (18) Reverse driven gear (30) Washer
(4) Thrust bearing (19) Outer baulk ring (Except 1.6 L (31) Thrust bearing
(5) Needle bearing model) (32) Differential bevel gear sleeve
(6) Driven shaft (20) Synchro cone (Except 1.6 L (33) Washer
(7) Key model) (34) Lock washer
(8) Woodruff key (21) Inner baulk ring (Except 1.6 L (35) Lock nut
(9) Drive pinion collar model) (36) 2nd baulk ring (1.6 L model)
(10) Needle bearing (22) 2nd driven gear
(11) Snap ring (Outer) (23) 2nd driven gear bush Tightening torque: N·m (kgf-m, ft-lb)
(12) Washer (24) 3rd-4th driven gear T1: 29 (3.0, 21.7)
(13) Sub gear (25) Driven pinion shim T2: 118 (12.0, 86.8)
(14) 1st driven gear (26) Roller bearing T3: 265 (27, 195)
(15) Baulk ring (27) 5th driven gear
MT-10
GENERAL DESCRIPTION
3. MAIN SHAFT ASSEMBLY
B3M2120B
(1) Oil seal (13) 4th drive gear (27) 5th-Rev coupling sleeve
(2) Needle bearing (14) 4th needle bearing race (28) Rev baulk ring
(3) Transmission main shaft (15) Needle bearing (29) Rev synchro cone
(4) Needle bearing (16) 4th gear thrust washer (30) Ball bearing
(5) 3rd drive gear (17) Ball bearing (31) Synchro cone stopper
(6) Inner baulk ring (Turbo and 2.5 L (18) Baulk ring (Except turbo and 2.5 L (32) Snap ring
model) model) (33) Lock washer
(7) 3rd synchro cone (Turbo and 2.5 L (19) 5th gear thrust washer (34) Lock nut
model) (20) 5th needle bearing race (35) Reverse idler gear shaft
(8) Outer baulk ring (Turbo and 2.5 L (21) Needle bearing (36) Straight pin
model) (22) Main shaft rear plate (37) Reverse idler gear
(9) 3rd-4th coupling sleeve (23) 5th drive gear (38) Washer
(10) 3rd-4th synchronizer hub (24) 5th baulk ring
(11) 3rd-4th shifting insert key (25) 5th-Rev shifting insert key Tightening torque: N·m (kgf-m, ft-lb)
(12) 4th baulk ring (26) 5th-Rev synchronizer hub T: 118 (12.0, 86.8)
MT-11
GENERAL DESCRIPTION
4. AUXILIARY TRANSMISSION GEARS
B3M2173B
MT-12
GENERAL DESCRIPTION
(1) O-ring (19) Input shaft (37) High-low shifter shaft

(2) High-low counter shaft (20) Needle bearing (38) Low switch
(3) Straight pin (21) Snap ring (Outer-25) (39) Gasket
(4) High-low counter washer (22) High-low baulk ring (40) Straight pin
(5) Counter gear (23) High-low coupling sleeve (41) High-low shifter fork
(6) Needle bearing (24) High-low synchronizer spring (42) High-low shifter piece
(7) Counter gear collar (25) High-low synchronizer hub (43) Ball
(8) Snap ring (Outer-19) (26) Shifting insert key (44) Spring
(9) Input shaft holder (27) High-low baulk ring (45) Gasket
(10) Input shaft shim (28) Friction damper (46) Plug
(11) Oil seal (29) Input low gear
(12) O-ring (30) Needle bearing Tightening torque: N·m (kgf-m, ft-lb)
(13) Snap ring (Outer-28) (31) Input low gear spacer T1: 15.7 (1.6, 11.6)
(14) Oil squeeze (32) Ball T2: 20 (2.0, 14.5)
(15) Straight pin (33) Main shaft T3: 25 (2.5, 18.1)
(16) Snap ring (Outer-28) (34) Straight pin
(17) Ball bearing (35) High-low shifter lever
(18) Snap ring (Inner-68) (36) Washer
MT-13
GENERAL DESCRIPTION
5. SHIFTER FORK AND SHIFTER ROD
H3M1966A
(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 (11) 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: 20 (2.0, 14.5)
(6) Gasket (14) Ball
(7) Checking ball spring (15) Spring
(8) Ball (16) Snap ring (Outer)
MT-14
GENERAL DESCRIPTION
6. TRANSFER CASE AND EXTENSION
TR0949
(1) Oil guide (16) Return spring (31) Transfer drive gear
(2) Gasket (17) O-ring (32) Ball bearing
(3) Transfer case (18) Adjusting select shim (33) Extension case
(4) Ball (19) Reverse check sleeve (34) Oil seal
(5) Reverse accent spring (20) Gasket (35) Dust cover
(6) Gasket (21) Neutral switch (36) Shift bracket
(7) Plug (22) Gasket (37) Snap ring
(8) Oil seal (23) Back-up light switch
(9) Snap ring (Inner) (24) Roller bearing Tightening torque: N·m (kgf-m, ft-lb)
(10) Reverse check plate (25) Transfer driven gear T1: 6.4 (0.65, 4.7)
(11) Reverse check spring (26) Roller bearing T2: 10 (1.0, 7.2)
(12) Reverse return spring (27) Adjusting washer T3: 25 (2.5, 18.1)
(13) Reverse check cam (28) Ball bearing T4: 26 (2.7, 20)
(14) Reverse accent shaft (29) Center differential T5: 40 (4.1, 29.7)
(15) Return spring cap (30) Adjusting washer
MT-15
GENERAL DESCRIPTION
7. FRONT DIFFERENTIAL
H3M1967B
(1) Drive pinion shaft (8) Snap ring (Outer) (15) Retainer lock plate
(2) Hypoid driven gear (9) Roller bearing
(3) Pinion shaft (10) Differential case Tightening torque: N·m (kgf-m, ft-lb)
(4) Straight pin (11) 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-16
GENERAL DESCRIPTION
8. TRANSMISSION MOUNTING
• Except 1.6 L MODEL
(4) (7)
T1
(3)
(5)
T4 (6)
(2)
T3
T5
T2
(1) (8)
(9)
(3)
(11)
(2)
(8) (10)
T2
T5
T5
T6
TR0012
(1) Pitching stopper (8) Cushion D Tightening torque: N·m (kgf-m, ft-lb)
(2) Spacer (9) Center crossmember T1: 7.5 (0.76, 5.5)
(3) Cushion C (10) Rear plate T2: 35 (3.6, 26)
(4) Front plate (11) Front crossmember T3: 50 (5.1, 37)
(5) Dynamic damper T4: 58 (5.9, 43)
(6) Rear cushion rubber T5: 70 (7.1, 51)
(7) Rear crossmember T6: 140 (14.3, 103)
MT-17
GENERAL DESCRIPTION

tion. points.
• Remove contamination including dirt and corro- • Apply gear oil onto sliding or revolution surfaces
sion before removal, installation, and disassembly. before installation.
• Keep the disassembled parts in order and pro- • Replace deformed or otherwise damaged snap
tect them from dust or dirt. rings with new ones.
• Before removal, installation or disassembly, be • Before installing O-rings or oil seals, apply suffi-
sure to clarify the failure. Avoid unnecessary re- cient amount of gear oil to avoid damage and defor-
moval, installation, disassembly and replacement. mation.
• When disassembling the case and other light al- • Be careful not to incorrectly install or fail to install
loy parts, use a plastic hammer to force it apart. Do O-rings, snap rings and other such parts.
not pry it apart with a screwdriver or other tool. • Before securing a part on a vise, place cushion-
• Be careful not to burn your hands, because each ing material such as wood blocks, aluminum plate,
part on the vehicle is hot after running. or shop cloth between the part and the vise.
• Use SUBARU genuine gear oil, grease etc. or • Avoid damaging the mating surface of the case.
the equivalent. Do not mix gear oil, grease etc. with • Before applying sealant, completely remove the
that of another grade or from other manufacturers. old seal.
D: PREPARATION TOOL
1. SPECIAL TOOLS
398791700 REMOVER Used for removing and installing spring pin (6
mm).
B3M1938
399411700 ACCENT BALL Used for installing reverse shifter rail arm.
INSTALLER
B3M1939
MT-18
GENERAL DESCRIPTION

399527700 PULLER SET Used for removing and installing roller bearing
(Differential).
(1) BOLT (899521412)
(2) PULLER (399527702)
(3) HOLDER (399527703)
(4) ADAPTER (398497701)
(5) BOLT (899520107)
(6) NUT (021008000)
B3M1940A
399780104 WEIGHT Used for measuring preload on roller bearing.
B3M1941
498077000 REMOVER Used for removing roller bearing of drive pinion
shaft.
B3M1942
498077300 CENTER DIFFER- Used for removing the center differential cover
ENTIAL BEARING ball bearing.
REMOVER
B3M1943
MT-19
GENERAL DESCRIPTION

498147000 DEPTH GAUGE Used for adjusting main shaft axial end play.
B3M1944
498247001 MAGNET BASE • Used for measuring backlash between side
gear and pinion, and hypoid gear.
• Used with DIAL GAUGE (498247100).
B3M1945
498247100 DIAL GAUGE • Used for measuring backlash between side
gear and pinion, and hypoid gear.
• Used with MAGNET BASE (498247001).
B3M1946
498427100 STOPPER Used for securing the drive pinion shaft assem-
bly and driven gear assembly when removing
the drive pinion shaft assembly lock nut.
B3M1947
MT-20
GENERAL DESCRIPTION

498787100 MAIN SHAFT Used for removing and installing transmission
STOPPER main shaft lock nut.
B3M1948
498937000 TRANSMISSION Used for removing and installing transmission
HOLDER main shaft lock nut.
B3M1949
499277100 BUSH 1-2 • Used for installing 1st driven gear thrust plate
INSTALLER and 1st-2nd driven gear bush.
• Used for installing roller bearing outer races to
differential case.
B3M1950
499277200 INSTALLER Used for press-fitting the 2nd driven gear, roller
bearings, and 5th driven gear onto the driven
shaft.
B3M1951
MT-21
GENERAL DESCRIPTION

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 WRENCH ASSY Used for removing and installing differential side
retainer.
B3M1953
499827000 PRESS Used for installing speedometer oil seal when
installing speedometer cable to transmission.
B3M1954
499857000 5TH DRIVEN GEAR Used for removing 5th driven gear.
REMOVER
B3M1955
MT-22
GENERAL DESCRIPTION

499877000 RACE 4-5 • Used for installing 4th needle bearing race and
INSTALLER ball bearing onto transmission main shaft.
• Used with REMOVER (899714110).
B3M1956
499917500 DRIVE PINION Used for adjusting drive pinion shim.
GAUGE ASSY
B3M1957
499927100 HANDLE Used for fitting transmission main shaft.
B3M1958
499937100 TRANSMISSION Stand used for transmission disassembly and
STAND SET assembly.
B3M1959
MT-23
GENERAL DESCRIPTION

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
899714110 REMOVER Used for fixing transmission main shaft, drive
pinion, rear drive shaft.
B3M1962
899864100 REMOVER Used for removing parts on transmission main
shaft and drive pinion.
B3M1963
MT-24
GENERAL DESCRIPTION

899884100 HOLDER Used for tightening lock nut on sleeve.
B3M1964
899904100 REMOVER Used for removing and installing straight pin.
B3M1965
899988608 SOCKET WRENCH Used for removing and installing drive pinion
(27) lock nut.
B3M1966
398497701 ADAPTER • Used for installing roller bearing onto differen-
tial case.
• Used with INSTALLER (499277100).
B3M1967
MT-25
GENERAL DESCRIPTION

499587000 INSTALLER Used for installing driven gears to driven shaft.
B3M1968
899824100 PRESS Used for installing speedometer shaft oil seal.
B3M1969
(35) lock nut.
B3M1970
(35) lock nut.
B3M1971
MT-26
GENERAL DESCRIPTION

498057300 INSTALLER Used for installing extension oil seal.
B3M1972
498255400 PLATE Used for measuring backlash.
B3M1973
498077400 SYNCHRONIZER • Used for removing synchronizer cone of main
CONE REMOVER shaft.
• Used for removing 5th driven gear of drive pin-
ion shaft.
B3M1974
BRACKET
B3M1975
MT-27
GENERAL DESCRIPTION

B3M1976
398527700 PULLER ASSY • Used for removing extension case roller bear-
ing.
• Used for removing front differential side
retainer bearing cup.
B3M1977
398643600 GAUGE Used for measuring total end play, extension
end play and drive pinion height.
B3M1978
38177700 INSTALLER • Used for installing bearing cone of transfer
driven gear (transfer case side).
• Used for installing ball bearing of transfer drive
gear.
B3M1905
MT-28
GENERAL DESCRIPTION

398507703 DUMMY COLLAR • Used for installing input shaft holder oil seal.
• For dual-range model.
B3M2122
398663600 PLIERS • Used for removing and installing input shaft
snap ring.
B3M2123
499757001 SNAP RING GUIDE • Used for installing snap ring (OUT 25).
B3M2124
899858600 RETAINER • Used for removing ball bearing.
B3M2125
MT-29
GENERAL DESCRIPTION

899474100 EXPANDER • Used for removing and installing snap ring.
B3M2126
899580100 INSTALLER • Used when pressing ball bearings into input
shaft.
B3M2127
399513600 INSTALLER • Used when pressing ball bearings into input
shaft.
B3M2129
499797000 INSTALLER Used for installing differential side retainer oil
seal.
B3M2197
MT-30
GENERAL DESCRIPTION

TOOL NAME REMARKS
MT-31
TRANSMISSION GEAR OIL
2. Transmission Gear Oil 5) Pour gear oil into the gauge hole.
A: INSPECTION Recommended gear oil:

Use GL-5 or equivalent.
2) Turn the ignition switch to OFF, and wait until the Gear oil capacity:
engine cools. Single-range model;
3) Remove the oil level gauge and wipe it clean. 3.5 2 (3.7 US qt, 3.1 Imp qt)
4) Reinsert the level gauge all the way. Be sure that Dual-range model;
the level gauge is correctly inserted and in the 4.0 2 (4.2 US qt, 3.5 Imp qt)
proper direction. 6) Check the level of the transmission gear oil.
5) Pull out the oil level gauge again and check the
oil level on it. If it is below the lower level, add oil CAUTION:
through the oil level gauge hole to bring the level up When inserting the level gauge into transmis-
to the upper level. sion gear, align the protrusion on the side of
the top part of level gauge with the notch in the
gauge hole.
NOTE:
The level should be within the specified range
marked on the gauge.
GI0042A
B: REPLACEMENT
1) Pull out the oil level gauge.
3) Drain the transmission gear oil completely.
CAUTION:
Directly after the engine has been running, the
transmission gear oil is hot. Be careful not to
burn yourself.
NOTE:
Tighten the transmission gear oil drain plug after
draining the transmission gear oil.
Tightening torque:
44 N·m (4.5 kgf-m, 32.5 ft-lb)
S3M0470A
(A) Drain plug

(B) Gasket
MT-32
MANUAL TRANSMISSION ASSEMBLY
3. Manual Transmission As- (4) Vehicle speed sensor

sembly
A: REMOVAL
1) Open the front hood fully, and support with stay.
3) Remove the air intake duct and cleaner case.
(Non-turbo model) <Ref. to IN-7, REMOVAL, Air In-
take Duct.> and <Ref. to IN-6, REMOVAL, Air
Cleaner Case.>
4) Remove the air cleaner case stay. (Non-turbo
S2M0907
model)
7) Remove the snap pin and pin from drive select
cable.
8) Remove the drive select cable on transmission.
(Dual-range model)
S2M0900
5) Remove the intercooler (Turbo model) <Ref. to

6) Disconnect the following connectors:
S3M0641A
(1) Neutral position switch connector
(2) Back-up light switch connector (A) Snap pin
(3) High-low switch connector (Dual-range (B) Clevis pin
model)
(C) Drive select cable
• Non-turbo MODEL
9) Remove the starter. <Ref. to SC-5, REMOVAL,
Starter.>
10) Remove the operating cylinder from transmis-
sion. (2.0 L and 2.5 L model)
• Non-turbo MODEL
S2M0743
• Turbo MODEL
TR0069
TR0428
MT-33
• Turbo MODEL (1) Remove the clutch operating cylinder from

transmission.
(2) Remove the plug using 10 mm hexagon
wrench.
TR0070
11) Disconnect the return spring and clutch cable.

(1.6 L model)
S2M1935
(3) Screw the 6 mm dia. bolt into release fork

shaft, and remove it.
G2M0545
TR0072
13) Set the ST.

S2M1936A
NOTE:
Also is available Part No. 41099AA010. (A) Shaft
ST 41099AA020 ENGINE SUPPORT ASSY (B) Bolt
(4) Raise the release fork and unfasten the re-

lease bearing tabs to free release fork.
NOTE:
Step (4) is required to prevent interference with en-
gine when removing the engine from transmission.
G2M0313
14) Separate the clutch release fork from release

bearing. (Turbo model)
MT-34
15) Remove the bolt which holds right upper side of 22) Remove the gear shift rod and stay from trans-
transmission to engine. mission.
(1) Disconnect the stay from transmission.
(2) Disconnect the rod from transmission.
B2M2791

B3M1824A
(Non-turbo model) with OBD <Ref. to EX-7, RE-
MOVAL, Front Exhaust Pipe.> without OBD <Ref.
(A) Stay
to EX(w/oOBD)-9, REMOVAL, Front Exhaust
Pipe.> (B) Rod
17) Remove the center exhaust pipe. (Turbo mod- 23) Disconnect the stabilizer link from transverse
el). <Ref. to EX(TURBO)-8, REMOVAL, Center Ex- link.
haust Pipe.> 24) Remove the bolt securing ball joint of trans-
18) Remove the rear exhaust pipe and muffler. verse link to housing.
CAUTION: • Except sedan turbo MODEL
When removing the exhaust pipes, be careful
each exhaust pipe does not drop out.
20) Remove the hanger bracket from right side of
transmission.
G4M0491
• Sedan turbo MODEL
B2M0032
21) Remove the propeller shaft. <Ref. to DS-15,

REMOVAL, Propeller Shaft.>
TR0090
G4M0491
MT-35
25) Remove the spring pins and separate the front 28) Remove the transmission rear crossmember
drive shafts from each side of transmission. from vehicle.
NOTE:
Discard the removing spring pin. Replace with a
new one.
G2M0831
29) Remove the transmission.

NOTE:
G2M0325
Move the transmission jack toward rear until main
26) Remove the nuts which hold lower side of shaft is withdrawn from clutch cover.
transmission to engine. 30) Separate the transmission assembly and rear
cushion rubber.
B2M2790
27) Place the transmission jack under transmis-

sion.
CAUTION:
Always support the transmission case with a
transmission jack.
G2M0326
MT-36
B: INSTALLATION 7) Connect the engine and transmission.

1) Install the rear cushion rubber to transmission (1) Install the starter.
assembly. <Ref. to SC-6, INSTALLATION, Starter.>
(2) Tighten the bolt which holds right upper side
Tightening torque: of transmission to engine.
35 N·m (3.57 kgf-m, 25.8 ft-lb)
2) Install the clutch release lever and bearing onto Tightening torque:
transmission. (Turbo model) <Ref. to CL-26, IN- 50 N·m (5.1 kgf-m, 36.9 ft-lb)
STALLATION, Release Bearing and Lever.>
3) Install the transmission onto engine.
(1) Gradually raise the transmission with trans-
mission jack.
(2) Engage them at splines.
NOTE:
Be careful not to strike the main shaft against clutch
cover.
B2M2791
Tightening torque:
T1: 70 N·m (7.1 kgf-m, 51 ft-lb) 8) Remove the ST.
T2: 140 N·m (14.3 kgf-m, 103 ft-lb)
G2M0313
G2M0832
5) Take off the transmission jack. Tightening torque:
6) Tighten the nuts which hold lower side of trans- T1: 50 N·m (5.1 kgf-m, 37 ft-lb)
mission to engine. T2: 58 N·m (5.9 kgf-m, 43 ft-lb)
Tightening torque:
50 N·m (5.1 kgf-m, 36.9 ft-lb)
T1
T2
TR0086

B2M2790
11) Install the front drive shaft into transmission.
MT-37
12) Drive the spring pin into chamfered hole of • Sedan turbo MODEL
drive shaft.
Tightening torque:
NOTE: 45 N·m (4.6 kgf-m, 33.2 ft-lb)
Always use a new spring pin.
TR0090
G2M0325
15) Install the gear shift rod and stay.
13) Install the ball joints of lower arm into knuckle (1) Install the gear shift rod onto transmission.
arm of housing, and tighten the installing bolts.
Tightening torque:
49 N·m (5.0 kgf-m, 36 ft-lb)
B3M1824A
(A) Stay
(B) Rod
B2M3402A
(2) Install the stay onto transmission.
(A) Transverse link 16) Install the propeller shaft. <Ref. to DS-16, IN-
(B) Ball joint STALLATION, Propeller Shaft.>
14) Install the stabilizer link from transverse link. 18) Install the hanger bracket on right side of trans-
• Except sedan turbo MODEL mission.
Tightening torque:
30 N·m (3.1 kgf-m, 22.1 ft-lb)
B2M0032
19) Install the rear exhaust pipe and muffler.

TR0089
MT-38
20) Install the front exhaust pipe and center ex- 25) Install the drive select cable on transmission.
haust pipe. (Non-turbo model) (Dual-range model)
Without OBD
Exhaust Pipe.>
With OBD
Pipe.>
Exhaust Pipe.>
23) Install the operating cylinder. (2.0 L and 2.5 L S3M0641A
model)
(A) Snap pin
Tightening torque: (B) Clevis pin
37 N·m (3.8 kgf-m, 27.5 ft-lb) (C) Drive select cable
• Non-turbo MODEL
26) Connect the following connectors:
Tightening torque:
13 N·m (1.3 kgf-m, 9.4 ft-lb)
(2) Vehicle speed sensor connector
(3) Neutral position switch connector
(4) Back-up light switch connector
(5) High-low switch connector (Dual-range
model)
TR0069 27) Install the air cleaner case stay.
• Turbo MODEL Tightening torque:
16 N·m (1.6 kgf-m, 11.6 ft-lb)
28) Install the air cleaner case and duct.
30) Take off the vehicle from lift arms.
TR0070
24) Connect the return spring and clutch cable.

(1.6 L model)
G2M0545
MT-39
4. Transmission Mounting Sys- 8) Remove the rear crossmember.

tem
A: REMOVAL
1. PITCHING STOPPER
3) Remove the air intake duct (Non-turbo model).
<Ref. to IN-7, REMOVAL, Air Intake Duct.>
4) Remove the air cleaner case (Non-turbo model).
G2M0831
5) Remove the intercooler (Turbo model). <Ref. to 9) Remove the rear cushion rubber.
B: INSTALLATION
1. PITCHING STOPPER
Tightening torque:
T1: 50 N·m (5.1 kgf-m, 37 ft-lb)
T2: 58 N·m (5.9 kgf-m, 43 ft-lb)
2) Install the air intake duct and cleaner case.
(Non-turbo model)
and <Ref. to IN-7, INSTALLATION, Air Intake
TR0072
Duct.>
2. CROSSMEMBER AND CUSHION RUB- 3) Install the intercooler. (Turbo model)
BER
cooler.>
1) Disconnect the ground cable from battery. 4) Connect the battery ground cable to battery.
2) Jack-up the vehicle and support it with sturdy
racks.
(Non-turbo model)
Without OBD
Pipe.>
With OBD
<Ref. to EX-7, REMOVAL, Front Exhaust Pipe.>
4) Remove the center exhaust pipe. (Turbo model)
haust Pipe.>
7) Set the transmission jack under the transmission
body.
CAUTION:
Always support the transmission case with a
transmission jack.
MT-40
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
35 N·m (3.6 kgf-m, 26 ft-lb) Make sure that the pitching stopper is not bent or
2) Install the rear crossmember. damaged. Make sure that the rubber is not stiff,
cracked, or otherwise damaged.
Tightening torque:
T1: 70 N·m (7.1 kgf-m, 51 ft-lb) 2. CROSSMEMBER AND CUSHION RUB-
T2: 140 N·m (14.3 kgf-m, 103 ft-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.
G2M0832
3) Remove the transmission jack.

5) Install the front and center exhaust pipes. (Non-
turbo model)
Without OBD
Exhaust Pipe.>
With OBD
Pipe.>
Exhaust Pipe.>
MT-41
OIL SEAL
5. Oil Seal 7) Using the ST, install the oil seal.

A: INSPECTION
Check the oil seal portion for leakage. If leakage is
found, replace the oil seal with a new one.
B: REPLACEMENT
2) Drain the gear oil completely.
NOTE:
Tighten the drain plug after draining gear oil.
Tightening torque:
B3M1982
44 N·m (4.5 kgf-m, 32.5 ft-lb)
9) Install the heat shield cover.
11) Pour gear oil and check the oil level. <Ref. to
MT-32, REPLACEMENT, Transmission Gear Oil.>
B3M0037

5) Remove the propeller shaft. <Ref. to DS-15, RE-
MOVAL, Propeller Shaft.>
6) Using the ST, remove the oil seal.
B3M2135A
(A) Oil seal
MT-42
SWITCHES AND HARNESS
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
(Non-turbo model) <Ref. to IN-6, REMOVAL, Air
Cleaner Case.> and <Ref. to IN-7, REMOVAL, Air
Intake Duct.>
3) Remove the intercooler (Turbo model). <Ref. to
IN(TURBO)-10, REMOVAL, Intercooler.> B3M1372C
4) Disconnect the connector of back-up light switch
and neutral position switch. (A) Neutral switch (Brown connector)
• Non-turbo MODEL (B) Back-up light switch (Gray connector)
2. HIGH-LOW SWITCH
<Ref. to IN-6, REMOVAL, Air Cleaner Case.> and
3) Disconnect the connector of high-low switch.
B2M0337B
(A) Neutral switch (Brown)

(B) Back-up light switch (Gray)
• Turbo MODEL
S2M0743A
(A) Neutral switch (Brown)

(B) Back-up light switch (Gray)
(C) High-low switch (Black)
4) Remove the high-low switch cable from clamp.

5) Remove the high-low switch.
TR0428
(A)
(B)
TR0912
(A) Clamp
(B) High-low switch
MT-43
1. BACK-UP LIGHT SWITCH AND NEU- 1. BACK-UP LIGHT SWITCH
TRAL POSITION SWITCH Inspect the back-up light switch. <Ref. to LI-7, 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 ft-lb)
2) Disconnect the connector of neutral position
switch.
3) Measure the resistance between neutral posi-
tion switch terminals.
Non-turbo model:
Gear shift position Terminal No. Specified resistance
Neutral position Less than 1Ω
1 and 2
Other positions More than 1MΩ
Turbo model:
B3M1372C
Neutral position Less than 1Ω
(A) Neutral switch 1 and 3
Other positions More than 1MΩ
(B) Back-up light switch
• Non-turbo MODEL
2) Connect the connector of back-up light switch
and neutral position switch.
3) Install the air intake duct and cleaner case.
(Non-turbo model) <Ref. to IN-6, INSTALLATION,
Air Cleaner Case.> and <Ref. to IN-7, INSTALLA-
2 1
TION, Air Intake Duct.>
cooler.>
TR0100
2. HIGH-LOW SWITCH
1) Install the high-low switch. • Turbo MODEL
Tightening torque:
24.5 N·m (2.5 kgf-m, 18.1 ft-lb)
2) Install the high-low switch cable to clamp. 2 1
4 3
3) Connect the connector of high-low switch.
4) Install the air intake duct and cleaner case. <Ref.
to IN-6, INSTALLATION, Air Cleaner Case.> and
TR0101
4) Replace defective parts.
MT-44
3. HIGH-LOW SWITCH
1) Turn ignition switch to OFF.
2) Disconnect connector high-low switch.
3) Measure the resistance between high-low
switch terminals.
LO position Less than 1Ω
1 and 2
HIGH position More than 1MΩ
B3M2134
4) Replace defective parts.
MT-45
VEHICLE SPEED SENSOR
7. Vehicle Speed Sensor

A: REMOVAL
3) Remove the front, center rear exhaust pipes and
muffler.
4) Disconnect the connector from vehicle speed
sensor.
5) Turn and remove the vehicle speed sensor.
B6M1449
B: INSTALLATION
NOTE:
• Discard the vehicle speed sensor and after 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 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 ft-lb)
3) Connect the connector to vehicle speed sensor.
4) Install the front, center exhaust pipes and muf-
fler.
C: INSPECTION
Inspect the vehicle speed sensor.
Without OBD
<Ref. to EN(w/oOBD)-92, DTC 33 VEHICLE
SPEED SIGNAL, Diagnostic Procedure with Diag-
With OBD Non-Turbo model
<Ref. to EN-210, DTC P0500 — VEHICLE SPEED
SENSOR MALFUNCTION —, Diagnostic Proce-
Turbo model
<Ref. to EN(TURBO)-230, DTC P0500 — VEHI-
CLE SPEED SENSOR MALFUNCTION —, Diag-
nostic Procedure with Diagnostic Trouble Code
(DTC).>
MT-46
8. Preparation for Overhaul

A: PROCEDURE
1) Clean oil, grease, dirt and dust from transmis-
sion.
2) Remove the drain plug to drain oil. After drain-
ing, retighten it as before.
NOTE:
Tightening torque:
44 N·m (4.5 kgf-m, 32.5 ft-lb)
B3M0037
3) Attach the transmission to ST.

ST 499937100 TRANSMISSION STAND
G3M0517
4) Rotating parts should be coated with oil prior to

assembly.
5) All disassembled parts, if to be reused, should
be reinstalled in the original positions and 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-47
TRANSFER CASE AND EXTENSION CASE ASSEMBLY
9. Transfer Case and Extension 2) Remove the bearing cone from bearing of the
transfer driven gear.
Case Assembly
A: REMOVAL
1) Remove the manual transmission assembly
from vehicle. <Ref. to MT-33, REMOVAL, Manual
Transmission Assembly.>
2) Remove the back-up light switch and neutral po-
sition switch. <Ref. to MT-43, REMOVAL, Switches
and Harness.>
3) Remove the transfer case with extension case
assembly.
B3M2172A
(A) Bearing cone (Extension case)

(B) Extension case
3) While pressing the bearing cone horizontally,

turn the driven shaft ten rotations.
4) Measure the height “W” between transfer case
and taper roller bearing on the transfer driven gear.
B3M1373
4) Remove the shifter arm.

5) Remove the extension case assembly.
B3M1984A
5) Measure the depth “X”.

NOTE:
Measure with bearing cone and thrust washer re-
B3M1374
moved.
B: INSTALLATION
1) Install the center differential and transfer driven
gear into transfer case.
B3M1406A
6) Calculate the space “t” using the following equa-

tion: t = X − W + 0.2 to 0.3 mm (0.008 to 0.012 in)
B3M1983
MT-48
7) Select the nearest washer in the following table: 11) Measure the depth “T” between extension case
and transfer drive gear.
Standard clearance between thrust washer and
ST 398643600 GAUGE
taper roller bearing:
0.2 — 0.3 mm T (0.008 — 0.012 in T)
NOTE:
T: Tight
Thrust washer (50 × 61 × t)
803050060 0.50 (0.0197)
803050061 0.55 (0.0217)
803050062 0.60 (0.0236)
803050063 0.65 (0.0256) B3M1395A
803050064 0.70 (0.0276)
12) Calculate the space “U” using the following
803050065 0.75 (0.0295) equation: U = S − T − 30 mm (1.18 in) [Thickness of
803050066 0.80 (0.0315) ST]
803050067 0.85 (0.0335) 13) Select the suitable washer in the following ta-
803050068 0.90 (0.0354) ble:
803050069 0.95 (0.0374)
Standard clearance:
803050070 1.00 (0.0394)
0.15 — 0.35 mm (0.0059 — 0.0138 in)
803050071 1.05 (0.0413)
803050072 1.10 (0.0433) Thrust washer
803050073 1.15 (0.0453) Part No. Thickness mm (in)
803050074 1.20 (0.0472) 803036050 0.9 (0.035)
803050075 1.25 (0.0492) 803036054 1.0 (0.039)
803050076 1.30 (0.0512) 803036051 1.1 (0.043)
803050077 1.35 (0.0531) 803036055 1.2 (0.047)
803050078 1.40 (0.0551) 803036052 1.3 (0.051)
803050079 1.45 (0.0571) 803036056 1.4 (0.055)
803036053 1.5 (0.059)
8) Fit the thrust washers on transfer drive shaft.
803036057 1.6 (0.063)
9) Install the bearing cone into extension case.
803036058 1.7 (0.067)
10) Measure the depth “S” between transfer case
and center differential. 14) Fit the thrust washer on center differential.
ST 398643600 GAUGE 15) Apply proper amount of liquid gasket to the
transfer case mating surface.
Liquid gasket:
THREE BOND 1215
B3M1407A
TR0522
MT-49
16) Install the extension assembly into transfer 19) Install the transfer case with extension case as-
case. sembly to transmission case.
B3M1374 B3M1373
17) Install the shifter arm to transfer case. C: DISASSEMBLY

1. TRANSFER CASE
1) Remove the reverse check assembly. <Ref. to
MT-57, REMOVAL, Reverse Check Sleeve.>
2) Remove the oil guide.
B3M1396
18) Hang the shifter arm on 3rd-4th fork rod.
B3M1378
2. EXTENSION CASE
1) Remove the transfer drive gear assembly. <Ref.
to MT-52, REMOVAL, Transfer Drive Gear.>
2) Remove the shift bracket.
B3M1397B
(A) Shifter arm

(B) 3rd-4th fork rod
B3M1381
3) Remove the oil seal from extension case. <Ref.

to MT-42, Oil Seal.>
MT-50
D: ASSEMBLY
1. EXTENSION CASE
1) Using the ST, install the oil seal to extension
case. <Ref. to MT-42, Oil Seal.>
NOTE:
Use a new oil seal.
2) Install the shift bracket to extension case.
Tightening torque:
25 N·m (2.5 kgf-m, 18.1 ft-lb)
B3M1381
3) Install the transfer drive gear to extension case.

<Ref. to MT-52, INSTALLATION, Transfer Drive
Gear.>
2. TRANSFER CASE
1) Install the oil guide to transfer case.
Tightening torque:
6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
B3M1378
2) Install the reverse check sleeve assembly to

transfer case. <Ref. to MT-57, INSTALLATION,
Reverse Check Sleeve.>
MT-51
TRANSFER DRIVE GEAR
10.Transfer Drive Gear C: DISASSEMBLY

1) Remove the snap ring.
A: REMOVAL
and Harness.>
assembly. <Ref. to MT-48, REMOVAL, Transfer
Case and Extension Case Assembly.>
4) Remove the extension case assembly. B3M1988
5) Remove the transfer driven gear.
6) Remove the transfer drive gear. 2) Remove the ball bearing.
B3M1989
B3M1986
B: INSTALLATION D: ASSEMBLY
1) Install the transfer drive gear. 1) Set the ST applying to inner race of bearing and
install to drive shaft.
Tightening torque: ST 398177700 INSTALLER
26 N·m (2.7 kgf-m, 20 ft-lb)
CAUTION:
Do not apply pressure in excess of 10 kN (1 ton,
1.1 US ton, 1.0 Imp ton)
ST
B3M1986
2) Install the transfer driven gear.

3) Install the extension case assembly. TR0523
4) Install the transfer case and extension case as- 2) Install the snap ring on transfer drive shaft.
sembly. <Ref. to MT-48, INSTALLATION, Transfer
3) Check the clearance between snap ring and ball
bearing. <Ref. to MT-53, INSPECTION, Transfer
5) Install the back-up light switch and neutral posi- Drive Gear.>
tion switch. <Ref. to MT-44, INSTALLATION,
Switches and Harness.>
6) Install the manual transmission assembly from
vehicle. <Ref. to MT-37, INSTALLATION, Manual
MT-52
TRANSFER DRIVE GEAR
E: INSPECTION
1) Bearings
Replace the bearings in the following cases:
• Broken or rusty bearings
• Worn or damaged
• Bearings that fail to turn smoothly or make ab-
normal noise when turned after gear oil lubrication.
2) Drive gear
Replace the drive gear in the following cases:
• If their tooth surfaces and shaft are excessively
broken or damaged.
3) Measure the clearance between snap ring and
inner race of ball bearing with a thickness gauge.
Clearance:
0.01 — 0.15 mm (0.0004 — 0.0059 in)
B3M1991
If the measurement is not within specification, se-

lect a suitable snap ring.
805030041 1.53 (0.0602)
805030042 1.65 (0.0650)
805030043 1.77 (0.0697)
MT-53
TRANSFER DRIVEN GEAR
11.Transfer Driven Gear B: INSTALLATION

1) Install the bearing cup to extension case and
A: REMOVAL transfer case.
from vehicle. <Ref. to MT-33, REMOVAL, Manual (C)
(A)
and Harness.>
4) Remove the extension case assembly.
5) Remove the transfer driven gear.
(B) (D)
B3M1983 TR0125
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.
B3M1983
3) Install the transfer case and extension case as-

sembly.<Ref. to MT-48, INSTALLATION, Transfer
4) Install the back-up light switch and neutral posi-
B3M1993A Switches and Harness.>
5) Install the manual transmission assembly to ve-
(A) Bearing cup (transfer case) hicle. <Ref. to MT-37, INSTALLATION, Manual
(B) Bearing cup (extension case) Transmission Assembly.>
MT-54
TRANSFER DRIVEN GEAR
1) Using the ST, remove the roller bearing (exten- 1) Using the ST, install the roller bearing (extension
sion case side). case side).
ST 498077000 REMOVER ST1 398177700 INSTALLER
ST2 899864100 REMOVER
CAUTION:
B3M2136A
(A) Roller bearing
2) Using the ST1 and ST2, remove the roller bear-

ing (transfer case side). B3M2138A
ST2 899864100 REMOVER (A) Roller bearing
2) Using the ST, install the roller bearing (transfer

case side).
CAUTION:
B3M2137A
(A) Roller bearing
B3M2139A
(A) Roller bearing
E: INSPECTION
1) Bearings
• Broken or rusty bearings
• Worn or damaged
2) Driven gear
Replace the drive gear in the following cases:
• If their tooth surfaces and shaft are excessively
broken or damaged.
MT-55
CENTER DIFFERENTIAL
12.Center Differential D: ASSEMBLY

Install the ball bearing to center differential assem-
A: REMOVAL bly.
from vehicle. <Ref. to MT-33, REMOVAL, Manual CAUTION:
Transmission Assembly.> Do not apply pressure in excess of 10 kN (1 ton,
2) Remove the transfer case with extension case 1.1 US ton, 1.0 Imp ton).
assembly.<Ref. to MT-48, REMOVAL, Transfer
3) Remove the extension case assembly. <Ref. to
MT-48, REMOVAL, Transfer Case and Extension
Case Assembly.>
4) Remove the transfer driven gear. <Ref. to MT-
54, REMOVAL, Transfer Driven Gear.>
5) Remove the center differential.
B: INSTALLATION
1) Install the center differential into transfer case. B3M1399B
2) Install the transfer driven gear. <Ref. to MT-54,
INSTALLATION, Transfer Driven Gear.> (A) Ball bearing
3) Install the extension case assembly. <Ref. to
MT-48, INSTALLATION, Transfer Case and Exten- E: INSPECTION
sion Case Assembly.> 1) Bearings
4) Install the transfer case with extension case as- Replace the bearings in the following cases:
sembly. <Ref. to MT-48, REMOVAL, Transfer • Broken or rusty bearings
Case and Extension Case Assembly.> • Worn or damaged
5) Install the back-up light switch and neutral posi- • Bearings that fail to turn smoothly or make ab-
tion switch. <Ref. to MT-43, REMOVAL, Switches normal noise when turned after gear oil lubrication.
and Harness.> • Bearings having other defects
6) Install the manual transmission assembly to ve- 2) Center differential
hicle. <Ref. to MT-37, INSTALLATION, Manual Replace the center differential assembly in the fol-
Transmission Assembly.> lowing case:
C: DISASSEMBLY • Worn or damaged
NOTE:
Do not disassemble the center differential because
it is a non-disassemble part.
Remove the ball bearing using ST.
NOTE:
Do not reuse the ball bearing.
ST 498077300 CENTER DIFFERENTIAL
BEARING REMOVER
B3M1398C
MT-56
REVERSE CHECK SLEEVE
13.Reverse Check Sleeve 2) Install the ball, spring, washer and plug to trans-
fer case.
A: REMOVAL
Tightening torque:
10 N·m (1.0 kgf-m, 7.2 ft-lb)
3) Remove the shifter arm.
4) Remove the plug, spring washer and reverse
check ball.
B3M1376
3) Install the shifter arm to transfer case assembly.

4) Install the transfer case with extension case as-
hicle. <Ref. to MT-37, INSTALLATION, Manual
B3M1376 Transmission Assembly.>
5) Remove the reverse check sleeve. C: DISASSEMBLY
1) Cover the reverse check sleeve with a rag, and
remove the snap ring using a screwdriver.
NOTE:
Replace the snap ring with a new one if deformed
or weakened.
B3M1377
B: INSTALLATION
1) Install the reverse check sleeve.
Tightening torque:
6.4 N·m (0.65 kgf-m, 4.7 ft-lb) B3M1383C
(A) Snap ring
B3M1377
MT-57
2) Remove the reverse check plate, reverse check D: ASSEMBLY

spring, reverse check cam, return spring (5th-Rev), 1) Install the return spring (1st-2nd), return spring
reverse accent shaft, return spring cap and return cap, reverse accent shaft, check cam, return spring
spring (1st-2nd). and check spring onto reverse check sleeve.
NOTE:
Be sure the bent section of reverse check spring is
positioned in the groove in check cam.
B3M1384A
(A) Reverse check plate

(B) Reverse check spring
B3M1384A
(C) Return spring (5th-Rev)
(D) Reverse check cam
(A) Reverse check spring
(E) Reverse accent shaft
(B) Reverse check cam
(F) Return spring cap
(C) Return spring (5th-Rev)
(G) Return spring (1st-2nd)
(D) Reverse accent shaft
3) Remove the O-ring. (E) Return spring cap
NOTE: (F) Return spring (1st-2nd)
• Reverse check sleeve assembly uses an O-ring (G) Reverse check sleeve
which should not be scratched.
2) Hook the bent section of reverse check spring
• Be careful not to break the adjustment shim over reverse check plate.
placed between reverse check sleeve assembly 3) Rotate the cam so that the protrusion of reverse
and case. check cam is at the opening in plate.
4) With the cam held in that position, install the
plate onto reverse check sleeve and hold with snap
ring.
5) Position the O-ring in groove in sleeve.
MT-58
• 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 the cam by hand for smooth rotation. 2) Shifter arm turns lightly toward the 1st/2nd gear
• Move the cam and shaft all the way toward plate side but heavily toward the reverse gear side be-
and release. cause of the function of return spring, until arm con-
If the cam does not return properly, replace the re- tacts the stopper.
verse check spring; if shaft does not, check for 3) Make adjustment so that the heavy stroke (re-
scratches on the inner surface of sleeve. If sleeve verse side) is a little more than the light stroke (1st/
is in good order, replace the spring. 2nd side).
4) To adjust, remove the bolts holding reverse
check sleeve assembly to the case, move the
sleeve assembly outward, and place adjustment
shim (0 to 1 ea.) between sleeve assembly and
case to adjust the clearance.
CAUTION:
Be careful not to break the O-ring when placing
shim(s).
NOTE:
B3M0048D • When the shim is removed, the neutral position
will move closer to reverse; when shim is added,
(A) Snap ring the neutral position will move closer to 1st gear.
(B) Reverse check plate • If the shims alone cannot adjust clearance, re-
(C) Check spring
place the reverse accent shaft and re-adjust.
(D) Check cam Adjustment shim
• Select a suitable reverse accent shaft and re-
verse check plate.<Ref. to MT-59, ADJUSTMENT, 32190AA000 0.15 (0.0059)
Reverse Check Sleeve.> 32190AA010 0.30 (0.0118)
Reverse accent shaft

Neutral position is closer to 1st
32188AA090 3
gear.
Neutral position is closer to
32188AA110 1
reverse gear.
MT-59
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 reverse position. If the arm
does not return properly, replace the reverse check
plate.
Reverse check plate
(A): Angle
Part No. Remarks
No. θ
Arm stops closer to
32189AA000 0 28°
5th gear.
Arm stops closer to
32189AA010 1 31°
5th gear.
Arm stops in the cen-
32189AA020 2 34°
ter.
Arm stops closer to
32189AA030 3 37°
reverse gear.
Arm stops closer to
32189AA040 4 40°
reverse gear.
B3M0054D
MT-60
TRANSMISSION CASE
14.Transmission Case 7) Separate the transmission case into right and

left cases by loosening the coupling bolts and nuts.
A: REMOVAL
1. SINGLE-RANGE
2) Remove the clutch release lever. <Ref. to CL-
26, REMOVAL, Release Bearing and Lever.>
Case and Extension Case Assembly.> B3M1359
4) Remove the bearing mounting bolts. 8) Remove the drive pinion shaft assembly from left
side transmission case.
NOTE:
Use a hammer handle, etc. to remove if too tight.
S3M0099
5) Remove the main shaft rear plate.
B3M0101H
(A) Main shaft assembly

(B) Drive pinion shaft assembly
9) Remove the main shaft assembly.
S3M0100C
(A) Main shaft rear plate
6) Put vinyl tape around the splines of right and left

axle drive shafts to prevent damage to oil seal.
B3M1405B
(A) Vinyl tape
MT-61
TRANSMISSION CASE
10) Remove the differential assembly. 6) Using the ST, drive out the straight pin, and re-
NOTE: move high-low shifter lever.
• Be careful not to confuse the right and left roller ST 398791700 STRAIGHT PIN REMOVER 2
bearing outer races. NOTE:
• Be careful not to damage the retainer oil seal. When driving out the straight pin, remove it in the
direction that it does not butt against transmission
case.
G3M0557
2. DUAL-RANGE H3M1420B

from vehicle. <Ref. to MT-33, REMOVAL, Manual (A) Straight pin
Transmission Assembly.> (B) High-low shifter lever
2) Remove the clutch release lever. <Ref. to CL-
7) Remove the main shaft rear plate.
26, REMOVAL, Release Bearing and Lever.>
4) Remove the input shaft holder.
S3M0100C
(A) Main shaft rear plate
8) Put vinyl tape around the splines of right and left

B3M2175A axle drive shafts to prevent damage to oil seals.
(A) Input shaft holder

(B) Input shaft
5) Remove the high-low switch. <Ref. to MT-43,

REMOVAL, Switches and Harness.>
B3M1405B
(A) Vinyl tape
MT-62
TRANSMISSION CASE
9) Separate the transmission case into right and 12) Remove the main shaft assembly and input
left cases by loosening the seventeen coupling shaft assembly.
bolts and nuts. CAUTION:
Be careful not to drop the input shaft and main
shaft as they are separable.
B3M1359
10) Remove the drive pinion shaft assembly from

left side transmission case. H3M1424B
NOTE:
Use a hammer handle, etc. to remove if too tight. (A) Main shaft ASSY
(B) Input shaft ASSY
(A)
13) Remove the differential assembly.
NOTE:
• Be careful not to confuse the right and left roller
bearing outer races.
• Be careful not to damage the retainer oil seal.
TR0146
(A) Drive pinion shaft assembly
11) Removing high-low shifter fork:

Raise the main shaft assembly slightly, and remove
the high-low shifter fork together with high-low
shifter shaft and washer. G3M0557
NOTE: B: INSTALLATION
Be careful not to drop the two high-low shifter piec-
es. 1. SINGLE-RANGE
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-
B3M0075C
5) Apply liquid gasket, and then put the case right
side and left side together.
(A) High-low shifter fork Liquid gasket:
(B) Input shaft ASSY THREE BOND 1215 or equivalent
MT-63
TRANSMISSION CASE
6) Tighten the seventeen bolts with bracket, clip, 8) Backlash adjustment of hypoid gear and preload
etc. as shown in the figure. adjustment of roller bearing:
NOTE: NOTE:
• Insert the bolts from bottom and tighten the nuts Support the drive pinion assembly with ST.
at top. ST 498427100 STOPPER
• Put the cases together so that drive pinion shim
and input shaft holder shim are not caught up in be-
tween.
• Confirm that the speedometer gear is meshed.
Tightening torque:
8 mm bolt
25 N·m (2.5 kgf-m, 18.1 ft-lb)
★ 10 mm bolt
39 N·m (4.0 kgf-m, 28.9 ft-lb)
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 the ST3 on transmission
main shaft. Shift the gear into 4th or 5th and turn
the shaft several times. Screw in the retainer while
turning ST3 until a slight resistance is felt on ST2.
This is the contact point of hypoid gear and drive
B3M0399B pinion shaft. Repeat the above sequence several
times to ensure the contact point.
7) Tighten the ball bearing attachment bolts. ST1 399780104 WEIGHT
Tightening torque: ST2 499787000 WRENCH ASSY
29 N·m (3.0 kgf-m, 21.7 ft-lb) ST3 499927100 HANDLE
S3M0099 B3M1361A
MT-64
TRANSMISSION CASE
11) Remove the weight and screw in the retainer 17) After checking the tooth contact of hypoid
without O-ring on upper side and stop at the point gears, remove the lock plate. Then loosen the re-
where slight resistance is felt. tainer until the O-ring groove appears. Fit the O-
NOTE: ring into groove and tighten the retainer into the po-
At this point, the backlash between hypoid gear sition where retainer has been tightened in.
and drive pinion shaft is zero. Tighten the lock plate.
ST 499787000 WRENCH ASSY NOTE:
Carry out this job on both upper and lower retain-
ers.
Tightening torque:
T: 25 N·m (2.5 kgf-m, 18.1 ft-lb)
B3M1360A
12) Fit the lock plate. Loosen the retainer on the

lower side by 1-1/2 notches of lock plate and turn in
the retainer on upper side by the same amount in
order to obtain the backlash. S3M0014C
NOTE: 18) Selecting of main shaft rear plate. <Ref. to MT-

The notch on the lock plate moves by 1/2 notch if 75, ADJUSTMENT, Main Shaft Assembly for Sin-
the plate is turned upside down. gle-Range.>
13) Turn in the retainer on the upper side addition- 19) Install the clutch release lever and bearing.
ally by 1 notch in order to apply preload on taper <Ref. to CL-26, INSTALLATION, Release Bearing
roller bearing. and Lever.>
14) Tighten temporarily both the upper and lower 20) Install the transfer case with extension case as-
lock plates and mark both holder and lock plate for sembly. <Ref. to MT-48, INSTALLATION, Transfer
later readjustment. Case and Extension Case Assembly.>
15) Turn the transmission main shaft several times 21) Install the manual transmission assembly into
while tapping around the retainer lightly with plastic the vehicle.<Ref. to MT-37, INSTALLATION, Man-
hammer. ual Transmission Assembly.>
16) Inspect and adjust the backlash and tooth con-
tact of hypoid gear. <Ref. to MT-99, INSPECTION,
2. DUAL-RANGE
Front Differential Assembly.> 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 and input shaft
assembly.
Connect the main shaft assembly and input the
shaft assembly, and install needle bearing knock
pin hole into transmission case knock pin.
4) Install the drive pinion shaft assembly.
Install the roller bearing knock pin hole into trans-
5) Apply liquid gasket, and then put the case right
side and left side together.
Liquid gasket:
MT-65
TRANSMISSION CASE
6) Tighten the seventeen bolts with bracket, clip, 8) Tighten the input shaft holder attaching bolts.
etc. as shown in the figure.
Tightening torque:
NOTE: 20 N·m (2.0 kgf-m, 14.5 ft-lb)
• Insert the bolts from bottom and tighten the nuts
at top.
• Put the cases together so that the drive pinion
shim and input shaft holder shim are not caught up
in between.
• Confirm that the speedometer gear is meshed.
Tightening torque:
8 mm bolt
25 N·m (2.5 kgf-m, 18.1 ft-lb)
★ 10 mm bolt
B3M2175A
39 N·m (4.0 kgf-m, 28.9 ft-lb)
(B) Input shaft
9) Backlash adjustment of hypoid gear and preload

adjustment of roller bearing
NOTE:
Support the drive pinion assembly with ST.
ST 498427100 STOPPER
S3M0161A
7) Tighten the ball bearing attachment bolts.

Tightening torque:
29 N·m (3.0 kgf-m, 21.7 ft-lb)
B3M1362A
10) Place the transmission with case left side fac-

ing downward and put ST1 on bearing cup.
S3M0099
MT-66
TRANSMISSION CASE
11) Screw the retainer assembly into left case from 16) Turn the transmission main shaft several times
the bottom with ST2. Fit the ST3 on transmission while tapping around the retainer lightly with plastic
main shaft. Shift the gear into 4th or 5th and turn hammer.
the shaft several times. Screw in the retainer while 17) Inspect and adjust the backlash and tooth con-
turning ST3 until a slight resistance is felt on ST2. tact of hypoid gear. <Ref. to MT-99, INSPECTION,
This is the contact point of hypoid gear and drive Front Differential Assembly.>
pinion shaft. Repeat the above sequence several 18) After checking the tooth contact of hypoid
times to ensure the contact point. gears, remove the lock plate. Then loosen the re-
ST1 399780104 WEIGHT tainer until the O-ring groove appears. Fit the O-
ST2 499787000 WRENCH ASSY ring into groove and tighten the retainer into the po-
ST3 499927100 HANDLE 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 ft-lb)
B3M1361A
12) Remove the weight and screw in the retainer

without O-ring on upper side and stop at the point
where slight resistance is felt.
NOTE:
At this point, the backlash between hypoid gear
and drive pinion shaft is zero. S3M0014C
ST 499787000 WRENCH ASSY
19) Selection of main shaft rear plate <Ref. to MT-
75, ADJUSTMENT, Main Shaft Assembly for Sin-
gle-Range.>
21) Install the clutch release lever and bearing.
<Ref. to CL-26, INSTALLATION, Release Bearing
and Lever.>
22) Install the manual transmission assembly into
B3M1360A
the vehicle.<Ref. to MT-37, INSTALLATION, Man-
ual Transmission Assembly.>
13) Fit the lock plate. Loosen the retainer on the
lower side by 1-1/2 notches of lock plate and turn in
C: INSPECTION
the retainer on upper side by the same amount in Check the transmission case for cracks, damage,
order to obtain the backlash. and oil leaks.
NOTE:
The notch on the lock plate moves by 1/2 notch if
the plate is turned upside down.
14) Turn in the retainer on the upper side addition-
ally by 1 notch in order to apply preload on taper
roller bearing.
15) Tighten temporarily both the upper and lower
lock plates and mark both holder and lock plate for
later readjustment.
MT-67
MAIN SHAFT ASSEMBLY FOR SINGLE-RANGE
15.Main Shaft Assembly for Sin- C: DISASSEMBLY

gle-Range 1) Put vinyl tape around the main shaft splines to
protect 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-33, REMOVAL, Manual shaft assembly.
Transmission Assembly.> NOTE:
2) Remove the transfer case with extension case Remove the caulking before removing lock nut.
assembly. <Ref. to MT-48, REMOVAL, Transfer ST1 499987000 TRANSMISSION HOLDER
ST2 498937003 SOCKET WRENCH (35)
3) Remove the transmission case. <Ref. to MT-48,
REMOVAL, Transfer Case and Extension Case
Assembly.>
4) Remove the drive pinion shaft assembly. <Ref.
to MT-86, REMOVAL, Drive Pinion Shaft Assem-
bly.>
B: INSTALLATION
1) Install the needle bearing and oil seal onto the
front of transmission main shaft assembly.
B3M0439A
NOTE:
• Wrap the 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.
B3M0437B
(A) 5th-Rev sleeve and hub ASSY

(B) Baulk ring
(C) 5th drive gear
4) Remove the snap ring and synchro cone stopper

from 5th-Rev sleeve and hub assembly.
B3M0528A
3) Install the drive pinion assembly. <Ref. to MT-

86, INSTALLATION, Drive Pinion Shaft Assem-
bly.>
4) Install the transmission case. <Ref. to MT-63,
INSTALLATION, Transmission Case.>
Case and Extension Case Assembly.> B3M0435B
hicle. <Ref. to MT-37, INSTALLATION, Manual (A) Synchro cone stopper
(B) Snap ring
MT-68
5) Using the ST1, ST2 and a press, remove the ball 6) Using the ST1 and ST2, remove rest of the
bearing, synchro cone and baulk ring (Rev). parts.
NOTE: NOTE:
• Replace the sleeve and hub with new ones. Do Replace the sleeve and hub with new ones. Do not
not attempt to disassemble because they must en- attempt to disassemble because they must engage
gage at a specified point. If they should be disas- at a specified point. If they should be disassem-
sembled, mark engagement point on splines bled, mark engagement point on splines before-
beforehand. hand.
• Do not reuse the ball bearing. ST1 899864100 REMOVER
ST1 499757002 INSTALLER ST2 899714110 REMOVER
ST2 498077400 SYNCHRO CONE REMOV-
ER
B3M1365A
(A) Ball bearing

(B) Synchro cone
(C) Baulk ring
B3M0835A
MT-69
D: ASSEMBLY 3) Install the 4th needle bearing race onto trans-

mission main shaft using ST1, ST2 and a press.
1. EXCEPT 2.5 L AND TURBO MODEL
CAUTION:
1) Assemble when each sleeve and hub assembly Do not apply pressure in excess of 10 kN (1 ton,
are disassembled. 1.1 US ton, 1.0 Imp ton).
NOTE: ST1 899714110 REMOVER
Position the open ends of spring 120° apart. ST2 499877000 RACE 4-5 INSTALLER
B3M0543D
(A) 4th needle bearing race
4) Install the baulk ring, needle bearing, 4th drive

gear and 4th gear thrust washer to transmission
main shaft.
NOTE:
Align the baulk ring and gear & hub assembly with
key groove.
B3M1366A
2) Install the 3rd drive gear, baulk ring, sleeve and

hub assembly for 3rd needle bearing on transmis-
sion main shaft.
NOTE:
Align the groove in baulk ring with shifting insert.
S3M0045A
(A) Groove
(B) 4th gear side
MT-70
5) Drive the ball bearing onto the rear section of 8) Install the baulk ring and synchro cone onto 5th-
transmission main shaft using ST1, ST2 and a Rev sleeve and hub assembly using ST and a
press. press.
CAUTION: CAUTION:
Do not apply pressure in excess of 10 kN (1 ton, Do not apply pressure in excess of 10 kN (1 ton,
1.1 US ton, 1.0 Imp ton). 1.1 US ton, 1.0 Imp ton).
ST1 899714110 REMOVER NOTE:
ST2 499877000 RACE 4-5 INSTALLER • Use a new ball bearing.
• After press fitting, make sure the synchro cone
rotates freely.
B3M0553F
6) Using the ST1 and ST2, install the 5th gear

thrust washer and 5th needle bearing race onto the
rear section of transmission main shaft. B3M1370A
CAUTION:
(A) Baulk ring
(B) Synchro cone
1.1 US ton, 1.0 Imp ton).
(C) Ball bearing
NOTE:
Face the thrust washer in correct direction. 9) Install the synchro cone stopper and snap ring to
ST1 899714110 REMOVER 5th-Rev sleeve and hub assembly.
ST2 499877000 RACE 4-5 INSTALLER
B3M0435B
B3M0091D
(A) Synchro cone stopper
(A) Face this surface to 5th gear side. (B) Snap ring
7) Install the bearing onto synchro cone.
MT-71
10) Install rest of the parts to the rear section of 2. 2.5 L AND TURBO MODEL
transmission main shaft.
1) Assemble each sleeve and hub assembly.
NOTE:
NOTE:
Position the open ends of spring 120° apart.
B3M1371A
(A) Needle bearing

(B) 5th drive gear
(C) Baulk ring
(D) 5th-Rev sleeve and hub ASSY
(E) Lock washer
(F) Lock nuts
11) Tighten the lock nuts to the specified torque us-

ing ST1 and ST2.
NOTE:
B3M1366A
Secure the lock nuts in two places after tightening.
ST1 499987003 SOCKET WRENCH 2) Install the 3rd drive gear, outer baulk ring, syn-
ST2 498937000 TRANSMISSION HOLDER chro cone, inner baulk ring, sleeve and hub assem-
bly for 3rd needle bearing on transmission main
Tightening torque: shaft.
118 N·m (12.0 kgf-m, 86.8 ft-lb)
NOTE:
B3M0837A
(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-72
3) Install the 4th needle bearing race onto trans- 5) Drive the ball bearing onto the rear section of
mission main shaft using ST1, ST2 and a press. transmission main shaft using ST1, ST2 and a
CAUTION: press.
Do not apply pressure in excess of 10 kN (1 ton, CAUTION:
1.1 US ton, 1.0 Imp ton). Do not apply pressure in excess of 10 kN (1 ton,
ST1 899714110 REMOVER 1.1 US ton, 1.0 Imp ton).
ST2 499877000 RACE 4-5 INSTALLER ST1 899714110 REMOVER
B3M0543D
B3M0553F
(A) 4th needle bearing race
4) Install the baulk ring, needle bearing, 4th drive thrust washer and 5th needle bearing race onto the
gear and 4th gear thrust washer to transmission rear section of transmission main shaft.
main shaft. CAUTION:
NOTE: Do not apply pressure in excess of 10 kN (1 ton,
Align the baulk ring and gear & hub assembly with 1.1 US ton, 1.0 Imp ton).
key groove. NOTE:
Face the thrust washer in correct direction.
S3M0045A
(A) Groove
(B) 4th gear side B3M0091D
(A) Face this surface to 5th gear side.
7) Install the bearing onto synchro cone.
MT-73
8) Install the baulk ring and synchro cone onto 5th- 10) Install the rest parts to the rear section of trans-
Rev sleeve and hub assembly using ST and a mission main shaft.
press. NOTE:
CAUTION: Align the groove in baulk ring with shifting insert.
NOTE:
• Use a new ball bearing.
rotates freely.
B3M1371A
(A) Needle bearing

(B) 5th drive gear
(C) Baulk ring
(E) Lock washer
B3M1370A (F) Lock nuts
(A) Baulk ring 11) Tighten the lock nuts to the specified torque us-
(B) Synchro cone
ing ST1 and ST2.
(C) Ball bearing NOTE:
Secure the lock nuts in two places after tightening.
9) Install the synchro cone stopper and snap ring to ST1 499987003 SOCKET WRENCH
5th-Rev sleeve and hub assembly. ST2 498937000 TRANSMISSION HOLDER
Tightening torque:
118 N·m (12.0 kgf-m, 86.8 ft-lb)
B3M0435B

(B) Snap ring
MT-74
Disassembled parts should be washed clean first Selection of main shaft rear plate:
and then inspected carefully. Using the ST, measure the amount (A) of ball bear-
1) Bearings ing protrusion from transmission main case surface
Replace the bearings in the following cases: and select the proper plate in the following table:
• Bearings whose balls, outer races and inner rac- NOTE:
es are broken or rusty. Before measuring, tap the end of main shaft with a
• Worn bearings plastic hammer lightly in order to make the clear-
• Bearings that fail to turn smoothly or make ab- ance zero between the main case surface and the
normal noise when turned after gear oil lubrication. moving flange of bearing.
• Bearings having other defects ST 498147000 DEPTH GAUGE
2) Bushing (each gear)
Replace the bushing in the following cases: Dimension (A)
Part No. Mark
• When the sliding surface is damaged or abnor- mm (in)
mally worn. 4.00 — 4.13
• When the inner wall is abnormally worn. (0.1575 — 32294AA041 1
0.1626)
3) Gears
• Replace the gears with new ones if their tooth 3.87 — 3.99
(0.1524 — 32294AA051 2
surfaces are broken, damaged, or excessively
0.1571)
worn.
• Correct or replace if the cone that contacts the
baulk ring is rough or damaged.
• Correct or replace if the inner surface or end face
is damaged.
4) Baulk ring
Replace the ring in the following cases:
• When the inner surface and end face are dam-
aged.
• When the ring inner surface is abnormally or par-
tially worn down.
• When the contact surface of the synchronizer B3M0531A
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.
8) Gearshift mechanism
Repair or replace the gearshift mechanism if ex-
cessively worn, bent, or defective in any way.
MT-75
MAIN SHAFT ASSEMBLY FOR DUAL-RANGE
16.Main Shaft Assembly for C: DISASSEMBLY

Dual-Range 1) Put vinyl tape around the main shaft splines to
protect 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-33, REMOVAL, Manual shaft assembly.
2) Remove the transfer case with extension case Remove the caulking before taking off lock nut.
assembly. <Ref. to MT-48, REMOVAL, Transfer ST1 498937000 TRANSMISSION HOLDER
REMOVAL, Transmission Case.>
bly.>
5) Remove the main shaft assembly and input shaft
assembly.
B: INSTALLATION
1) Install the needle bearing onto the front of trans-
mission main shaft assembly.
2) Connect the main shaft assembly and input shaft B3M0439A
assembly. 3) Remove the 5th-Rev sleeve and hub assembly,

3) Install the needle bearing outer race knock pin baulk ring, 5th drive gear and needle bearing.
hole into transmission case knock pin.
4) Install the drive pinion assembly. <Ref. to MT-
86, INSTALLATION, Drive Pinion Shaft Assem-
bly.>
hicle. <Ref. to MT-37, INSTALLATION, Manual B3M0437B
(A) 5th-Rev sleeve and hub ASSY
(B) Baulk ring
(C) 5th drive gear
4) Remove the snap ring and synchro cone stopper

from 5th-Rev sleeve and hub assembly.
B3M0435B

(B) Snap ring
MT-76
5) Using the ST1, ST2 and a press, remove the ball 6) Using the ST1 and ST2, remove rest of the
bearing, synchro cone and baulk ring (Rev). parts.
NOTE: NOTE:
• Replace the sleeve and hub with new ones. Do Replace the sleeve and hub with new ones. Do not
not attempt to disassemble because they must en- attempt to disassemble because they must engage
gage at a specified point. If they should be disas- at a specified point. If they should be disassem-
sembled, mark engagement point on splines bled, marking engagement point on splines before-
beforehand. hand.
• Do not reuse the ball bearing. ST1 899864100 REMOVER
ST1 499757002 INSTALLER ST2 899714110 REMOVER
ST2 498077400 SYNCHRO CONE REMOV-
ER
B3M1365A
(A) Ball bearing

(B) Synchro cone
(C) Baulk ring
B3M0835A
7) Remove the snap ring from main shaft.

ST 899474100 EXPANDER
H3M1432B
MT-77
8) Remove rest of the parts. 2) Install the 3rd drive gear, baulk ring, sleeve and
hub assembly for 3rd-4th needle bearing on trans-
mission main shaft.
NOTE:
3) Install the 4th needle bearing race onto trans-
mission main shaft using ST1, ST2 and a press.
S3M0169A
(A) Sleeve and hub ASSY

(B) High-low baulk ring
(C) Friction damper
(D) Low input gear
(E) Needle bearing
(F) Input low gear spacer
(G) Ball B3M0543D
D: ASSEMBLY (A) 4th needle bearing race

1) Assemble when each sleeve and hub assembly
are disassembled. 4) Install the baulk ring, needle bearing, 4th drive
gear and 4th gear thrust washer to transmission
NOTE:
main shaft.
Position the open ends of spring 120° apart.
NOTE:
S3M0444A
(A) High-low coupling sleeve S3M0045A
(B) Shifting insert

(C) High-low synchronizer spring (A) Groove
(D) High-low synchronizer hub (B) 4th gear side
(E) Sleeve
(F) Insert key
(G) 3rd-4th synchronizer hub
(H) Sleeve
(I) Insert key
(J) 5th-Rev synchronizer hub
MT-78
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
ST1 899714110 REMOVER press.
ST2 499877000 RACE 4-5 INSTALLER NOTE:
• Use a new ball bearing.
rotates freely.
B3M0553F

thrust washer and 5th needle bearing race onto the
rear section of transmission main shaft.
B3M1370A
NOTE:
(A) Baulk ring
(B) Synchro cone
(C) Ball bearing
9) Install the synchro cone stopper and snap ring to

5th-Rev sleeve and hub assembly.
B3M0091D
(A) Face this surface to 5th gear side.

B3M0435B

(B) Snap ring
MT-79
10) Install rest of the parts to the rear section of 13) Install the parts to the front section of transmis-
transmission main shaft. sion main shaft.
NOTE: NOTE:
Align the groove in baulk ring with shifting insert. Be careful not to damage the graded section of
transmission main shaft when installing the needle
bearing.
NOTE:
• Face the grooved side toward input gear.
• Align the high-low baulk ring's groove with shift-
ing insert.
B3M1371A
(A) Needle bearing

(B) 5th drive gear
(C) Baulk ring
(E) Lock washer S3M0169B
(F) Lock nuts
(A) Ball
11) Tighten the lock nuts to the specified torque us- (B) Input low gear spacer
ing ST1 and ST2.
(C) Needle bearing
NOTE: (D) Low input gear
Secure the lock nuts in two places after tightening. (E) Friction damper
ST1 499987003 SOCKET WRENCH (F) High-low baulk ring
ST2 498937000 TRANSMISSION HOLDER (G) Sleeve and hub ASSY
Tightening torque: 14) Install a new snap ring to the rod section of
118 N·m (12.0 kgf-m, 86.8 ft-lb) transmission main shaft using ST1 and ST2.
12) Install the needle bearing on main shaft.
NOTE:
Select a suitable outer snap ring so that axial clear-
ance between snap ring and hub is held within
0.060 to 0.100 mm (0.0024 to 0.0039 in).
ST1 499757002 INSTALLER
ST2 499757001 SNAP RING GUIDE
Snap ring
805025051 2.42 (0.0953)
805025052 2.47 (0.0972)
805025053 2.52 (0.0992)
805025054 2.57 (0.1012)
805025055 2.62 (0.1031)
805025056 2.67 (0.1051)
805025057 2.72 (0.1071)
805025058 2.37 (0.0933)
MT-80
E: INSPECTION
Disassembled parts should be washed clean first
and then inspected carefully.
1) Bearings
• Bearings whose balls, outer races and inner rac-
es are broken or rusty.
• Worn bearings
• Bearings having other defects
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 the gears with new ones if their tooth
worn.
is damaged.
4) Baulk ring
aged.
tially worn down.
• When the contact surface of the synchronizer
6) Oil seal
7) O-ring
F: ADJUSTMENT
Choose the main shaft rear plate. <Ref. to MT-75,
ADJUSTMENT, Main Shaft Assembly for Single-
Range.>
MT-81
INPUT SHAFT ASSEMBLY
17.Input Shaft Assembly C: DISASSEMBLY

1) Remove the O-ring from input shaft holder. Also,
A: REMOVAL remove the input shaft holder shim.
from vehicle. <Ref. to MT-33, REMOVAL, Manual NOTE:
Transmission Assembly.> • Use a new O-ring.
2) Remove the transfer case with extension case • Number of shims used varies from none to two.
bly.>
5) Remove the main shaft assembly and input shaft
assembly.
B: INSTALLATION S3M0167A
1) Install the needle bearing onto the front of trans-
mission main shaft assembly. (A) Input shaft holder
2) Connect the main shaft assembly and input shaft (B) O-ring
assembly. (C) Input shaft holder shim
3) Install the needle bearing outer race knock pin
hole into transmission case knock pin. 2) Put vinyl tape around the input shaft splines to
4) Install the drive pinion assembly. <Ref. to MT- protect oil seal from damage.
86, INSTALLATION, Drive Pinion Shaft Assem- 3) Remove the inner snap ring.
bly.> ST 398663600 PLIERS
7) Install the manual transmission assembly on ve-
G3M0828
4) Hold the input shaft holder stationary and re-

move the input shaft by tapping its end with a plas-
tic hammer.
H3M1430B

(B) Input shaft
MT-82
5) Remove the outer snap ring. Then remove the D: ASSEMBLY

oil squeeze plate and straight pin. 1) Install the ball bearing onto input shaft.
NOTE:
Place the snap ring between input shaft gear and
ball bearing beforehand. Use the table at 5) as a
guide in selecting a suitable snap ring.
S3M0157C
(A) Snap ring

(B) Oil squeeze plate
6) Remove the snap ring.
G3M0831
2) Install the snap ring on input shaft.
S3M0158C
(A) Snap ring
7) Using a press and ST, remove the ball bearing. S3M0158C
NOTE:
(A) Snap ring
Remove the inner snap ring before pressing.
ST 498077000 REMOVER 3) Inspect the clearance between ball bearing and
snap ring. <Ref. to MT-85, INSPECTION, Input
Shaft Assembly.>
4) Install the straight pin and oil squeeze plate to in-
put shaft.
G3M0830
8) Remove the oil seal from input shaft holder.
S3M0159C
(A) Straight pin

(B) Oil squeeze plate
5) Install the snap ring.
MT-83
6) Drive the oil seal into input shaft holder. 8) Install the snap ring to input shaft holder.
NOTE: NOTE:
Apply a coat of grease to sealing lips before install- Select a suitable snap ring so that clearance be-
ing oil seal. tween snap ring and bearing is held within 0 to 0.12
ST 398507703 DUMMY COLLAR mm (0 to 0.0047 in).
ST 398663600 PLIERS
G3M0833
G3M0828
7) Wind vinyl tape around the shaft splines and in-
sert input shaft into holder by lightly tapping it by
Snap ring
hand.
805168020 1.84 (0.0724)
805168030 1.92 (0.0756)
805168040 2.00 (0.0787)
9) Install the O-ring to input shaft holder.
B3M2140A
(A) Vinyl tape

(B) Input shaft
S3M0168C
(A) O-ring
(B) Input shaft holder
MT-84
E: INSPECTION 9) Measure the clearance between snap ring and

Disassembled parts should be washed clean first ball bearing using thickness gauge.
and then inspected carefully. Clearance:
1) Bearings 0 — 0.12 mm (0 — 0.0047 in)
• Bearings whose balls, outer races and inner rac-
es are broken or rusty.
• Worn bearings
mally worn. S3M0160C
3) Gears (A) Snap ring
• Replace the gears with new ones if their tooth
surfaces are broken, damaged, or excessively If the measurement is not within specification, se-
worn. lect a suitable snap ring.
• Correct or replace if the cone that contacts the Snap ring
baulk ring is rough or damaged. Part No. Thickness mm (in)
• Correct or replace if the inner surface or end face 805028050 2.48 (0.0976)
is damaged. 805028060 2.56 (0.1008)
4) Baulk ring
805028070 2.64 (0.1039)
aged.
tially worn down.
6) Oil seal
7) O-ring
MT-85
DRIVE PINION SHAFT ASSEMBLY
18.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-33, 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-48, REMOVAL, Transfer ASSY
4) Remove the drive pinion shaft assembly.
NOTE:
Use a hammer handle, etc. to remove if too tight.
B3M0064B
(A) Plate
(B) Scale
5) Position the ST by inserting the knock pin of ST

B3M0101H into the knock hole in transmission case.
ST 499917500 DRIVE PINION GAUGE
(A) Main shaft assembly ASSY
(B) Drive pinion shaft assembly 6) Slide the drive pinion gauge scale with finger tip
and read the value at the point where it matches
B: INSTALLATION with the end face of drive pinion.
1) Remove the differential assembly. ST 499917500 DRIVE PINION GAUGE
2) Alignment marks/numbers on hypoid gear set: ASSY
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.
B3M0065C
(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 ST. (Add if the number on drive
G3M0554
pinion is prefixed by + and subtract if the number is
3) Place the drive pinion shaft assembly on right prefixed by −.)
hand transmission main case without shim and ST 499917500 DRIVE PINION GAUGE
tighten the bearing mounting bolts. ASSY
MT-86
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 indicated NOTE:
value. Attach a cloth to the end of driven shaft (on the fric-
tional side of thrust needle bearing) during disas-
Drive pinion shim sembly or reassembly to prevent damage.
Part No. Thickness mm (in) 1) Straighten the lock nut at staked portion. Re-
32295AA031 0.150 (0.0059) move the lock nut using ST1, ST2 and ST3.
32295AA041 0.175 (0.0069) ST1 899884100 HOLDER
32295AA051 0.200 (0.0079) ST2 498427100 STOPPER
32295AA061 0.225 (0.0089) ST3 899988608 SOCKET WRENCH (27)
32295AA071 0.250 (0.0098)
32295AA081 0.275 (0.0108)
32295AA091 0.300 (0.0118)
32295AA101 0.500 (0.0197)
9) Install the differential assembly. <Ref. to MT-95,

INSTALLATION, Front Differential Assembly.>
10) Set the transmission main shaft assembly and
drive pinion assembly in position. (So there is no
clearance between the two when moved all the way
to the front). Inspect the suitable 1st — 2nd, 3rd — G3M0595
4th and 5th shifter fork so that coupling sleeve and 2) Withdraw the drive pinion from driven shaft.
reverse driven gear are positioned in the center of
Remove the differential bevel gear sleeve, adjust-
their synchronizing mechanisms. <Ref. to MT-92,
ing washer No. 1, adjusting washer No. 2, thrust
INSPECTION, Drive Pinion Shaft Assembly.>
bearing, needle bearing, drive pinion collar, needle
11) Install the transmission case. <Ref. to MT-63, bearing and thrust bearing.
hicle.<Ref. to MT-33, Manual Transmission As-
sembly.>
B3M0536G
(A) Differential bevel gear sleeve

(B) Washer No. 1 (25 × 37.5 × t)
(C) Thrust bearing (25 × 37.5 × 3)
(D) Washer No. 2 (25 × 37.5 × 4)
(E) Needle bearing (25 × 30 × 20)
(F) Drive pinion collar
(G) Needle bearing (30 × 37 × 23)
(H) Thrust bearing (33 × 50 × 3)
MT-87
3) Remove the roller bearing and washer using ST 7) Remove the roller bearing, 3rd-4th driven gear
and press. using ST1 and ST2.
NOTE: ST1 499757002 INSTALLER
Do not reuse the roller bearing. ST2 899714110 REMOVER
ST 498077000 REMOVER
G3M0610
G3M0607 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. (Except 1.6 L
move the lock nut using ST1 and ST2.
model)
ST2 899884100 HOLDER
S3M0445A
G3M0608
(A) 2nd driven gear
5) Remove the 5th driven gear using ST. (B) Inner baulk ring
ST 499857000 5TH DRIVEN GEAR REMOV- (C) Synchro cone
ER (D) Outer baulk ring
10) Remove the 2nd driven gear assembly. (1.6 L

model)
G3M0609
6) Remove the woodruff key.
MT-88
11) Remove the 1st driven gear, 2nd gear bushing, 4) Install the 2nd driven gear bushing onto driven
gear and hub using ST1 and ST2. shaft using ST1, ST2 and press.
NOTE: CAUTION:
Replace the gear and hub if necessary. Do not at- Do not apply pressure in excess of 10 kN (1 ton,
tempt to disassemble if at all possible because they 1.1 US ton, 1.0 Imp ton).
must engage at a specified point. If they should be NOTE:
disassembled, mark engagement point before- • Attach a cloth to the end of driven shaft to pre-
hand. vent damage.
ST1 499757002 INSTALLER • When press fitting, align the oil holes of shaft and
ST2 899714110 REMOVER bush.
G3M0611
12) Remove the sub gear for 1st driven gear.

B3M0078F
D: ASSEMBLY
1) Install the sleeve and assembly by matching 5) Install the 2nd driven gear, inner baulk ring, syn-
alignment marks. chro cone, outer baulk ring and insert onto driven
shaft. (Except 1.6 L model)
NOTE:
• Use a new gear and hub assembly, if gear or hub
have been replaced.
S3M0445A
(A) 2nd driven gear

B3M0077E
(B) Inner baulk ring
(C) Synchro cone
(A) 1st gear side
(D) Outer baulk ring
(B) 2nd gear side
(C) Flush surface 6) Install the 2nd driven gear, 1st-2nd bulk ring and
(D) Stepped surface insert onto driven shaft. (1.6 L model)
2) Install the washer, snap ring and sub gear to 1st
driven gear.
3) Install the 1st driven gear, 1st baulk ring, gear
and hub assembly onto driven shaft.
NOTE:
• Take care to install the gear and hub assembly in
proper direction.
• Align the baulk ring and gear & hub assembly
with key groove.
MT-89
7) After installing the key on driven shaft, install the 10) Install the lock washer. Install the lock nut and
3rd-4th driven gear using ST and press. tighten to the specified torque using ST.
CAUTION: ST 499987300 SOCKET WRENCH (50)
Do not apply pressure in excess of 10 kN (1 ton, Tightening torque:
1.1 US ton, 1.0 Imp ton). 265 N·m (27 kgf-m, 195 ft-lb)
NOTE:
Align the groove in baulk ring with insert.
G3M0618
NOTE:
• Stake the lock nut at two points.
G3M0615
• Using the spring balancer, check that starting
8) Install a set of roller bearings onto the driven torque of roller bearing is 0.1 to 1.5 N (0.01 to 0.15
shaft using ST and press. kgf, 0.02 to 0.33 ft).
CAUTION:
B3M0079
11) Install the roller bearing onto drive pinion.

NOTE:
When installing the roller bearing, note its direc-
G3M0616
tions (front and rear) because the knock pin hole in
9) Position the woodruff key in groove on the rear outer race is offset.
of driven shaft. Install the 5th driven gear onto drive
shaft using ST and press.
CAUTION:
B3M1661A
(A) Roller bearing

(B) Knock pin hole
G3M0617
MT-90
12) Install the washer using ST1, ST2 and press. 14) Install the drive pinion collar, needle bearing,
NOTE: adjusting washer No. 2, thrust bearing, adjusting
• Discard the old lock nuts, replace with new ones. washer No. 1 and differential bevel gear sleeve in
• Secure the lock nut in four places. that order.
ST1 499277100 BUSH 1-2 INSTALLER NOTE:
ST2 499277200 INSTALLER Be careful because the spacer must be installed in
proper direction.
B3M0080E
B3M0083D
(A) Washer
(A) Driven shaft
13) Install the thrust bearing and needle bearing. (B) Drive shaft
Install the driven shaft assembly. (C) Drive pinion collar
(D) Needle bearing (25 × 30 × 20)
(E) Washer No. 2 (25 × 36 × 4)
(F) Thrust bearing (25 × 37.5 × 3)
(G) Washer No. 1 (25 × 36 × t)
(H) Differential bevel gear sleeve
B3M0082
MT-91
E: INSPECTION 4) Baulk ring

Disassembled parts should be washed clean first Replace the ring in the following cases:
and then inspected carefully. • When the inner surface and end face are dam-
1) Bearings aged.
Replace the bearings in the following cases: • When the ring inner surface is abnormally or par-
• Bearings whose balls, outer races and inner rac- tially worn down.
es are broken or rusty. • If the gap between the end faces of the ring and
• Worn bearings the gear splined part is excessively small when the
• Bearings that fail to turn smoothly or make ab- ring is pressed against the cone.
normal noise when turned after gear oil lubrication. Clearance (A):
• The ball bearing on the rear side of the drive pin- 0.5 — 1.0 mm (0.020 — 0.040 in)
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
bearing, its rotation feels like it is slightly dragging
unlike the other bearings.
S3M0188A

B3M0038E Replace the insert if deformed, excessively worn,
(A) Drive pinion shaft
(B) Ball bearing

mally worn.
3) Gears
• Replace the gears with new ones if their tooth S3M0189
6) Oil seal
worn.
7) O-ring
is damaged.
MT-92
F: ADJUSTMENT 3) After removing the ST2, measure the starting

torque using torque driver.
1. THRUST BEARING PRELOAD ST1 899884100 HOLDER
1) After completing the preceding steps 1) through ST3 899988608 SOCKET WRENCH (27)
3), select the adjusting washer No. 1 so that dimen- Starting torque:
sion (H) is zero through visual check. Position the 0.3 — 0.8 N·m
washer (18.3 × 30 × 4) and lock washer (18 × 30 × (0.03 — 0.08 kgf-m, 0.2 — 0.6 ft-lb)
2) and install the lock nut (18 × 13.5).
B3M0085A
4) If the starting torque is not within specified limit,

select a new adjusting washer No. 1 and recheck
starting torque.
B3M0538A
2) Using the ST1, ST2 and ST3, tighten the lock nut
to specified torque. B3M0536I
ST1 899884100 HOLDER
ST2 498427100 STOPPER (A) Adjusting washer No.1
ST3 899988608 SOCKET WRENCH (27) (B) Adjusting washer No.2
Tightening torque:
Adjusting washer No. 1
118 N·m (12 kgf-m, 86.8 ft-lb)
803025051 3.925 (0.1545)
803025052 3.950 (0.1555)
803025053 3.975 (0.1565)
803025054 4.000 (0.1575)
803025055 4.025 (0.1585)
803025056 4.050 (0.1594)
803025057 4.075 (0.1604)
G3M0626
MT-93
5) If the specified starting torque range cannot be

obtained when a No. 1 adjusting washer is used,
then select a suitable No. 2 adjusting washer from
those listed in the following table. Repeat steps 1)
through 4) to adjust starting torque.
B3M0536I
(A) Adjusting washer No. 1

(B) Adjusting washer No. 2
Starting torque Dimension H Washer No. 2

Low Small Select thicker one.
High Large Select thinner one.
Adjusting washer No. 2

803025059 3.850 (0.1516)
803025054 4.000 (0.1575)
803025058 4.150 (0.1634)
6) Recheck that the starting torque is within speci-

fied range, then clinch the lock nut at four positions.
MT-94
FRONT DIFFERENTIAL ASSEMBLY
19.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.
2) Remove the transfer case with extension case • Be careful not to fold the sealing lip of oil seal.
assembly. <Ref. to MT-48, REMOVAL, Transfer • Wrap the right and left spline sections of axle
Case and Extension Case Assembly.> shaft with vinyl tape to prevent scratches.
bly.>
Single-range model
<Ref. to MT-68, REMOVAL, Main Shaft Assembly
for Single-Range.>
Dual-range model
G3M0557
for Dual-Range.> 3) Install the main shaft assembly. <Ref. to MT-76,
6) Remove the differential assembly. INSTALLATION, Main Shaft Assembly for Dual-
NOTE: Range.>
• Be careful not to confuse the right and left roller 4) Install the drive pinion assembly. <Ref. to MT-
bearing outer races. 86, INSTALLATION, Drive Pinion Shaft Assem-
• Be careful not to damage the retainer oil seal. bly.>
G3M0557
7) Remove the differential side retainers using ST.

B3M1360A
MT-95
C: DISASSEMBLY 4) Pull out the pinion shaft, and remove the differ-
ential bevel pinion and gear and washer.
1. DIFFERENTIAL CASE ASSEMBLY
1) Remove the right and left snap rings from differ-
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 the hypoid
driven gear.
B3M0552C
(A) Pinion shaft

(B) Bevel pinion
(C) Bevel gear
(D) Washer
5) Remove the roller bearing using ST.

ST 399527700 PULLER SET
G3M0668
B3M0551C
2. SIDE RETAINER
(A) Snap ring 1) Remove the O-ring.
(B) Axle drive shaft
(C) Hypoid driven gear
3) Drive out the straight pin from differential assem-

bly toward hypoid driven gear.
B3M2192
G3M0667
MT-96
2) Remove the oil seal. 5) Remove the bearing outer race from side retain-
NOTE: er.
Do not reuse the oil seal. Prepare a new oil seal. ST 398527700 PULLER ASSY
NOTE:
• Fix the shaft of ST secure enough that it will not
loosen and fall from side retainer.
• When replacing the bearing outer race, replace it
with inner race as a set.
B3M2193
3) Remove either side of split pin and pin, and re-

move the claw.
B3M2195A
(A) Shaft
(B) Side retainer
D: ASSEMBLY
1. DIFFERENTIAL CASE ASSEMBLY
1) Install the bevel gear and bevel pinion together
B3M2198A
with washers, and insert pinion shaft.
NOTE:
(A) Claw Face the chamfered side of washer toward gear.
(B) Split pin
(C) Pin
4) Attach two claws to the outer race securely, and

set ST to side retainer.
NOTE:
• Attach notch portions of the two shafts securely
to side retainer.
• Restore the removed claws to original position,
and install the pin and split pin. B3M0099D
(A) Bevel pinion

(B) Bevel gear
(C) Pinion shaft
B3M2194A
(A) Shaft
(B) Claw
MT-97
2) Measure the backlash between bevel gear and 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-100, ADJUST- Do not apply pressure in excess of 10 kN (1 ton,
MENT, Front Differential Assembly.> 1.1 US ton, 1.0 Imp ton).
NOTE: NOTE:
Be sure the pinion gear tooth contacts adjacent Be careful because the roller bearing outer races
gear teeth during measurement. are used as a set.
ST1 498247001 MAGNET BASE ST1 499277100 BUSH 1-2 INSTALLER
ST2 498247100 DIAL GAUGE ST2 398497701 ADAPTER
Standard backlash:
0.13 — 0.18 mm (0.0051 — 0.0071 in)
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 the straight pin into holes T: 62 N·m (6.3 kgf-m, 45.6 ft-lb)
from the hypoid driven gear side, using ST.
NOTE:
Lock the straight pin after installing.
B3M0554C
(A) Hypoid driven gear

(B) Differential case
B3M0609C
(A) Pinion shaft

(B) Differential case
(C) Straight pin
MT-98
2. SIDE RETAINER E: INSPECTION

1) Install the bearing outer race to side retainer. Repair or replace the differential gear in the follow-
ing cases:
NOTE: • The hypoid drive gear and drive pinion shaft
Press-in while being careful not to scratch the side tooth surface are damaged, excessively worn, or
retainer and bearing outer race. seized.
2) Install a new oil seal. • The roller bearing on the drive pinion shaft has a
ST 49979700 INSTALLER worn or damaged roller path.
• There is damage, wear, or seizure of the differ-
ential bevel pinion, differential bevel gear, washer,
pinion shaft, and straight pin.
• The differential case has worn or damaged slid-
ing surfaces.
B3M2196A
3) Install a new O-ring.

NOTE:
Do not stretch or damage the O-ring.
B3M2192
B3M0558C
(A) Drive pinion shaft

(B) 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
MT-99
1. BEVEL PINION GEAR BACKLASH 3. TOOTH CONTACT OF HYPOID GEAR

Measure the backlash between bevel gear and pin- Check the tooth contact of hypoid gear as follows:
ion. If it is not within specifications, install a suitable Apply a uniform thin coat of red lead on both tooth
washer to adjust it. surfaces of 3 or 4 teeth of the hypoid gear. Move
NOTE: the hypoid gear back and forth by turning the trans-
Be sure the pinion gear tooth contacts adjacent mission main shaft until a definite contact pattern is
gear teeth during measurement. developed on hypoid gear, and judge whether face
contact is correct. If it is inaccurate, make adjust-
ST1 498247001 MAGNET BASE ment. <Ref. to MT-100, ADJUSTMENT, Front Dif-
ST2 498247100 DIAL GAUGE ferential Assembly.>
Standard backlash: • Tooth contact is correct.
0.13 — 0.18 mm (0.0051 — 0.0071 in)
B3M0070D
G3M0670
(A) Toe
2. HYPOID GEAR BACKLASH (B) Coast side
Set the ST1, ST2 and ST3. Insert the needle (C) Heel
through transmission oil drain plug hole so that the (D) Drive side
needle comes in contact with the tooth surface at a
right angle and check the backlash. F: ADJUSTMENT
ST1 498247001 MAGNET BASE 1. BEVEL PINION GEAR BACKLASH
ST2 498247100 DIAL GAUGE
ST3 498255400 PLATE 1) Disassemble the front differential. <Ref. to MT-
95, REMOVAL, Front Differential Assembly.>
Backlash: 2) Select a different washer from the table and in-
0.13 — 0.18 mm (0.0051 — 0.0071 in) stall.
Washer
0.925 — 0.950
803038021
(0.0364 — 0.0374)
0.975 — 1.000
803038022
(0.0384 — 0.0394)
1.025 — 1.050
803038023
(0.0404 — 0.0413)
3) Adjust until the specified value is obtained.

B3M1363A
Standard backlash:
NOTE: 0.13 — 0.18 mm (0.0051 — 0.0071 in)
If the backlash is outside specified range, adjust it
by turning the holder in right side case.
MT-100
2. HYPOID GEAR BACKLASH • Backlash is insufficient.

To increase backlash, loosen the holder on lower
Adjust backlash by turning the holder in right side
side (case left side) and turn in the holder on upper
case.
side (case right side) by the same amount.
B3M0072
B3M1360A
• The drive pinion shim selected before is too
NOTE: thick.
Each time holder rotates one tooth, backlash Reduce its thickness.
changes by 0.05 mm (0.020 in).
B3M0073
H3M1203C
• The drive pinion shim selected before is too thin.
3. TOOTH CONTACT OF HYPOID GEAR Increase its thickness.
Adjust until the teeth contact is correct.
• Backlash is excessive.
To reduce backlash, loosen the holder on upper
side (case right side) and turn in the holder on lower
side (case left side) by the same amount.
B3M0074
B3M0071
MT-101
SPEEDOMETER GEAR
20.Speedometer Gear B: INSTALLATION

1) Install the washer and speedometer shaft, and
A: REMOVAL press fit the oil seal with ST.
from vehicle. <Ref. to MT-33, REMOVAL, Manual NOTE:
Transmission Assembly.> Use a new oil seal, if it has been removed.
2) Remove the back-up light switch and neutral po- ST 899824100 or 499827000PRESS
sition switch. <Ref. to MT-43, REMOVAL, Switches 2) Install the vehicle speed sensor. <Ref. to MT-46,
and Harness.> INSTALLATION, Vehicle Speed Sensor.>
3) Remove the transfer case with extension case 3) Install the speedometer driven gear and snap
assembly. <Ref. to MT-48, REMOVAL, Transfer ring.
Case and Extension Case Assembly.> NOTE:
4) Remove the transmission case. <Ref. to MT-61, Use a new snap ring, if it has been removed.
5) Remove the vehicle speed sensor. <Ref. to MT-
46, REMOVAL, Vehicle Speed Sensor.>
6) Remove the outer snap ring and pull out speed-
ometer driven gear. Next, remove the oil seal,
speedometer shaft and washer.
B3M0525C
(A) Outer snap ring

(B) Speedometer driven gear

B3M0525C INSTALLATION, Transmission Case.>
(A) Outer snap ring sembly. <Ref. to MT-48, INSTALLATION, Transfer
(B) Speedometer driven gear Case and Extension Case Assembly.>
C: INSPECTION
Check the speedometer gear, oil seal and speed-
ometer shaft for damage. Replace if damaged.
MT-102
REVERSE IDLER GEAR
21.Reverse Idler Gear B: INSTALLATION

1) Install the reverse shifter lever, reverse idler
A: REMOVAL gear and reverse idler gear shaft, and secure with
1) Remove the manual transmission assembly straight pin.
2) Remove the back-up light switch and neutral po- Be sure to install the reverse idler shaft from rear
sition switch. <Ref. to MT-43, REMOVAL, Switches side.
and Harness.>
REMOVAL, Drive Pinion Shaft Assembly.>
bly.>
B3M0526C
Single-range model
for Single-Range.> (A) Reverse shifter lever
Dual-range model (B) Reverse idler gear
<Ref. to MT-76, REMOVAL, Main Shaft Assembly (C) Reverse idler gear shaft
for Dual-Range.> (D) Straight pin
7) Remove the differential assembly. <Ref. to MT-
2) Inspect and adjust the clearance between re-
95, REMOVAL, Front Differential Assembly.>
verse idler gear and transmission case wall. <Ref.
8) Remove the shifter forks and rods. <Ref. to MT-
to MT-103, INSTALLATION, Reverse Idler Gear.>
105, REMOVAL, Shifter Fork and Rod.>
and <Ref. to MT-104, ADJUSTMENT, Reverse
9) Pull out the straight pin, and remove the idler Idler Gear.>
gear shaft, reverse idler gear and washer.
3) Install the shifter forks and rods. <Ref. to MT-
105, INSTALLATION, Shifter Fork and Rod.>
4) Install the differential assembly. <Ref. to MT-95,
INSTALLATION, Front Differential Assembly.>
5) Install the main shaft assembly.
Single-range model
<Ref. to MT-68, INSTALLATION, Main Shaft As-
sembly for Single-Range.>
Dual-range model
B3M0524C
sembly for Dual-Range.>
6) Install the drive pinion shaft assembly. <Ref. to
(A) Straight pin
MT-86, INSTALLATION, Drive Pinion Shaft As-
sembly.>
(B) Idler gear shaft
(C) Idler gear
(D) Washer
10) Remove the reverse shifter lever. sembly. <Ref. to MT-48, INSTALLATION, Transfer
MT-103
REVERSE IDLER GEAR
C: INSPECTION D: ADJUSTMENT
1) Move the reverse shifter rod toward the reverse 1) Select the appropriate reverse shifter lever from
side. Inspect the clearance between reverse idler the table below, and adjust until the gap between
gear and transmission case wall. the reverse idler gear and transmission case wall is
If out of specification, select the appropriate re- within specification.
verse shifter lever and adjust.
Clearance A:
Clearance A: 6.0 — 7.5 mm (0.236 — 0.295 in)
6.0 — 7.5 mm (0.236 — 0.295 in)
G3M0796
G3M0796
Reverse shifter lever
2) After installing a suitable reverse shifter lever,
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: 2) Select the appropriate washer from the table be-

0 — 0.5 mm (0 — 0.020 in) low, and adjust until the gap between the reverse
idler gear and transmission case wall is within
specification.
Clearance:
0 — 0.5 mm (0 — 0.020 in)
B3M0063
3) Check the reverse idler gear and shaft for dam-

age. Replace if damaged.
B3M0063
Washer
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-104
SHIFTER FORK AND ROD
22.Shifter Fork and Rod 10) Drive out the straight pin, and pull out 3-4 fork
rod and shifter fork.
A: REMOVAL NOTE:
1) Remove the manual transmission assembly When removing the rod, keep other rods in neutral.
from vehicle. <Ref. to MT-33, REMOVAL, Manual Also, when pulling out the straight pin, remove it to-
Transmission Assembly.> ward the inside of case so that it does not hit
2) Remove the back-up light switch and neutral po- against the case.
and Harness.>
bly.>
6) Remove the main shaft assembly. B3M0523C
Single-range model
<Ref. to MT-68, REMOVAL, Main Shaft Assembly (A) Straight pin
for Single-Range.> (B) 3-4 fork rod
Dual-range model
(C) Shifter fork
for Dual-Range.> 11) Drive out the straight pin, and pull out 1-2 fork
7) Remove the differential assembly. <Ref. to MT- rod and shifter fork.
95, REMOVAL, Front Differential Assembly.> 12) Remove the outer snap ring, and pull out the
8) Drive out the straight pin with ST, and 5th shifter reverse shifter rod arm from reverse fork rod. Then
fork. take out the ball, spring and interlock plunger from
ST 398791700 STRAIGHT PIN REMOVER rod.
And then remove the rod.
NOTE:
When pulling out the reverse shifter rod arm, be
careful not to let the ball pop out of arm.
13) Remove the reverse shifter lever.
B: INSTALLATION
1) Install the reverse arm fork spring, ball and inter-
lock plunger to reverse fork rod arm. Insert the re-
verse fork rod into hole in reverse fork rod arm, and
B3M0333I hold it with outer snap ring using ST.
(A) Straight pin NOTE:
(B) 5th shifter fork
Apply grease to plunger to prevent it from falling.
ST 399411700 ACCENT BALL INSTALLER
9) Remove the plugs, springs and checking balls. 2) Position the ball, spring and new gasket in re-
verse shifter rod hole, on left side transmission
case, and tighten the checking ball plug.
3) Install the 1-2 fork rod into 1-2 shifter fork via the
hole on the rear of transmission case.
4) Align the holes in rod and fork, and new drive
straight pin into these holes using ST.
NOTE:
• Set other rods to neutral.
• Make sure the interlock plunger is on the 3-4 fork
rod side.
ST 398791700 STRAIGHT PIN REMOVER
MT-105
5) Install the interlock plunger onto 3-4 fork rod. 11) Install the main shaft assembly.
NOTE: Single-range model
Apply a coat of grease to plunger to prevent it from <Ref. to MT-68, INSTALLATION, Main Shaft As-
falling. sembly for Single-Range.>
Dual-range model
6) Install the 3-4 fork rod into 3-4 shifter fork via the
hole on the rear of transmission case.
sembly for Dual-Range.>
7) Align the holes in rod and fork, and new drive
12) Install the drive pinion shaft assembly. <Ref. to
straight pin into these holes.
MT-86, INSTALLATION, Drive Pinion Shaft As-
NOTE: sembly.>
• Set the reverse fork rod to neutral. 13) Install the transmission case. <Ref. to MT-63,
• Make sure the interlock plunger (installing be- INSTALLATION, Transmission Case.>
fore) is on the reverse fork rod side. 14) Install the transfer case with extension case as-
ST 398791700 STRAIGHT PIN REMOVER sembly. <Ref. to MT-48, INSTALLATION, Transfer
8) Install the 5th shifter fork onto the rear of reverse Case and Extension Case Assembly.>
fork rod. Align holes in the two parts and new drive 15) Install the back-up light switch and neutral po-
straight pin into place. sition switch. <Ref. to MT-44, INSTALLATION,
ST 398791700 STRAIGHT PIN REMOVER Switches and Harness.>
B3M0333J
(A) 5th shifter fork

(B) Reverse fork rod
(C) Straight pin
9) Position the balls, checking ball springs and new

gaskets into 3-4 and 1-2 rod holes, and install
plugs.
B3M0333J
(A) 5th shifter fork

(B) Reverse fork rod
(C) Straight pin
10) Install the differential assembly. <Ref. to MT-

95, INSTALLATION, Front Differential Assembly.>
MT-106
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 the 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 1st, 2nd driven
gear and reverse driven gear. If any clearance is
not within specifications, replace the shifter fork as
required.
Clearance (a) and (b):
9.5 mm (0.374 in)
B3M1411A
(A) 3rd drive gear

(B) Coupling sleeve
(C) 4th drive gear
S3M0430A 3rd-4th shifter fork

(A) 1st driven gear Approach to 4th gear
32810AA061 1
(B) Reverse driven gear by 0.2 mm (0.008 in).
(C) 2nd driven gear 32810AA071 — Standard
Become distant from
1st-2nd shifter fork 32810AA101 3 3rd gear by 0.2 mm
(0.008 in).
Approach to 1st gear
32804AA060 1
by 0.2 mm (0.008 in).
32804AA070 — Standard
Become distant from
32804AA080 3 2nd gear by 0.2 mm
(0.008 in).
MT-107
5) Inspect the clearance between 5th drive gear 6) Inspect the rod end clearances (A) and (B). If
and coupling sleeve. If any clearance is not within any clearance is not within specifications, replace
specifications, replace the shifter fork as required. the rod or fork as required.
Clearance (a): Clearance (A):
9.3 mm (0.366 in) 1st — 2nd to 3rd — 4th:
0.4 — 1.4 mm (0.016 — 0.055 in)
Clearance (B):
3rd — 4th to 5th:
0.5 — 1.3 mm (0.020 — 0.051 in)
S3M0191A
(A) 5th drive gear

(B) Coupling sleeve
B3M0530A
5th shifter fork (Non-turbo)
32812AA201 4
by 0.2 mm (0.008 in).
Become distant from
32812AA221 6 5th gear by 0.2 mm
(0.008 in).
5th shifter fork (Turbo)

32812AA231 7
by 0.2 mm (0.008 in).
32812AA241 — Standard
Become distant from
32812AA251 9 5th gear by 0.2 mm
(0.008 in).
MT-108
COUNTER GEAR
23.Counter Gear 6) Remove the counter shaft from transmission

case, taking care not to drop the counter gear and
A: REMOVAL two washers.
1) Remove the manual transmission assembly NOTE:
from vehicle. <Ref. to MT-33, REMOVAL, Manual • Be careful not to damage the O-ring.
Transmission Assembly.> • Be careful not to drop the straight pin on front
2) Remove the transfer case with extension case side.
assembly. <Ref. to MT-48, REMOVAL, Transfer • Be careful not to drop the two needle bearings
Case and Extension Case Assembly.> and collar contained in counter gear.
4) Move the counter gear shaft until it touches
transmission case, and remove the snap ring with a
suitable tool.
H3M1427B
(A) Counter shaft

(B) Counter gear
S3M0102A
(C) Washers
5) Slide the washer at rear of high-low counter B: INSTALLATION

shaft, and remove the straight pin from counter 1) Install the O-ring and straight pin onto counter
shaft. gear shaft.
2) Install the following parts in main case (Right-
side), and push the shaft perfectly into case.
• Counter gear shaft
• Two counter gear washers
• Two needle bearings
• Counter gear collar
• Counter gear
• Straight pin
• Snap ring
H3M1426B
5) Install the manual transmission assembly on ve-
NOTE:
• Make sure that the cut-out end surface of counter
gear shaft does not protrude above the end surface
of the case.
• Position the cut-out portion of counter gear shaft
as shown in the figure.
MT-109
COUNTER GEAR
C: INSPECTION
1) After installing the snap ring, measure the clear-
ance between snap ring and counter washer.
Clearance:
0.05 — 0.35 mm (0.0020 — 0.0138 in)
2) If the clearance is out of measured value, select
a snap ring and install to put clearance within mea-
sured value. <Ref. to MT-110, ADJUSTMENT,
Counter Gear.>
D: ADJUSTMENT
Selection of snap ring:
If the measurement is not within specification, se-
lect suitable snap ring.
Snap ring
031319000 1.50 (0.0591)
805019010 1.72 (0.0677)
MT-110
GENERAL DIAGNOSTIC
24.General Diagnostic
A: INSPECTION
1. MANUAL TRANSMISSION
1. Gears are difficult to intermesh. (a) Worn, damaged or burred chamfer of Replace.
NOTE: internal spline of sleeve and reverse
The cause for difficulty in shifting gears driven gear
can 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
the other is malfunction of the transmis-
(c) Worn or scratched bushings Replace.
sion. However, if the operation is heavy
and engagement of the gears is difficult, (d) Incorrect contact between synchro- Correct or replace.
defective clutch disengagement may also nizer ring and gear cone or wear
be responsible. Check whether the clutch
is 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 Tighten or replace.
road. (c) Worn fork shifter, broken shifter fork Replace.
• Gear slips out during acceleration. rail spring
(d) Worn or damaged ball bearing Replace.
(e) Excessive clearance between splines Replace.
of synchronizer hub and synchronizer
sleeve
(f) Worn tooth step of synchronizer hub Replace.
(responsible for slip-out of 3rd gear)
(g) Worn 1st driven gear, needle bearing Replace.
and race
(h) Worn 2nd driven gear, needle bearing Replace.
and race
(i) Worn 3rd drive gear and bushing Replace.
(j) Worn 4th drive gear and bushing Replace.
(k) Worn reverse idler gear and bushing Replace.
3. Unusual noise comes from transmis- (a) Insufficient or improper lubrication Lubricate or replace with specified oil.
sion. (b) Worn or damaged gears and bearings Replace.
NOTE: NOTE:
If an unusual noise is heard when the ve- If the trouble is only wear of the tooth sur-
hicle is parked with its engine idling and if faces, merely a high roaring noise will oc-
the noise ceases when the clutch is disen- cur at high speeds, but if any part is
gaged, it may be considered that the broken, rhythmical knocking sound will be
noise comes from the transmission. heard even at low speeds.
MT-111
GENERAL DIAGNOSTIC
2. DIFFERENTIAL
1. Broken differential (case, gear, bear- (a) Insufficient or improper oil Disassemble the differential and replace
ing, etc.) broken components and at the same time
NOTE: check other components for any trouble,
Abnormal noise will develop and finally it and replace if necessary.
will become impossible to continue to run (b) Use of vehicle under severe condi- Readjust the bearing preload and back-
due to broken pieces obstructing the gear tions such as excessive load and lash and face contact of gears.
revolution. improper use of clutch
(c) Improper adjustment of taper roller Adjust.
bearing
(d) Improper adjustment of drive pinion Adjust.
and hypoid driven gear
(e) Excessive backlash due to worn dif- Add recommended oil to specified level.
ferential side gear, washer or differential Do not use the vehicle under severe
pinion vehicle under severe operating operating conditions.
conditions.
(f) Loose hypoid driven gear clamping Tighten.
bolts
2. Differential and hypoid gear noises (a) Insufficient oil Lubricate.
Troubles of the differential and hypoid (b) Improper adjustment of hypoid driven Check tooth contact.
gear always appear as noise problems. gear and drive pinion
Therefore noise is the first indication of (c) Worn teeth of hypoid driven gear and Replace as a set.
the trouble. However noises from the drive pinion Readjust the bearing preload.
engine, muffler, tire, exhaust gas, bear-
(d) Loose roller bearing Readjust the hypoid driven gear to drive
ing, body, etc. are easily mistaken for the
pinion backlash and check tooth contact.
differential noise. Pay special attention to
the hypoid gear noise because it is easily (e) Distorted hypoid driven gear or differ- Replace.
confused with other gear noises. There ential case
are the following four kinds of noises. (f) Worn washer and differential pinion Replace.
• Gear noise when driving: If noise shaft
increases as vehicle speed increases it
may be due to insufficient gear oil, incor-
rect gear engagement, damaged gears,
etc.
• Gear noise when coasting: Damaged
gears due to maladjusted bearings and
incorrect shim adjustment
• Bearing noise when driving or when
coasting: Cracked, broken or damaged
bearings
• Noise which mainly occurs when turn-
ing: Unusual noise from differential side
gear, differential pinion, differential pinion
shaft, etc.
MT-112
CLUTCH SYSTEM
CL
Page
2. Clutch Disc and Cover ..............................................................................20
3. Flywheel ....................................................................................................24
4. Release Bearing and Lever.......................................................................26
5. Operating Cylinder ....................................................................................29
6. Master Cylinder .........................................................................................31
7. Clutch Pipe and Hose ...............................................................................35
8. Clutch Fluid ...............................................................................................37
9. Clutch Fluid Air Bleeding...........................................................................38
10. Clutch Pedal..............................................................................................41
11. Clutch Cable..............................................................................................49
12. Clutch Switch ............................................................................................50
13. General Diagnostic Table..........................................................................51
GENERAL DESCRIPTION
CLUTCH SYSTEM
A: SPECIFICATIONS
Model 1.6 L 2.0 L NON-TURBO 2.0 L TURBO 2.5 L
Type Push type Pull type Push type
Clutch cover
Diaphragm set load kgf (lb) 450 (992) 830 (1,830) 550 (1,213)
Facing material Woven (Non asbestos)
230 x 150 x 3.5 228.6 x 155 x 6.6
Clutch disc O.D. x I.D. x thickness mm (in) 225 x 150 x 3.5 (8.86 x 5.91 x 0.138) (9.06 x 5.91 x (9.00 x 6.10 x
0.138) 0.260)
Spline O.D. mm (in) 25.2 (0.992), (No. of teeth: 24)
Clutch release lever ratio 3.0 1.6 1.7 1.6
Release bearing Grease-packed self-aligning
Full stroke mm (in) 130 — 135 (5.12 — 5.31)
Clutch pedal 3 — 13 10 — 12
Free play mm (in) 10 — 20 (0.39 — 0.79)
(0.12 — 0.51) (0.39 — 0.79)
13.3 — 14.7 24 — 26
Stroke mm (in) 24 — 26 (0.94 — 1.02)
(0.524 — 0.579) (0.94 — 1.02)
Play at release lever 3—4
mm (in) 3 — 4 (0.12 — 0.16) —
center (0.12 — 0.16)
Clutch disc Standard 1.3 — 1.9 (0.051 — 0.075)
Depth of rivet head
mm (in) Limit of
0.3 (0.012)
sinking
0.8 (0.031) at 1.0 (0.039) at
Limit for deflection mm (in) 0.8 (0.031) at R = 110 (4.33)
R = 107 (4.21) R = 110 (4.33)
I.D.: Inner diameter

O.D.: Outer diameter
CL-2
GENERAL DESCRIPTION
CLUTCH SYSTEM
B: COMPONENT
1. CLUTCH ASSEMBLY FOR 1.6 L NON-TURBO MODEL
(2)
(1)
(6) (5)
(12)
(4)
(7)
(9)
(3)
(8)
(10)
(11)
(7)
TR0430
(1) Clutch release lever sealing (9) Clutch cover

(2) Clutch cable bracket (10) Clutch disk
(3) Retainer spring (11) Flywheel
(4) Pivot (12) Clutch return spring bracket
(5) Clutch release lever
(6) Return spring Tightening torque: N·m (kgf-m, ft-lb)
(7) Clip T: 15.7 (1.6, 11.6)
(8) Clutch release bearing
CL-3
GENERAL DESCRIPTION
CLUTCH SYSTEM
2. CLUTCH ASSEMBLY FOR 2.0 L NON-TURBO MODEL
S2M2066A
(1) Clutch release lever sealing (6) Clutch 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) Clutch release lever (9) Flywheel
(5) Clip
CL-4
GENERAL DESCRIPTION
CLUTCH SYSTEM
3. CLUTCH ASSEMBLY FOR 2.5 L MODEL
B2M4686A
(1) Clutch release lever seal (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) Double mass flywheel
(5) Clip
CL-5
GENERAL DESCRIPTION
CLUTCH SYSTEM
4. CLUTCH ASSEMBLY FOR TURBO MODEL
S2M2158A
(1) Clutch release lever sealing (6) Clutch cover Tightening torque: N·m (kgf-m, ft-lb)
(2) Clutch release lever (7) Clutch disc T1: 15.7 (1.6, 11.6)
(3) Clutch release lever shaft (8) Flywheel T2: 44 (4.5, 32.5)
(4) Plug T3: 72 (7.3, 52.8)
(5) Clutch release bearing
CL-6
GENERAL DESCRIPTION
CLUTCH SYSTEM
5. CLUTCH PIPE AND HOSE FOR NON-TURBO MODEL

• LHD MODEL
(10)
(7) (8)
(9)
T3
T2
T3
T3
(6)
(3)
(4)
(5)
T4
(2)
(1)
T1
TR0535
(1) Operating cylinder (6) Pipe Tightening torque: N·m (kgf-m, ft-lb)
(2) Washer (7) Master cylinder ASSY T1: 8 (0.8, 5.8)
(3) Clutch hose (8) Clevis pin T2: 15 (1.5, 10.8)
(4) Bracket (9) Snap pin T3: 18 (1.8, 13.0)
(5) Clip (10) Lever T4: 37 (3.8, 27.5)
CL-7
GENERAL DESCRIPTION
CLUTCH SYSTEM
• RHD MODEL
(10)
(8)
(7)
(4)
(9)
T2
T3
(11)
(6)
T4
(3)
T2
(12)
T4
T5
(2)
(1) (5)
T1 (11)
TR0896
(1) Operating cylinder (7) Master cylinder ASSY Tightening torque: N·m (kgf-m, ft-lb)
(2) Washer (8) Clevis pin T1: 8 (0.8, 5.8)
(3) Clutch hose (9) Snap pin T2: 15 (1.5, 10.8)
(4) Bracket (10) Pedal T3: 18 (1.8, 13.0)
(5) Clip (11) Clamp T4: 25 (2.5, 18.1)
(6) Clutch pipe (12) Bracket T5: 37 (3.8, 27.5)
CL-8
GENERAL DESCRIPTION
CLUTCH SYSTEM
6. CLUTCH PIPE AND HOSE FOR TURBO MODEL

• LHD MODEL
(8)
(7) (9)
(10)
T2
T3
T3
(3) (6)
(4)
(5)
(2)
T3
(1)
T1
T4
TR0536
(1) Operating cylinder (6) Pipe Tightening torque: N·m (kgf-m, ft-lb)
(2) Washer (7) Master cylinder ASSY T1: 8 (0.8, 5.8)
(3) Clutch hose (8) Clevis pin T2: 15 (1.5, 10.8)
(4) Bracket (9) Snap pin T3: 18 (1.8, 13.0)
(5) Clip (10) Lever T4: 37 (3.8, 27.5)
CL-9
GENERAL DESCRIPTION
CLUTCH SYSTEM
• RHD MODEL
(7) (9)
T4
(6)
(8)
T3
B A
(10) (4) T3
T1 (11)
(11)
B
T3
A
T3 T5 (12) (5)
(3) T3 (10) (12)
(2) T5 (10)
(11)
(1)
T5
T2
T6
TR0897
(1) Operating cylinder (7) Clevis pin Tightening torque: N·m (kgf-m, ft-lb)
(2) Washer (8) Snap pin T1: 7.5 (0.76, 5.53)
(3) Clutch hose (9) Pedal T2: 8 (0.8, 5.8)
(4) Bracket (10) Clamp T3: 15 (1.5, 10.8)
(5) Clip (11) Clutch pipe T4: 18 (1.8, 13.0)
(6) Master cylinder ASSY (12) Bracket T5: 25 (2.5, 18.1)
T6: 37 (3.8, 27.5)
CL-10
GENERAL DESCRIPTION
CLUTCH SYSTEM
7. MASTER CYLINDER
• NON-TURBO MODEL
(1) (12) T1
(11)
(2)
(10)
(3)
(4) (9)
(8)
(5)
(7)
(6) T2
TR0898
(1) Reservoir cap (7) Gasket Tightening torque: N·m (kgf-m, ft-lb)
(2) Reservoir tank (8) Return spring T1: 10 (1.0, 7)
(3) Oil seal (9) Piston T2: 46.6 (4.75, 34.4)
(4) Straight pin (10) Push rod
(5) Master cylinder (11) Piston stop ring
(6) Clutch damper (12) Cylinder boot
CL-11
GENERAL DESCRIPTION
CLUTCH SYSTEM
• LHD TURBO MODEL
(1) (12) T1
(11)
(2)
(10)
(3)
(4) (9)
(8)
(5)
(7)
(6) T2
TR0899
(1) Reservoir cap (7) Gasket Tightening torque: N·m (kgf-m, ft-lb)
(2) Reservoir tank (8) Return spring T1: 10 (1.0, 7)
(3) Oil seal (9) Piston T2: 46.6 (4.75, 34.4)
(4) Straight pin (10) Push rod
(5) Master cylinder (11) Piston stop ring
(6) Clutch damper (12) Cylinder boot
CL-12
GENERAL DESCRIPTION
CLUTCH SYSTEM
• RHD TURBO MODEL
(6)
(1)
T3
(5)
(4)
(4)
(2)
(3) (13) T2
(3) (12)
T3
(7) (11)
T1
(10)
(9)
(8)
TR0900
(1) Reservoir cap (7) Oil seal (13) Cylinder boot

(2) Reservoir tank (8) Master cylinder
(3) Washer (9) Return spring Tightening torque: N·m (kgf-m, ft-lb)
(4) Clip (10) Piston T1: 8 (0.8, 5.8)
(5) Hose (11) Push rod T2: 10 (1.0, 7)
(6) Reservoir tank bracket (12) Piston stop ring T3: 18 (1.8, 13.3)
CL-13
GENERAL DESCRIPTION
CLUTCH SYSTEM
8. CLUTCH PEDAL FOR 2.0 L AND 2.5 L MODEL

• LHD MODEL
(7)
(3)
(26)
(11)
T2 (25)
(4)
T2
(2)
(24)
T2
(23)
(11) T1
(27)
T1
(22)
(2)
(1) (20)
(21)
T1 (1)
(19) (18)
(14)
(13) (14) (4)
(8)
(2)
(12)
(2)
(17)
(16)
(15) (7)
(12) (11)
(1) (5)
(6)
(9)
(10)
TR0901
(1) Stopper (12) Clutch clevis pin (23) Stop light switch
(2) Bushing (13) Assist rod A (24) Pedal bracket
(3) Spring pin (14) Clip (25) Clutch master cylinder bracket
(4) Snap pin (15) Assist spring (26) Lever
(5) Brake pedal pad (16) Assist bushing (27) Adjust bolt
(6) Brake pedal (17) Assist rod B
(7) Clevis pin (18) Spring A Tightening torque: N·m (kgf-m, ft-lb)
(8) Brake pedal spring (19) Rod T1: 8 (0.8, 5.8)
(9) Clutch pedal pad (20) Bushing B T2: 18 (1.8, 13.0)
(10) Clutch pedal (21) O-ring
(11) Bushing C (22) Clip
CL-14
GENERAL DESCRIPTION
CLUTCH SYSTEM
• RHD MODEL
(10)
(9)
(8)
(5)
(7) (6) (4)
(19)
T2
(16)
T3 (15)
(1) (14)
T1 (13)
(11)
(12)
(17)
(4) (18)
(1)
(18)
(2)
(3)
(4)
TR0902
(1) Stopper (9) Assist bushing (17) Spacer

(2) Clutch pedal pad (10) Assist rod B (18) Bushing
(3) Clutch pedal (11) Spring A (19) Clutch pedal bracket
(4) Bushing (12) Rod S
(5) Clutch clevis pin (13) Bushing B Tightening torque: N·m (kgf-m, ft-lb)
(6) Assist rod A (14) O-ring T1: 8 (0.8, 5.8)
(7) Clip (15) Clip T2: 18 (1.8, 13.0)
(8) Assist spring (16) Clutch switch (With cruise control) T3: 30 (3.1, 22.4)
CL-15
GENERAL DESCRIPTION
CLUTCH SYSTEM
9. CLUTCH PEDAL FOR 1.6 L MODEL

• LHD MODEL
T1
T3
(11)
(12)
T4
(3)
T3
(15)
T2
(16)
(14) (2)
(13)
T2
(1)
(2)
(4)
(2) (8)
(5)
(13) (7)
(6)
(1)
(14)
(2)
(8)
(9)
(10)
TR0903
(1) Stopper (9) Clutch pedal pad Tightening torque: N·m (kgf-m, ft-lb)
(2) Bushing (10) Clutch pedal T1: 5.9 (0.60, 4.3)
(3) Clutch pedal bracket (11) Clutch cable T2: 8 (0.8, 5.8)
(4) Snap pin (12) Clutch cable clamp T3: 18 (1.8, 13.0)
(5) Brake pedal pad (13) Clip T4: 29 (3.0, 21.7)
(6) Brake pedal (14) Spring assist
(7) Clevis pin (15) Stop light switch
(8) Spring (16) Adjust bolt
CL-16
GENERAL DESCRIPTION
CLUTCH SYSTEM
• RHD MODEL
(7)
T1
(6)
T3
(3)
(9)
T3
T4 (10)
(1) (8)
T2 (2)
(11) (2)
(2)
(2)
(1)
(1)
(4)
(5)
TR0904
(1) Stopper (7) Clutch cable clamp Tightening torque: N·m (kgf-m, ft-lb)
(2) Bushing (8) Spacer T1: 5.9 (0.6, 4.3)
(3) Clutch pedal bracket (9) Bracket T2: 8 (0.8, 5.8)
(4) Clutch pedal pad (10) Adjust bolt T3: 18 (1.8, 13.0)
(5) Clutch pedal (11) Spring T4: 29 (3.0, 21.7)
(6) Clutch cable
CL-17
GENERAL DESCRIPTION
CLUTCH SYSTEM

tion. points.
• Remove contamination including dirt and corro- • Apply grease onto sliding or revolution surfaces
sion before removal, installation or disassembly. before installation.
• Keep the disassembled parts in order and pro- • Before installing O-rings or snap rings, apply suf-
tect them from dust or dirt. ficient amount of fluid to avoid damage and defor-
• Before removal, installation or disassembly, be mation.
sure to clarify the failure. Avoid unnecessary re- • Before securing a part on a vise, place cushion-
moval, installation, disassembly, and replacement. ing material such as wood blocks, aluminum plate,
• Be careful not to burn your hands, because each or shop cloth between the part and the vise.
part on the vehicle is hot after running. • Keep fluid away from the vehicle body. If any flu-
• Use SUBARU genuine fluid, grease etc. or the id contacts the vehicle body, immediately flush the
equivalent. Do not mix fluid, grease etc. with that of area with water.
another grade or from other manufacturers.
D: PREPARATION TOOL
1. SPECIAL TOOLS
STOPPER ening tightening bolt, etc.
B2M3853
499747100 CLUTCH DISC Used when installing clutch disc to flywheel.
GUIDE
B2M4112
CL-18
GENERAL DESCRIPTION
CLUTCH SYSTEM

499057000 TORX PLUS • Used for removing flywheel (Dual mass fly-
wheel type).
• For 2.5 L model.
B2M4213

TOOL NAME REMARKS
Dial Gauge Used for measuring clutch disk run-out.
CL-19
CLUTCH DISC AND COVER
CLUTCH SYSTEM
2. Clutch Disc and Cover 2. EXCEPT 2.5 L MODEL

A: REMOVAL 1) Remove the transmission assembly from vehicle
body. <Ref. to MT-33, REMOVAL, Manual Trans-
1. 2.5 L MODEL mission Assembly.>
2) Install the ST on flywheel.
1) Remove the transmission assembly from vehicle
body. <Ref. to MT-33, REMOVAL, Manual Trans-
mission Assembly.>
2) Insert the ST on flywheel.
ST 499747100 CLUTCH DISC GUIDE
S2M1847A
(A) Clutch cover
B2M3345B 3) Remove the clutch cover and clutch disc.

NOTE:
(A) Double mass flywheel
• Take care not to allow oil on the clutch disc fac-
3) Remove the clutch cover and clutch disc. ing.
• Do not disassemble either the clutch cover or
NOTE:
clutch disc.
• Take care not to allow oil on the clutch disc fac-
ing. B: INSTALLATION
• Do not disassemble either the clutch cover or
clutch disc. 1. 2.5 L MODEL
• Put matching marks to the flywheel and clutch 1) Insert the ST into clutch disc and install them on
cover before removing the clutch cover. the flywheel by inserting the ST end into pilot bear-
ing.
NOTE:
When installing the clutch disc, be careful to its di-
rection.
B2M3346
B2M4687A
(A) Flywheel
(B) Flywheel side
CL-20
CLUTCH SYSTEM
2) Install the clutch cover on flywheel and tighten 2) Install the clutch cover on flywheel and tighten
the bolts to specified torque. the bolts to specified torque.
NOTE: NOTE:
• Align matching marks. • When installing the clutch cover on flywheel, po-
• Note the front and rear of the clutch disc when in- sition the clutch cover so that there is a gap of 120°
stalling. or more between “0” marks on the flywheel and
• Tighten the clutch cover installing bolts gradual- clutch cover. (“0” marks indicate the directions of
ly. Each bolt should be tightened to the specified residual unbalance.)
torque in a crisscross fashion. • Note the front and rear of the clutch disc when in-
stalling.
Tightening torque:
• Temporarily tighten the bolts by hand. Each bolt
15.7 N·m (1.6 kgf-m, 11.6 ft-lb) should be tightened to the specified torque in a
crisscross fashion.
Tightening torque:
15.7 N·m (1.6 kgf-m, 11.6 ft-lb)
B2M3346A
3) Remove the ST.

2. EXCEPT 2.5 L MODEL
1) Insert the ST into clutch disc and install them on
the flywheel by inserting the ST end into pilot bear-
ing.
NOTE:
When installing the clutch disc, be careful to its di-
rection.
B2M1011B
(A) “0” marks
3) Remove the ST.

4) Install the transmission assembly. <Ref. to MT-
37, INSTALLATION, Manual Transmission Assem-
B2M4608A bly.>
(A) Flywheel side
CL-21
CLUTCH SYSTEM
C: INSPECTION 3) Oil soakage on facing

Replace the clutch disc and inspect the transmis-
1. CLUTCH DISC sion front oil seal, transmission case mating sur-
1) Facing wear face, engine rear oil seal and other points for oil
Measure the depth of rivet head from the surface of leakage.
facing. Replace if facings are worn locally or worn • 2.5 L MODEL
down to less than the specified value.
Depth of rivet head:
Limit of sinking
0.3 mm (0.012 in)
NOTE:
Do not wash the clutch disc with any cleaning fluid.
• 2.5 L MODEL
B2M3349C
B3M3348
B2M3355C
4) Deflection on facing
If deflection exceeds the specified value at the out-
er circumference of facing, repair or replace.
Limit for deflection:
1.6 L model
B3M3354 0.8 mm (0.031 in) at R = 107 mm (4.21 in)
2.0 L model
2) Hardened facing 0.8 mm (0.031 in) at R = 110 mm (4.33 in)
Correct by using emery paper or replace. 2.5 L model
1.0 mm (0.039 in) at R = 110 mm (4.33 in)
• 2.5 L MODEL
B2M3350B
CL-22
CLUTCH SYSTEM
• Except 2.5 L MODEL 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 center
of diaphragm spring.
• 2.5 L MODEL
B2M3356B
5) Worn spline, loose rivets and torsion spring fail-

ure
Replace defective parts.
• 2.5 L MODEL
B2M3351A
B2M3349A
B2M3358A
(A) Thrust rivet

(B) Diaphragm spring
B2M3355D
(A) Spline
(B) Rivet
(C) Torsion spring
CL-23
FLYWHEEL
CLUTCH SYSTEM
3. Flywheel B: INSTALLATION
A: REMOVAL 1. 2.5 L MODEL
1. 2.5 L MODEL 1) Install the flywheel and ST.
1) Remove the transmission assembly. <Ref. to
MT-33, REMOVAL, Manual Transmission Assem-
bly.>
2) Remove the clutch cover and clutch disc. <Ref.
to CL-20, REMOVAL, Clutch Disc and Cover.>
3) Remove the flywheel using ST1 and ST2.
ST1 498497100 CRANKSHAFT STOPPER
ST2 499057000 TORX PLUS
B2M3359A
2) Tighten the flywheel attaching bolts to the spec-

ified torque.
ST 499057000 TORX PLUS
NOTE:
Tighten the flywheel installing bolts gradually. Each
bolt should be tightened to the specified torque in a
B2M3347B crisscross fashion.
(A) Flywheel
Tightening torque:
72 N·m (7.3 kgf-m, 52.8 ft-lb)
2. EXCEPT 2.5 L MODEL
1) Remove the transmission assembly. <Ref. to
MT-33, REMOVAL, Manual Transmission Assem-
bly.>
2) Remove the clutch cover and clutch disc. <Ref.
to CL-20, REMOVAL, Clutch Disc and Cover.>
3) Using the ST, remove the flywheel.
B2M3360A
3) Install the clutch disc and cover. <Ref. to CL-20,

2.5 L MODEL, INSTALLATION, Clutch Disc and
Cover.>
bly.>
B2M0332B
(A) Flywheel
CL-24
FLYWHEEL
CLUTCH SYSTEM
2. EXCEPT 2.5 L MODEL C: INSPECTION

1) Install the flywheel and ST. CAUTION:
ST 498497100 CRANKSHAFT STOPPER Since this bearing is grease sealed and is of a
non-lubrication type, do not wash with gasoline
or any solvent.
1) Damage of facing and ring gear
If defective, replace the flywheel.
• 2.5 L MODEL
B2M3361A
2) Tighten the flywheel attaching bolts to the spec-

ified torque.
NOTE:
Tighten the flywheel installing bolts gradually. Each B2M3353B
bolt should be tightened to the specified torque in a
crisscross fashion.
(A) Flywheel
Tightening torque: (B) Ring gear
72 N·m (7.3 kgf-m, 52.8 ft-lb)
B2M0331B
S2M1851A
3) Install the clutch disc and cover. <Ref. to CL-21,
EXCEPT 2.5 L MODEL, INSTALLATION, Clutch (A) Flywheel
Disc and Cover.> (B) Ring gear
37, INSTALLATION, Manual Transmission Assem- 2) Smoothness of rotation
bly.> Rotate the ball bearing applying pressure in thrust
direction.
3) If noise or excessive play is noted, replace the
flywheel.
CL-25
RELEASE BEARING AND LEVER
CLUTCH SYSTEM
4. Release Bearing and Lever 4) Remove the clutch release bearing from the
clutch cover using flat-type screwdriver.
A: REMOVAL
1. NON-TURBO MODEL
body.
<Ref. to MT-33, REMOVAL, Manual Transmission
Assembly.>
2) Remove the two clips from clutch release lever
and remove the release bearing.
CAUTION:
S2M1843A
Be careful not to deform clips.
3) Remove the release lever seal. (A) Clutch release bearing
B: INSTALLATION
1. NON-TURBO MODEL
NOTE:
Before or during assembling, lubricate the following
points with a light coat of grease.
• Contact surface of lever and pivot
• Contact surface of lever and bearing
B2M4222A
• Transmission main shaft spline (Use grease con-
taining molybdenum disulphide.)
(A) Clutch release lever
• Contact surface of lever and operating cylinder
(B) Release lever seal 1) While pushing the release lever to pivot and
twisting it to both sides, fit the retainer spring onto
4) Remove the release lever retainer spring from the constricted portion of pivot.
release lever pivot with a screwdriver by accessing NOTE:
it through clutch housing release lever hole. Then • Apply grease (SUNLIGHT 2: P/N 003602010) to
remove the release lever. 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.
B2M4223A

(B) Screwdriver B2M4224A
2. TURBO MODEL (A) Release lever

body. <Ref. to MT-33, REMOVAL, Manual Trans- 2) Install the release bearing and fasten it with two
mission Assembly.> clips.
2) Remove the clutch release lever from transmis-
sion.
3) Put the clutch release bearing in engine side.
CL-26
CLUTCH SYSTEM
3) Install the release lever seal. 3) Apply grease to the specified points:
• Spline FX2200
• Shaft SUNLIGHT 2
B2M4222A
(A) Release lever

(B) Release lever seal
4) Install the transmission assembly.

<Ref. to MT-37, INSTALLATION, Manual Trans-
mission Assembly.>
2. TURBO MODEL
1) Install the release bearing on transmission.
2) Insert the release fork into release bearing tab.
S2M1938A
(A) Spline (FX2200)

(B) Shaft (SUNLIGHT 2)
4) Insert the release fork shaft into release fork.

NOTE:
Make sure the cutout portion of release fork shaft
S2M1937A contacts spring pin.
(A) Release fork

(B) Release bearing
S2M1845A
(A) Release fork

(B) Release shaft
(C) Spring pin
CL-27
CLUTCH SYSTEM
5) Tighten the plug. 2) Check the bearing for smooth rotation by apply-
ing pressure in the thrust direction.
Tightening torque:
44 N·m (4.5 kgf-m, 32.5 ft-lb)
S2M1844A
S2M1846
(A) Bearing case
3) Check wear and damage of the bearing case
surface contacting with lever.
bly.>
C: INSPECTION 2. RELEASE LEVER
1) Check the lever pivot portion and the point of
1. RELEASE BEARING contact with release bearing case for wear.
NOTE:
Since this bearing is grease sealed and is of a non-
lubrication type, do not wash with gasoline or any
solvent when servicing the clutch.
1) Check the bearing for smooth movement by ap-
plying force in the radial direction.
Radial direction stroke:
1.4 mm (0.055 in)
S2M1102E

(B) Pivot
(C) Clutch release bearing
B2M0173B
(A) Bearing case
CL-28
OPERATING CYLINDER
CLUTCH SYSTEM
5. Operating Cylinder 4) Remove the operating cylinder from transmis-

sion.
A: REMOVAL • Non-turbo MODEL
1) Remove the air cleaner case and air intake duct
(Non-turbo model). <Ref. to IN-6, REMOVAL, Air
Intake Duct.>
3) Remove the clutch hose from operating cylinder.
CAUTION:
Cover the hose joint to prevent clutch fluid from
flowing out.
B2M1263
• Non-turbo MODEL
• Turbo MODEL
B2M1179J
S2M1853A
(A) Clutch hose
(B) Operating cylinder (A) Operating cylinder
• Turbo MODEL
S2M1842B
(A) Clutch hose

(B) Operating cylinder
CL-29
OPERATING CYLINDER
CLUTCH SYSTEM
B: INSTALLATION 2) After bleeding air from the operating cylinder,

1) Install in the reverse order of removal. ensure that clutch operates properly.
<Ref. to CL-38, Clutch Fluid Air Bleeding.>
NOTE:
Before installing the operating cylinder, apply C: INSPECTION
grease (SUNLIGHT 2: P/N 003602010) to contact 1) Check the operating cylinder for damage. If op-
point of the release lever and operating cylinder. erating cylinder is damaged, replace it.
2) Check the operating cylinder for fluid leakage or
Tightening torque:
damage on boot. If any leakage or damage is
T1: 18 N·m (1.8 kgf-m, 13.0 ft-lb)
found, replace the operating cylinder.
T2: 37 N·m (3.8 kgf-m, 27.5 ft-lb)
• Non-turbo MODEL
B2M1179C
• Turbo MODEL
G2M0978
NOTE:
• Be sure to install the clutch hose with the mark
side facing upward.
• Be careful not to twist the clutch hose during in-
stallation.
H2M2666B
(A) Marking
(B) Clutch hose
(C) Operating cylinder
CL-30
MASTER CYLINDER
CLUTCH SYSTEM
6. Master Cylinder B: INSTALLATION

1) Install the master cylinder to body, and install the
A: REMOVAL clutch pipe to master cylinder.
1) Thoroughly drain the brake fluid from reservoir
tank. CAUTION:
2) Remove the snap pin, clevis pin and separate Check that the pipe is routed properly.
the push rod of master cylinder from clutch pedal. 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-lb)
T2
B4M1189E
T1
(A) Clevis pin TR0469
(B) Snap pin
(C) Push rod 2) Connect the push rod of master cylinder to
(D) Lock nut
clutch pedal, and install the clevis pin and snap pin.
NOTE:
3) Remove the air cleaner case and air intake duct Apply grease to the clevis pin.
(Non-turbo model). <Ref. to IN-6, REMOVAL, Air
Intake Duct.>
5) Remove the clutch pipe from master cylinder.
6) Remove the master cylinder with reservoir tank.
CAUTION:
Be extremely careful not to spill brake fluid.
Brake fluid spilt on the vehicle body will harm
the paint surface; wipe it off quickly if spilt. B4M1189C
(A) Clevis pin

(B) Snap pin
(C) Push rod
3) After bleeding air from the system, ensure that

clutch operates properly.
<Ref. to CL-38, Clutch Fluid Air Bleeding.>
4) Install the air cleaner case and air intake duct
(Non-turbo model). <Ref. to IN-6, INSTALLATION,
TR0468 Air Cleaner Case.> and <Ref. to IN-7, INSTALLA-
TION, Air Intake Duct.>
5) Install the intercooler (Turbo model). <Ref. to
IN(TURBO)-11, INSTALLATION, Intercooler.>
CL-31
MASTER CYLINDER
CLUTCH SYSTEM
C: DISASSEMBLY 2. RHD TURBO MODEL

1. EXCEPT RHD TURBO MODEL 1) Remove the hose.
1) Remove the straight pin and reservoir tank.
(A)
(B)
TR0530
TR0471 2) Remove the reservoir tank and bracket.
(A) Reservoir tank (B)
(B) Straight pin
2) Remove the oil seal. (A)
(A)
TR0531
(A) Reservoir tank

(B) Bracket
(B)
TR0472 3) Remove the straight pin and adapter.
(B)
(A) Oil seal
(B) Master cylinder
(A)
3) Move the cylinder boot backward.
(A)
TR0524
(A) Straight pin

(B) Adapter
(B)
TR0473
(A) Cylinder boot

(B) Master cylinder
4) Remove the stop ring.

CAUTION:
Be careful when removing the snap ring to pre-
vent the rod, washer, piston and return spring
from flying out.
5) Remove the clutch damper.
CL-32
MASTER CYLINDER
CLUTCH SYSTEM
4) Remove the oil seal. D: ASSEMBLY

1. EXCEPT RHD TURBO MODEL
1) Install the clutch damper.
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:
TR0525
SILICONE GREASE G40M (Part No.
004404003)
5) Move the cylinder boot backward.
(A)
(B)
TR0474
TR0473
3) To assemble the master cylinder, reverse the
(A) Cylinder boot sequence of disassembly procedure.
(B) Master cylinder Tightening torque:
10 N·m (1.0 kgf-m, 7 ft-lb)
6) Remove the stop ring.
CAUTION:
Be careful when removing the snap ring to pre-
vent the rod, washer, piston and return spring
from flying out.
7) Remove the air bleeder.
CL-33
MASTER CYLINDER
CLUTCH SYSTEM
2. RHD TURBO MODEL

1) Apply a coat of grease to the contacting surfaces
of the push rod and piston before installation.
Grease:
SILICONE GREASE G40M (Part No.
004404003)
TR0526
2) Assemble in the reverse order of disassemble.

E: INSPECTION
If any damage, deformation, wear, swelling, rust or
other faults are found on the cylinder, piston, push
rod, fluid reservoir, return spring, gasket, clutch
damper, cylinder boot and hose replace the faulty
part.
(C)
(B)
(A)
(G)
(D)
(E)
(F)
TR0905
(A) Master cylinder body

(B) Return spring
(C) Piston
(D) Stop ring
(E) Rod ASSY
(F) Clutch damper
(G) Cylinder boot
CL-34
CLUTCH PIPE AND HOSE
CLUTCH SYSTEM
7. Clutch Pipe and Hose 2. RHD TURBO MODEL

A: REMOVAL 1) Remove the intercooler. <Ref. to IN(TURBO)-
1. EXCEPT RHD TURBO MODEL 2) Drain the clutch fluid. <Ref. to CL-37, Clutch Flu-
id.>
1) Remove the air cleaner case and air intake duct.
3) Remove the clutch pipe from the master cylin-
2) Drain the clutch fluid. <Ref. to CL-37, Clutch Flu-
der, connector and clutch hose.
id.>
3) Remove the clutch pipe from the clutch hose and
master cylinder.
4) Pull out the clamp, then remove the clutch hose
from bracket.
(B)
(A)
(C )
(A)
(B)
(D)
B2M4113A (B)
(A) Clamp
(A)
(B) Clutch hose
5) Remove the hose from operating cylinder.

6) Remove the bracket.
TR0527
(A) Clutch pipe

(B) Clip
(C) Connector
(D) Clutch hose
4) Pull out the clamp, then remove the clutch hose

from bracket.
B2M4113A
(A) Clamp
(B) Clutch hose
5) Remove the connector.

6) Remove the bracket.
CL-35
CLUTCH PIPE AND HOSE
CLUTCH SYSTEM
B: INSTALLATION 2. RHD TURBO MODEL

1. EXCEPT RHD TURBO MODEL Install in the reverse order of removal.
Install in the reverse order of removal. NOTE:
Bleed the clutch fluid. <Ref. to CL-38, Clutch Fluid
NOTE: Air Bleeding.>
Bleed the clutch fluid. <Ref. to CL-38, Clutch Fluid
Air Bleeding.> Tightening torque:
T1: 7.5 N·m (0.76 kgf-m, 5.53 ft-lb)
Tightening torque: T2: 8 N·m (0.8 kgf-m, 5.8 ft-lb)
T1: 15 N·m (1.5 kgf-m, 10.8 ft-lb) T3: 15 N·m (1.5 kgf-m, 10.8 ft-lb)
T1
(A)
T3
T3
T1
T1
(D) (A)
T3 T3
(A)
T1 (B)
T3 T5
T3
(C)
(C)
(B)
T4
T2
(A)
T5
T2
TR0477 TR0528
(A) Clutch pipe (LHD model) (A) Clutch pipe

(B) Clip (B) Connector
(C) Clutch hose (C) Clutch hose
(D) Clutch pipe (RHD model)
C: INSPECTION
Check the pipes and hoses for cracks, breakage, or
damage. Check the joints for fluid leakage. If any
cracks, breakage, damage, or leakage is found, re-
pair or replace the applicable pipe or hose.
CL-36
CLUTCH FLUID
CLUTCH SYSTEM
8. Clutch Fluid 6) Refill the brake fluid before reservoir tank be-
comes empty, and drain contaminated fluid again.
A: INSPECTION 7) Repeat the above procedure until the contami-
1) Park the vehicle on a level surface. nated fluid is completely drained.
2) Inspect the fluid level using scale on the outside
of the reservoir tank. If the level is below “MIN”, add
fluid to bring it up to “MAX”, and also inspect for
leakage.
(C)
(A)
(B)
TR0478
(A) Max. level

(B) Min. level
(C) Reservoir tank
B: REPLACEMENT
CAUTION:
• The FMVSS No. 116, fresh DOT3 or 4 brake
fluid must be used.
• Cover the bleeder with waste cloth, when
loosening it, to prevent brake fluid from being
splashed over surrounding parts.
• Avoid mixing different brands of brake fluid
to prevent degrading the quality of the fluid.
• Be careful not to allow dirt or dust to get into
the reservoir tank.
NOTE:
• During bleeding operation, keep the clutch 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
have two men working.
• The amount of brake fluid required is approx. 70
m2 (2.4 US fl oz, 2.5 Imp fl oz) for total clutch sys-
tem.
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:
FMVSS No. 116, fresh DOT3 or 4 brake fluid
5) Drain fluid in the same method as air bleeding.
CL-37
CLUTCH FLUID AIR BLEEDING
CLUTCH SYSTEM
9. Clutch Fluid Air Bleeding 5) Tighten the air bleeder.
A: PROCEDURE Tightening torque:

T: 8 N·m (0.8 kgf-m, 5.8 ft-lb)
1. NON-TURBO MODEL
NOTE:
Bleed air from the oil line with help of a co-worker.
1) Remove the air cleaner case and air intake duct.
2) Fit one end of a vinyl tube into the air bleeder of
operating cylinder and put the other end into a
brake fluid container.
B2M1179A
6) After depressing the clutch pedal, make sure

that there are no leaks evident in the entire system.
2. TURBO MODEL
NOTE:
Bleed air from the oil line with help of a co-worker.
B2M1179K 1) Remove the intercooler. <Ref. to IN(TURBO)-
(A) Clutch hose 2) Fit one end of a vinyl tube into the air bleeder of
(B) Air bleeder master cylinder and put the air bleeder of other end
into a brake fluid container. (RHD turbo model)
3) Slowly depress the clutch pedal and keep it de-
3) Slowly depress the clutch pedal and keep it de-
pressed. Then open the air bleeder to discharge air
together with the fluid.
together with the fluid. Release the air bleeder for 1
Release the air bleeder for 1 or 2 seconds. Next,
or 2 seconds. Next, with the bleeder closed, slowly
with the bleeder closed, slowly release the clutch
release the clutch pedal. (RHD turbo model)
pedal.
(A)
TR0909
B2M1178C
(A) Vinyl tube

(A) Operating cylinder
(B) Vinyl tube 4) Repeat these steps until there are no more air
bubbles in the vinyl tube. (RHD turbo model)
4) Repeat these steps until there are no more air
bubbles in the vinyl tube. CAUTION:
Cover the bleeder with waste cloth when loos-
NOTE: ening to prevent brake fluid from being
Cover the bleeder with waste cloth when loosening splashed over surrounding parts.
it, to prevent brake fluid from being splashed over
surrounding parts.
CL-38
CLUTCH SYSTEM
5) Tighten the air bleeder. (RHD turbo model) 9) Slowly depress the clutch pedal and keep it de-
Tightening torque:
together with the fluid.
T: 8 N·m (0.8 kgf-m, 5.8 ft-lb)
Release the air bleeder for 1 or 2 seconds. Next,
with the bleeder closed, slowly release the clutch
pedal.
NOTE:
Set the air breather screw part higher than tip of op-
erating cylinder when performing this procedure.
T
(A)
TR0910
6) Remove the operationg cylinder.

NOTE: (B)
Do not remove the clutch hose.
TR0893
(A) Operating cylinder

(B) Vinyl tube
10) Repeat these steps until there are no more air

bubbles in the vinyl tube.
CAUTION:
Cover the bleeder with waste cloth when loos-
TR0070 ening it, to prevent brake fluid from being
splashed over surrounding parts.
7) Fix the piston with clamp to avoid the piston from
jumping out.
TR0892
8) Fit one end of a vinyl tube into the air bleeder of

operating cylinder and put the other end into a
brake fluid container.
CL-39
CLUTCH SYSTEM
11) Tighten the air bleeder.

Tightening torque:
T: 8 N·m (0.8 kgf-m, 5.8 ft-lb)
12) Install the operating cylinder.
Tightening torque:
T: 37 N·m (3.8 kgf-m, 27.5 ft-lb)
TR0070
13) After depressing the clutch pedal, make sure

that there are no leaks evident in the entire system.
CL-40
CLUTCH PEDAL
CLUTCH SYSTEM
10.Clutch Pedal 7) Remove the cable clamp, and disconnect the

PHV cable from PHV. (with hill holder)
A: REMOVAL CAUTION:
1. LHD MODEL Carefully protect the boot and inner cable from
damage when disconnecting the PHV cable.
1) Remove the steering column. <Ref. to PS-29,
REMOVAL, Tilt Steering Column.>
2) Disconnect the connectors from stop light and
clutch switches.
3) Remove the snap pins which secure lever to
push rod and operating rod.
4) Remove the clevis pins which secure lever to
push rod and operating rod.
S4M0242B
(A) PHV cable

(B) Clamp
8) Remove the nut which secures clutch master

cylinder.
B4M1743A
(A) Operating rod

(B) Push rod
(C) Snap pin
(D) Clevis pin
5) Remove the air cleaner case and intake duct.

<Ref. to IN-6, REMOVAL, Air Cleaner Case.> and B4M1744
<Ref. to IN-7, REMOVAL, Air Intake Duct.> 9) Remove the bolts and nuts which secure brake
6) Remove the PHV adjusting nut and lock nut. and clutch pedals, and remove the pedal assembly.
(with hill holder)
• 1.6 L MODEL
3) Disconnect the clutch cable from release lever.
4) Remove the instrument panel lower cover.
5) Disconnect the operating rod of brake pedal.
6) Remove the electrical connectors (for stop light
S4M0241B switch, etc.)
(A) Adjusting nut

(B) Lock nut
(C) PHV
CL-41
CLUTCH PEDAL
CLUTCH SYSTEM
7) Remove the bolts and nuts which secure brake 6) Remove the PHV adjusting nut and lock nut.
and clutch pedals, and remove pedal bracket and (with hill holder)
clutch cable as a unit.
S4M0241B
(A) Adjusting nut

(B) Lock nut
(C) PHV
7) Remove the cable clamp and disconnect the

PHV cable from PHV. (with hill holder)
(A) (B) CAUTION:
Carefully protect the boot and inner cable from
damage when disconnecting the PHV cable.
TR0494
(A) Clutch pedal

(B) Brake pedal
8) Depress the clutch pedal, then disconnect the

clutch cable from clutch pedal.
2. RHD MODEL
1) Disconnect the ground cable from battery. S4M0242B
2) Disconnect the connector from clutch. (With
cruise control) (A) PHV cable
3) Remove the instrument panel lower cover. (B) Clamp
4) Remove the snap pin and clevis pin that join
push rod and clutch pedal. (Except 1.6 L model) 8) Disconnect the clutch cable from release lever.
5) Remove the master cylinder mounting nuts. (Ex- (1.6 L model)
cept 1.6 L model) 9) Remove the clutch pedal and bracket as a unit.
B4M1749B B4M1752B
(A) Master cylinder (A) Clutch pedal bracket

(B) Clutch pedal
CL-42
CLUTCH PEDAL
CLUTCH SYSTEM
10) Depress the clutch pedal, then disconnect the 3) Remove the clutch pedal and bushings.
clutch cable from clutch pedal. (1.6 L model)
B: INSTALLATION
CAUTION:
a new one.
boot.
• Always use new clevis pins. B2M4117A
2) Adjust the clutch pedal after installation. <Ref. to

CL-46, ADJUSTMENT, Clutch Pedal.> (A) Clutch pedal
(B) Bushing
C: DISASSEMBLY
4) Remove the stopper, clip, O-ring, rod S, and
1. LHD MODEL then remove the spring and bushing S.
1) Remove the clips, assist spring, rod and bush-
ing.
B2M4118A
(A) Clip
(B) O-ring
B2M4115A
(C) Bushing S
(A) Clip (D) Spring S
(B) Assist spring (E) Rod S
(C) Assist rod (F) Stopper
(D) Bushing 5) Remove the stoppers from clutch pedal.
(E) Clevis pin 6) Remove the clutch pedal pad. (Non-turbo mod-
2) Remove the spring pin and lever. el)
B2M4116A
(A) Pin
(B) Lever
CL-43
CLUTCH PEDAL
CLUTCH SYSTEM
• 1.6 L MODEL 2) Remove the clip, then pull out the clevis pin.
1) Remove the clip, and then remove the spring as-
sist and spring.
(A)
(A) (B) B2M4226A
TR0943 (A) Clevis pin
3) Remove the assist rod, spring and bushing.

(A) Spring assist 4) Remove the clutch pedal from clutch pedal
(B) Spring bracket.
2) Remove the clutch pedal and brake pedal.
B2M4227A
TR0944
(A) Clutch pedal bracket
3) Remove the bushing, stopper and clutch pedal (B) Clutch pedal
pad.
5) Remove the following parts (B to H) from clutch
(A) pedal bracket (A) as shown in the figure.
(B)
(A)
(C)
TR0945
(A) Bushing B2M4228A
(B) Stopper
(A) Clutch pedal bracket
(C) Clutch pedal pad
(B) Bushing C
4) Remove the adjuster bolt. (C) Clip
(D) O-ring
2. RHD MODEL
(E) Bushing S
• Except 1.6 L MODEL (F) Spring S
1) Remove the clutch switch. (With cruise control) (G) Rod S
(H) Bushing
CL-44
CLUTCH PEDAL
CLUTCH SYSTEM
6) Remove the spacer, bushing and pedal pad from 3) Remove the spacer, bushing, stopper and clutch
clutch pedal. pedal pad.
(B)
(A)
(B)
(C)
(E)
(D)
B2M4229A TR0948
(A) Spacer (A) Spacer

(B) Bushing (B) Bushing
(C) Bushing (C) Stopper
(D) Pedal pad (D) Clutch pedal pad
(E) Clutch pedal
4) Remove the adjust bolt and stopper.
(F) Bushing C
D: ASSEMBLY
• 1.6 L MODEL
1) Remove the spring and bushing. 1. LHD MODEL
1) Attach the stopper, etc. to pedal bracket tempo-
rarily.
2) Clean inside of bores of clutch pedal and brake
pedal, apply grease, and set bushings into bores.
3) Align bores of pedal bracket, clutch pedal and
brake pedal, attach the brake pedal return spring,
assist rods, spring, and bushing. (Except 1.6L mod-
(B) (A) el)
(A)
NOTE:
Clean up inside of bushings and apply grease be-
TR0946
fore installing the spacer.
(A) Bushing 4) Align the bores of pedal bracket, clutch pedal
(B) Spring
and brake pedal, then attach the brake pedal,
bushings, spring and clutch cable. (1.6L model)
2) Remove the clutch pedal. 5) Install the hill holder cable to clutch pedal. (Vehi-
cle with hill holder)
2. RHD MODEL
1) Clean and apply grease to the hole of sliding
portion between clutch pedal and bushing.
2) Install the pad, stopper, spacer and bushings to
clutch pedal.
NOTE:
Clean up inside of bushings and apply grease be-
fore installing the spacer.
TR0947
3) Install the rod S, spring S, bushing S, O-ring,
clip, bushing, clutch switch and bushing C to clutch
pedal bracket. (Except 1.6L model)
4) Install the pedal assembly, stopper, adjust rod,
clutch cable, bushings and spring to clutch pedal
bracket.
CL-45
CLUTCH PEDAL
CLUTCH SYSTEM
5) Install the clutch pedal to pedal bracket. F: ADJUSTMENT

Tightening torque: 1. CLUTCH PEDAL
T: 29 N·m (3.0 kgf-m, 21.7 ft-lb)
1) Turn the lock nuts until clutch pedal full stroke
length is within specifications.
CAUTION:
Do not attempt to turn the clutch switch to ad-
just clutch pedal full stroke length.
NOTE:
If lock nuts cannot adjust the clutch pedal full stroke
length to specifications, turn the master cylinder
B4M1753B push rod to adjust it.
6) Install the assist rod, bushing and assist spring Specified clutch pedal full stroke: A
to clutch pedal and pedal bracket. 130 — 135 mm (5.12 — 5.31 in)
7) Install the PHV cable to clutch pedal. (Vehicle Tightening torque (Clutch switch lock nut):
with hill holder). T: 8 N·m (0.8 kgf-m, 5.8 ft-lb)
E: INSPECTION
1. CLUTCH PEDAL
Move the clutch pedal pads in the lateral direction
with a force of approximately 10 N (1 kgf, 2 lb) to
ensure pedal deflection is in specified range.
CAUTION:
If excessive deflection is noted, replace the
bushings with new ones.
Deflection of clutch pedal: B4M1190C
Service limit 2) Turn the master cylinder push rod so that clevis
5.0 mm (0.197 in) or less 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 ft-lb)
B2M4119A
(A) Clutch pedal

(B) Brake pedal
B4M1189G
(A) Clevis pin

(B) Snap pin
(C) Push rod
CL-46
CLUTCH PEDAL
CLUTCH SYSTEM
3) Depress and release the clutch pedal two to 7) Push the release lever until operating cylinder
three times to ensure that 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-38, Clutch
Fluid Air Bleeding.>
4) Measure the clutch pedal full stroke length again
to ensure that it is within specifications. If it is not,
repeat adjustment procedures again from the 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 B4M1191B
right. It should move without resistance while it is
rattling. If resistance is felt, repeat adjustment pro- (1) Push rod
cedures again from the beginning. (2) Release lever
6) Push the release lever until operating cylinder (3) Operating cylinder
push rod retracts. Ensure that clutch fluid level in
reservoir tank increases. If the clutch fluid level in- 8) If the clutch fluid level increases, hydraulic clutch
creases, hydraulic the clutch is properly adjusted; if play is correct.
fluid level does not increase or push rod does not 9) If the clutch fluid level does not increase or push
retract, replace the master cylinder with a new rod does not retract, clutch pedal must be readjust-
one.<Ref. to CL-31, Master Cylinder.> ed.
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
(C)
B4M1191B
(1) Push rod (A)

(2) Release lever
(3) Operating cylinder (B)
TR0478
(A) Max. level

(B) Min. level
(C) Reservoir tank
• 1.6 L MODEL
3) Remove the release lever return spring from le-
ver.
4) Loosen the lock nut.
CL-47
CLUTCH PEDAL
CLUTCH SYSTEM
5) Adjust the spherical nut of the lever end so that

the play and full stroke is within the specified value,
(center of spherical nut).
CAUTION:
Take care not to twist the cable during adjust-
ment.
Play: 3 — 4 mm (0.12 — 0.16 in)
Full stroke: 24 — 26 mm (0.94 — 1.02 in)
(A) (B)
TR0504
(A) Play
(B) Full stroke
6) Upon completion of adjustment, securely lock

the spherical nut with lock nut.
Tightening torque:
5.9 N·m (0.60 kgf-m, 4.3 ft-lb)
(C)
(A)
(B)
TR0505
(A) Lock nut

(B) Spherical nut
(C) Clutch release lever
7) Install the return spring on lever.

NOTE:
Hook the long hook side of the return spring with
the lever.
8) Depress the clutch pedal to assure there is no
abnormality in the clutch system.
9) Install the air cleaner case and intake duct. <Ref.
CL-48
CLUTCH CABLE
CLUTCH SYSTEM
11.Clutch Cable
A: REMOVAL
3) Disconnect the clutch cable from release lever.
4) Depress the clutch pedal to the floor.
5) Remove the clutch cable clamp from pedal
bracket.
(A)
(B)
TR0529
(A) Clamp
(B) Clutch cable
6) Remove the clutch cable from body.

B: INSTALLATION
1) Clean the clutch pedal fitting hole, and apply
grease. Connect the clutch cable to body.
2) Fit the clutch pedal to pedal bolt, and connect
the clutch cable to bracket with clamp.
3) Connect the clutch cable end to pedal end.
4) Connect the clutch cable to release lever.
5) Install the grommet to toe board.
6) Adjust the cable after installation. <Ref. to CL-
46, ADJUSTMENT, Clutch Pedal.>
7) Install the air cleaner case and intake duct. <Ref.
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.
CL-49
CLUTCH SWITCH
CLUTCH SYSTEM
12.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 cable from battery. (2) Measure the resistance between 1 and 2 of
2) Disconnect the connector from clutch switch. 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 — 2/Less than 1 Ω
and hold where it moves smoothly, then measure Terminals/Specified resistance
stroke of clutch pedal.
When clutch pedal not depressed:
Specified clutch pedal full stroke:A 1 — 2/More than 1 M Ω
130 — 135 mm (5.12 — 5.31 in) Clutch switch (With cruise control)
Tightening torque:
T: 8 N·m (0.8 kgf-m, 5.8 ft-lb)
2 1
B2M4122
B4M1190C
2) If the clutch pedal stroke is out of specification,

adjust the stroke. <Ref. to CL-46, ADJUSTMENT,
Clutch Pedal.>
3) Connect clutch switch connector.
C: INSPECTION
1) If the clutch switch does not operate properly (or
if it does not stop at the specified position), replace
with a new one.
Specified position: L
2+1.5/0mm (0.079+0.059/0 in)
G4M0327
CL-50
CLUTCH SYSTEM

A: INSPECTION
1. CLUTCH
Symptom Possible cause Corrective
1. Clutch slippage. (a) Clutch facing smeared by oil Replace.
It is hard to perceive clutch slippage in (b) Worn clutch facing Replace.
the early stage, but pay attention to the (c) Deteriorated diaphragm spring Replace.
following symptoms
(d) Distorted pressure plate or flywheel Correct or replace.
• Engine speed up when shifting.
• High speed driving is impossible; espe- (e) Defective release bearing holder Correct or replace.
cially rapid acceleration impossible and
vehicle speed does not increase in pro-
portion 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
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 Replace the clutch disc.
As a symptom of this trouble, a harsh (b) Excessive deflection of clutch disc Correct or replace.
scratching noise develops and control facing
becomes quite difficult when shifting (c) Seized crankshaft pilot needle bearing Replace.
gears. The symptom becomes more
(d) Cracked clutch disc facing Replace.
apparent when shifting into the first gear.
However, because much trouble of this (e) Sticked clutch disc (smeared by oil or Replace.
sort is due to defective synchronization water)
mechanism, carry out the test as
described after.
• Method of testing: <Ref. to CL-52,
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 the clutch disc.
Clutch chattering is an unpleasant vibra- (b) Weak or broken torsion spring Replace the clutch disc.
tion to the whole body when the vehicle is (c) Defective facing contact or excessive Replace the clutch disc defection.
just started with clutch partially engaged. disc
(d) Warped pressure plate or flywheel Correct or replace.
(e) Loose disc rivets Replace the clutch disc.
(f) Loose engine mounting Retighten or replace the mounting.
(g) Improper adjustment of pitching stop- Adjustment.
per
CL-51
CLUTCH SYSTEM
Symptom Possible cause Corrective

4. Noisy clutch (a) Broken, worn or unlubricated release Replace the 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 the clutch disc.
(d) Loose torsion spring retainer Replace the clutch disc.
(e) Deteriorated or broken torsion spring Replace the clutch disc.
5. Clutch grabs. (a) Grease or oil on facing Replace the clutch disc.
When starting the vehicle with the clutch (b) Deteriorated cushioning spring Replace the clutch disc.
partially engaged, the clutch engages (c) Worn or rusted spline of clutch disc or Take off rust, apply grease or replace the
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 the clutch disc.
(e) Loose engine mounting Retighten or replace the 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 the bushing and/or shaft with a new one.
3. DIAGNOSTIC DIAGRAM OF CLUTCH DRAG
Step Check Yes No

1 CHECK GEAR NOISE. Is there any abnormal noise Go to step 2. Clutch is normal.
1)Start the engine. from the transmission gear?
2)Disengage the clutch and shift quickly from
neutral to reverse in idling condition.
2 CHECK GEAR NOISE. Is there any abnormal noise Go to step 3. Defective trans-
Disengage the clutch at idle and shift from neu- from the transmission gear? mission or exces-
tral to reverse within 0.5 — 1.0 seconds. sive clutch drag
torque.
Inspect the pilot
bearing, clutch
disc, transmission
and clutch disc
hub spline.
3 CHECK GEAR NOISE. Is there any abnormal noise Defect in clutch Clutch and fly-
1)Disengage the clutch at idle and shift from from the transmission gear? disengaging. wheel seizure.
neutral to reverse within 0.5 — 1.0 seconds. Inspect the clutch Inspect the clutch
2)With the clutch disengaged, shift from N to disc, clutch cover, disc, spline of
R, R to N several times. clutch release, and clutch disc hub.
clutch pedal free
play.
CL-52
CHASSIS SECTION
FRONT SUSPENSION FS
REAR SUSPENSION RS
WHEEL AND TIRE SYSTEM WT
DIFFERENTIALS DI
TRANSFER CASE TC
of SUBARU vehicles. DRIVE SHAFT SYSTEM DS
sembling, inspection and adjustment of ABS ABS
Please peruse and utilize this manual ABS (DIAGNOSTICS) ABS
their vehicle in optimum condition. BRAKE BR
SUBARU genuine parts. PARKING BRAKE PB
POWER ASSISTED SYSTEM PS

(POWER STEERING)

approval.

FRONT SUSPENSION
FS
Page
2. Wheel Alignment .........................................................................................8
3. Front Transverse Link ...............................................................................16
4. Front Ball Joint ..........................................................................................18
5. Front Strut .................................................................................................19
6. Front Stabilizer ..........................................................................................23
7. Front Crossmember ..................................................................................24
8. Sub Frame ................................................................................................25
GENERAL DESCRIPTION
FRONT SUSPENSION
A: SPECIFICATIONS
Sedan Wagon
Model OUTBACK
Turbo Non-turbo Turbo Non-turbo
Camber (tolerance: ±0°45′) −0°25′ −0°15′ −0°20′ −0°10′ −0°05′
Caster (common difference: ±0°45′) 3°35′ 3°25′ 3°35′ 3°25′ 3°25′
Toe-in 0±3 mm (0±0.12 in) Each toe angle: ±0°07′30”
Front Kingpin angle (tolerance: ±0°45′) 14°35′ 14°20′ 13°45′ 13°30′ 13°20′
Wheel arch height 396 mm 406 mm 387 mm 397 mm 402 mm
[tolerance: ±12 mm (±0.47 in)] (15.59 in) (15.98 in) (15.24 in) (15.28 in) (15.83 in)
20 mm 20 mm 20 mm 20 mm 20 mm
Diameter of stabilizer
(0.79 in) (0.79 in) (0.79 in) (0.79 in) (0.79 in)
Toe-in −1±2 mm (−0.039±0.079 in) Each toe angle: ±0°07′30”
Thrust angle 0°±20′
Rear Wheel arch height 376 mm 381 mm 376 mm 381 mm 386 mm
20 mm 17 mm
Diameter of stabilizer — —
(0.79 in) (0.67 in)
NOTE:
• Front and rear toe-ins and front camber can be
adjusted. If toe-in or camber tolerance exceeds
specifications, adjust toe-in and camber to the 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
α = Each toe angle
FS-2
GENERAL DESCRIPTION
FRONT SUSPENSION
FS-3
GENERAL DESCRIPTION
FRONT SUSPENSION
B: COMPONENT
T8
SU0037
FS-4
GENERAL DESCRIPTION
FRONT SUSPENSION
(1) Front crossmember (17) Dust seal Tightening torque: N·m (kgf-m, ft-lb)
(2) Bolt ASSY (18) Strut mount T1: 20 (2.0, 14.5)
(3) Housing (19) Spacer T2: 25 (2.5, 18.1)
(4) Washer (20) Upper spring seat T3: 30 (3.1, 22)
(5) Stopper rubber (Rear) (21) Rubber seat T4: 34 (3.5, 25)
(6) Rear bushing (22) Dust cover T5: 40 (4.1, 30)
(7) Stopper rubber (Front) (23) Helper T6: 45 (4.6, 33)
(8) Ball joint (24) Coil spring T7: 50 (5.1, 37)
(9) Transverse link (25) Damper strut T8: 55 (5.6, 41)
(10) Cotter pin (26) Adjusting bolt T9: 71 (7.2, 52)
(11) Front bushing (27) Castle nut T10: 100 (10.2, 74)
(12) Stabilizer link (28) Self-locking nut T11: 155 (15.8, 114)
(13) Clamp (29) Sub frame T12: 175 (17.8, 129)
(14) Bushing (30) Cover T13: 190 (19.4, 140)
(15) Stabilizer (31) Boss T14: 250 (25.5, 184)
(16) Jack-up plate (32) Clip
FS-5
GENERAL DESCRIPTION
FRONT SUSPENSION
C: CAUTION
tion.
points.
formation.
FS-6
GENERAL DESCRIPTION
FRONT SUSPENSION
D: PREPARATION TOOL
1. SPECIAL TOOLS
927380002 ADAPTER Used as an adapter for camber & caster gauge
when measuring camber and caster.
(1) 28199AC000 PLATE
(2) 28199AC010 BOLT
B4M2378A
927680000 INSTALLER & Used for replacing transverse link bushing.
REMOVER SET
B4M2385
927760000 STRUT MOUNT Used for disassembling and assembling strut
SOCKET and shock mount.
B4M2384

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
WHEEL ALIGNMENT
FRONT SUSPENSION
2. Wheel Alignment
A: INSPECTION
Check the following items before taking wheel alignment measurement.
Check items before taking wheel alignment measurement:
• tire air pressure
• unbalanced right and left tire wear, size difference
• tire run-out
• ball joint excessive play, wear
• tie rod end excessive play, wear
• wheel bearing excessive play
• right and left wheel base imbalance
• steering link part deformed, excessive play
• suspension part deformed, excessive play
Check, adjust and/or measure the wheel alignment in accordance with procedures indicated in the figure:
B4M1088B
FS-8
WHEEL ALIGNMENT
FRONT SUSPENSION
1. WHEEL ARCH HEIGHT

1) Set the vehicle on a level surface.
2) Set the vehicle to “curb weight” conditions. (Empty luggage compartment, install spare tire, jack, service
tools, and top up fuel tank.)
3) Set the steering wheel in a straight line, then remove the vehicle straight ahead more than 5 m (16 ft) to
settle the suspension.
4) Suspend the thread from wheel arch (point “A” in figure below) to determine a point directly above center
of wheel.
5) Measure the distance between measuring point “A” and center of wheel.
Inner
Outer rear
Front fender rear quarter arch
Wheel arch height

Wheel arch height
A
A
A Cross-section
of arch
Front wheel arch height
Rear wheel arch height
Measuring
Wheel arch height
point
End of spindle
SU0009
Specified wheel arch height

Model
Turbo Non-turbo
Front 396±12 mm (15.59±0.47 in) 406±12 mm (15.98±0.47 in)
Sedan
Rear 376±12 mm (14.80±0.47 in) 381±12 mm (15.0±0.47 in)
Front 387±12 mm (15.24±0.47 in) 397±12 mm (15.63±0.47 in)
Wagon
Rear 376±12 mm (14.80±0.47 in) 381±12 mm (15.0±0.47 in)
Front — 402±12 mm (15.83±0.47 in)
OUTBACK
Rear — 386±12 mm (15.20±0.47 in)
FS-9
WHEEL ALIGNMENT
FRONT SUSPENSION
2. CAMBER 2) Turn the camber adjusting bolt so that camber is

set at the specification.
• Inspection
NOTE:
1) Place the front wheel on turning radius gauge.
Moving the adjusting bolt by one scale graduation
Make sure ground contacting surfaces of front and
changes camber by approx. 0°10′.
rear wheels are set at the same height.
2) Set the ST into the center of wheel, and then in-
stall the wheel alignment gauge.
ST 927380002 ADAPTER
B4M0567B
(1) Alignment gauge

(2) Turning radius gauge
3) Follow the wheel alignment gauge operation

manual to measure camber angle.
NOTE:
Refer to the “SPECIFICATIONS” for camber val- S4M0300B
ues.
Front: <Ref. to FS-2, SPECIFICATIONS, General (1) Strut
Description.> (2) Adjusting bolt
Rear: <Ref. to RS-2, SPECIFICATIONS, General (3) Housing
Description.> (4) Outer
• Front Camber Adjustment (5) Inner
1) Loosen the two self-locking nuts located at lower (6) Camber is increased.
front portion of strut. (7) Camber is decreased.
CAUTION:
• When adjusting bolt needs to be loosened or
tightened, hold its head with a wrench and turn
self-locking nut.
• Discard the loosened self-locking nut and re-
FS-10
WHEEL ALIGNMENT
FRONT SUSPENSION
Left side Right side
Rotate counterclock-
Camber is increased. Rotate clockwise.
wise.
B4M0190 B4M0350
Camber is decreased. Rotate clockwise.
wise.
B4M0350 B4M0190
3) Tighten the two self-locking nuts. 4. STEERING ANGLE

Tightening torque: • Inspection
175 N·m (17.8 kgf-m, 129 ft-lb) 1) Place the vehicle on a turning radius gauge.
3. CASTER 2) While depressing the brake pedal, turn the steer-
ing wheel fully to the right and left. With the steering
• Inspection wheel held at each fully turned position, measure
1) Place the front wheel on turning radius gauge. both the inner and outer wheel steering angle.
Make sure ground contacting surfaces of front and
Steering angle:
rear wheels are set at the same height.
2) Set the ST into the center of wheel, and then in- Turbo and OUT-
Model Others
stall the wheel alignment gauge. BACK
ST 927380002 ADAPTER Inner wheel 34°30°±1.5° 37°20°±1.5°
Outer wheel 34°30°±1.5° 32°25°±1.5°
• Adjustment
Turn the tie-rod to adjust steering angle of both in-
ner and outer wheels.
CAUTION:
• Check the toe-in.
• Correct the boot if it is twisted.
B4M0567B
(1) Alignment gauge

(2) Turning radius gauge
3) Follow the wheel alignment gauge operation

manual to measure caster angle.
NOTE:
Refer to the “SPECIFICATIONS” for caster values.
S4M0348A
<Ref. to FS-2, SPECIFICATIONS, General De-
scription.>
(1) Lock nut
FS-11
WHEEL ALIGNMENT
FRONT SUSPENSION
5. FRONT WHEEL TOE-IN 3) Tighten the tie-rod lock nut.

• Inspection Tightening torque:
1) Using a toe gauge, measure the front wheel toe- 83 N·m (8.5 kgf-m, 61.5 ft-lb)
in. CAUTION:
Correct the tie-rod boot, if it is twisted.
Toe-in:
0±3 mm (0±0.12 in) NOTE:
2) Mark the rear sides of right and left tires at height Check the right and left wheel steering angle is
corresponding to center of spindles and measure within specifications.
the distance “A” between marks. 6. REAR WHEEL TOE-IN
3) Move the vehicle forward so that marks line up
with front sides at height corresponding to center of • Inspection
spindles. 1) Using a toe-in gauge, measure the rear wheel
4) Measure the distance “B” between right and left toe-in.
marks. Toe-in can then be obtained by the follow-
Toe-in:
ing equation:
−1±2 mm (−0.039±0.079 in)
A − B = Toe-in 2) Mark the rear sides of right and left tires at height
corresponding to center of wheels and measure the
distance “A” between marks.
3) Move the vehicle forward so that marks line up
with front sides at height corresponding to center of
spindles.
4) Measure the distance “B” between right and left
marks. Toe-in can then be obtained by the follow-
ing equation:
A − B = Toe-in
H4M1279B
• Adjustment
1) Loosen the right and left side steering tie-rods
lock nuts.
2) Turn the right and left tie rods equal amounts un-
til the toe-in is at the specification.
Both the right and left tie-rods are right-hand
threaded. To increase toe-in, turn both tie-rods
clockwise equal amounts (as viewed from inside of
the vehicle). H4M1279B
S4M0348A
(1) Lock nut
FS-12
WHEEL ALIGNMENT
FRONT SUSPENSION
• Adjustment
1) Loosen the self-locking nut on inner side of link
rear.
CAUTION:
• When loosening or tightening the adjusting
bolt, hold the bolt head and turn self-locking
nut.
S4M0349A
(1) Adjusting bolt

(2) Link rear
2) Turn the adjusting bolt head until toe-in is at the specification.
NOTE:
When right and left wheels are adjusted for toe-in at the same time, the movement of one scale graduation
changes toe-in by approx. 1.5 mm (0.6 in).
Left side Right side
Toe-in is increased. Rotate clockwise.
wise.
B4M0192 B4M0352
Toe-in is decreased. Rotate clockwise.
wise.
B4M0352 B4M0192
3) Tighten the self-locking nut.

Tightening torque:
100 N·m (10.2 kgf-m, 74 ft-lb)
FS-13
WHEEL ALIGNMENT
FRONT SUSPENSION
7. THRUST ANGLE 3) When the right and left adjusting bolts are turned
incrementally by one graduation in the same direc-
• Inspection
tion, the thrust angle will change approx. 16′ [“L” is
1) Position the vehicle on a level surface. almost equal to 12 mm (0.472 in)].
2) Move the vehicle 3 to 4 m (10 to 13 ft) directly
Thrust angle:
forward.
0°±20 ′
3) Determine the locus of both front and rear axles.
4) Measure the distance “L” between center line of
loci of the axles.
Thrust angle:
Less than 20 ′ when “L” is equal to or less
than 15 mm (59 in).
S4M0350B
(1) Center line of loci (front axle)

(2) Center line of loci (rear axle)
NOTE:
S4M0350B Thrust angle refers to a mean value of right and left
rear wheel toe angles in relation to the vehicle body
(1) Center line of loci (front axle) center line. Vehicle is driven straight in the thrust
(2) Center line of loci (rear axle) angle direction while swinging in the oblique direc-
tion depending on the degree of the mean thrust
• Adjustment angle.
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 thrust angle adjust-
ment.
B4M0193B
(1) Front
(2) Thrust angle
(3) Body center line
FS-14
WHEEL ALIGNMENT
FRONT SUSPENSION
Thrust angle: r = (α − β)/2

α: Right rear wheel toe-in angle
β: Left rear wheel toe-in angle
NOTE:
Here, use only positive toe-in values from each
wheel to substitute for α and β in the equation.
B4M0194B
(1) Front
(2) Body center line
FS-15
FRONT TRANSVERSE LINK
FRONT SUSPENSION
3. Front Transverse Link B: INSTALLATION

1) Temporarily tighten the two bolts used to secure
A: REMOVAL rear bushing of transverse link to body.
1) Set the vehicle on the lift.
2) Lift-up the vehicle and remove the wheel. NOTE:
3) Remove the sub frame. These bolts should be tightened to such an extent
that they can still move back and forth in the oblong
4) Disconnect the stabilizer link from transverse
shaped hole in the bracket (which holds the bush-
link.
ing).
5) Remove the bolt securing ball joint of transverse
link to housing. 2) Install the bolts used to connect transverse link
to crossmember and temporarily tighten with nut.
CAUTION:
Discard the loosened self-locking nut and re-
3) Insert the ball joint into housing.
4) Connect the stabilizer link to transverse link, and
temporarily tighten the bolts.
CAUTION:
Discard the loosened self-locking nut and re-
S4M0090
6) Remove the nut (do not remove bolt) securing

transverse link to crossmember.
7) Remove the two bolts securing bushing bracket
of transverse link to the vehicle body at rear bush-
ing location.
S4M0090
5) Tighten the following points in the order shown

below when wheels are in full contact with the
ground and vehicle is curb weight.
(1) Transverse link and stabilizer
S4M0091
Tightening torque:
8) Extract the ball joint from housing. Sedan Turbo model:
9) Remove the bolt securing transverse link to 45 N·m (4.6 kgf-m, 33 ft-lb)
crossmember, and then extract the transverse link Except sedan Turbo model:
from crossmember. 30 N·m (3.1 kgf-m, 22 ft-lb)
(2) Transverse link and crossmember
Tightening torque:
100 N·m (10.2 kgf-m, 74 ft-lb)
SU0010
FS-16
FRONT TRANSVERSE LINK
FRONT SUSPENSION
(3) Transverse link rear bushing and body D: ASSEMBLY

Tightening torque: 1. FRONT BUSHING
250 N·m (25.5 kgf-m, 184 ft-lb)
Assemble in the reverse order of disassembly.
NOTE:
• Move the rear bushing back and forth until trans- CAUTION:
verse link-to-rear bushing clearance is established Install the front bushing in correct direction, as
(as indicated in the figure) before tightening. shown in the figure.
• Check the wheel alignment and adjust if neces-
sary.
S4M0351A
S4M0352A (1) Face bushing toward center of ball joint

(2) Ball joint
(1) Rear bushing
2. REAR BUSHING
C: DISASSEMBLY 1) Install the rear bushing to transverse link and
1. FRONT BUSHING align aligning marks scribed on the two.
2) Tighten the self-locking nut.
Using the ST, press the front bushing out of place.
ST 927680000 INSTALLER & REMOVER CAUTION:
SET • Discard the loosened self-locking nut and re-
• 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 ft-lb)
E: INSPECTION
1) Check the transverse link for wear, damage and
cracks, and correct or replace if defective.
G4M0494 2) Check the bushings for cracks, fatigue or dam-
age.
2. REAR BUSHING 3) Check the rear bushing for oil leaks.
1) Scribe an aligning mark on the transverse link
and rear bushing.
2) Loosen the nut and remove rear bushing.
G4M0495
FS-17
FRONT BALL JOINT
FRONT SUSPENSION
4. Front Ball Joint C: INSPECTION

1) Measure the play of ball joint by the following
A: REMOVAL procedures. Replace with a new one when the play
1) Remove the wheel. exceeds specified value.
2) Pull out the cotter pin from ball stud, remove the (1) With 686 N (70 kgf, 154 lb) loaded in direc-
castle nut, and extract the ball stud from transverse tion shown in the figure, measure the dimension
link. 2 1.
3) Remove the bolt securing ball joint to housing.
G4M0500
G4M0499
(2) With 686 N (70 kgf, 154 lb) loaded in oppo-
4) Extract the ball joint from housing. site direction shown in the figure, measure the
B: INSTALLATION dimension 22.
1) Install the ball joint onto housing.
Tightening torque (Bolt):
50 N·m (5.1 kgf-m, 37 ft-lb)
CAUTION:
Do not apply grease to tapered portion of ball
stud.
2) Connect the ball joint to transverse link.
Tightening torque (Castle nut):
Sedan turbo model: G4M0501
30 N·m (3.1 kgf-m, 22 ft-lb)
(3) Calculate plays from the following formula.
Except sedan turbo model: S = 22 − 21
40 N·m (4.1 kgf-m, 30 ft-lb) (4) When plays are larger than the following val-
3) Retighten the castle nut further within 60° until a ue, replace with a new one.
slot in castle nut is aligned with the hole in ball stud
end, then insert a new cotter pin and bend it around FRONT BALL JOINT
castle nut. Specified play for replacement: S
4) Install the front wheel. Less than 0.3 mm (0.012 in)
2) When the play is smaller than specified value, vi-
sually inspect the dust cover.
3) The ball joint and cover that have been removed
must be checked for wear, damage or cracks, and
any defective part must be replaced.
4) If the dust cover is damaged, replace with a new
ball joint.
FS-18
FRONT STRUT
FRONT SUSPENSION
5. Front Strut 6) Remove the three nuts securing strut mount to

body.
A: REMOVAL
1) Remove the wheel.
2) Remove the bolt securing brake hose from strut.
B4M1788
3) Scribe an alignment mark on the camber adjust-

ing bolt which secures strut to housing.
4) Remove the bolt securing ABS sensor harness.
SU0011
B4M1784
5) Remove the two bolts securing housing to strut.

CAUTION:
While holding the head of adjusting bolt, loosen
self-locking nut.
FS-19
FRONT STRUT
FRONT SUSPENSION
B: INSTALLATION C: DISASSEMBLY
1) Install the strut mount at upper side of strut to 1) Using a coil spring compressor, compress the
body, and then tighten with nuts. coil spring.
Tightening torque:
20 N·m (2.0 kgf-m, 14.5 ft-lb)
2) Position the aligning mark on camber adjust-
ment 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
175 N·m (17.8 kgf-m, 129 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 the bolts which secure brake hose to strut.
Tightening torque:
33 N·m (3.4 kgf-m, 24.3 ft-lb)
5) Install the wheels.
NOTE:
Check the wheel alignment and adjust if necessary.
S4M0096A
3) Remove the strut mount, upper spring seat and

rubber seat from strut.
4) Gradually decreasing the compression force,
and then remove the coil spring.
5) Remove the dust cover and helper spring.
FS-20
FRONT STRUT
FRONT SUSPENSION
D: ASSEMBLY 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 in the figure.
on the strut, check for the presence of air in the
damping force generating mechanism of the strut
since air prevents proper damping force from being
produced.
2) Checking for the presence of air
(1) Place the strut vertically with piston rod fac-
ing up.
(2) Move the piston rod to center of its entire
stroke.
(3) While holding the piston rod end with finger-
S4M0353A
tips, move the rod up and down.
(4) If the piston rod moves at least 10 mm (0.39
(1) Coil spring end face
in) in the former step, purge air from the strut.
3) Air purging procedure 6) Install the helper and dust cover to the piston
(1) Place the strut vertically with piston rod fac- rod.
ing up. 7) Pull the piston rod fully upward, and install the
(2) Fully extend the piston rod. rubber seat and spring seat.
(3) With the piston rod fully extended, place the NOTE:
piston rod side down. The strut must stand ver- Ensure that upper spring seat is positioned as
tically. shown in the figure.
(4) Fully contract the piston rod.
(5) Repeat three or four times from the first
step.
NOTE:
After completely purging air from the strut, be sure
to place the strut with piston rod facing up. If it is
laid down, check for entry of air in the strut as out-
lined under “Checking for the presence of air”.
4) Using a coil spring compressor, compress the
coil spring.
S4M0097B
NOTE:
Make sure that the vertical installing direction of coil
(1) Outside of body
spring is as shown in the figure.
8) Install the strut mount to the piston rod, and then
tighten the self-locking nut temporarily.
CAUTION:
Be sure to use a new self-locking nut.
B4M0568B
(1) Flat (top side)

(2) Identification paint
(3) Inclined (bottom side)
FS-21
FRONT STRUT
FRONT SUSPENSION
9) Using a hexagon wrench to prevent strut rod 2. STRUT MOUNT

from turning, tighten the self-locking nut with ST.
Check the rubber part for creep, cracks and deteri-
ST 927760000 STRUT MOUNT SOCKET
oration, and replace it with a new one if defective.
Tightening torque:
54 N·m (5.5 kgf-m, 39.8 ft-lb)
3. DUST COVER
If any cracks or damage are found, replace it with a
new one.
4. COIL SPRING
One having permanent strain should be replaced
with a new one. When the vehicle posture is 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
S4M0096A defective.
10) Loosen the coil spring carefully. 5. HELPER
E: INSPECTION Replace it with a new one if cracked or damaged.
Check the disassembled parts for cracks, damage F: DISPOSAL
and wear, and replace with new parts if defective.
CAUTION:
1. DAMPER STRUT • Before handling gas filled struts, be sure to
1) Check for oil leakage. wear goggles to protect eyes from gas, oil and/
2) Move the piston rod up and down to check that it or filings.
operates smoothly without any binding. • Do not disassemble the strut damper or place
3) Play of piston rod into a fire.
• Measure the play as follows: • Drill holes before disposing of gas filled
struts.
Fix outer shell and fully extend the rod. Set a dial
gauge at the end of rod: L [10 mm (0.39 in)], then 1) Place the gas filled strut on a flat and level sur-
apply a force of W [20 N (2 kgf, 4 lb)] to threaded face with piston rod fully extended.
portion. With the force of 20 N (2 kgf, 4 lb) applied, 2) Using a 2 to 3 mm (0.08 to 0.12 in) dia. drill,
read dial gauge indication: P1. Apply a force of 20 N make holes in areas shown in the figure.
(2 kgf, 4 lb) in the opposite direction of “W”, then
read dial gauge indication: P2.
B4M1202A
G4M0508
The free play is determined by the following equa-

tion:
Play = P1, P2
Limit of play:
Less than 0.8 mm (0.031 in)
If the play is greater, replace the strut.
FS-22
FRONT STABILIZER
FRONT SUSPENSION
6. Front Stabilizer B: INSTALLATION

A: REMOVAL
1) Jack-up the front part of the vehicle and support NOTE:
it with safety stands (rigid racks). • Install the bushing (on front crossmember side)
2) Remove the jack-up plate from lower part of while aligning it with paint mark on stabilizer.
crossmember. • Ensure that bushing and stabilizer have the
3) Remove the sub frame. same identification colors when installing.
4) Remove the bolts which secure stabilizer to
crossmember.
SU0012
B4M1846 (1) Mark stamped on stabilizer

(2) Bushing identification color
5) Remove the bolt which secures stabilizer link to
front transverse link. 2) Always tighten the rubber bushing location when
wheels are in full contact with the ground and vehi-
cle is curb weight.
Tightening torque (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:
45 N·m (4.6 kgf-m, 33 ft-lb)
Stabilizer to crossmember:
25 N·m (2.5 kgf-m, 18.1 ft-lb)
S4M0355 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)
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-23
FRONT CROSSMEMBER
FRONT SUSPENSION
7. Front Crossmember B: INSTALLATION

A: REMOVAL
2) Lift-up the vehicle, and then remove the front Always tighten the rubber bushing when
tires and wheels. wheels are in full contact with the ground and
3) Remove the sub frame. vehicle is curb weight.
4) Remove both the stabilizer and jack-up plate. 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 ft-lb)
S4M0534A
Crossmember to body:
100 N·m (10.2 kgf-m, 74 ft-lb)
(1) Front stabilizer
(2) Front crossmember
2) Purge air from the power steering system.
NOTE:
5) Disconnect the tie-rod end from housing. Check the wheel alignment and adjust if necessary.
6) Remove the front exhaust pipe.
7) Remove the front transverse link from front C: INSPECTION
crossmember and body. Check the crossmember for wear, damage and
SU0010
8) Remove the nuts attaching engine mount cush-

ion rubber to crossmember.
9) Remove the steering universal joint.
10) Disconnect the power steering pipe from steer-
ing gear box.
11) Lift the engine by approx. 10 mm (0.39 in) by
using chain block.
12) Support the crossmember with a jack, remove
nuts securing crossmember to body and lower the
crossmember gradually along with steering gear-
box.
CAUTION:
When removing the crossmember downward,
be careful that tie-rod end does not interfere
with SFJ boot.
FS-24
SUB FRAME
FRONT SUSPENSION
8. Sub Frame B: INSTALLATION

A: REMOVAL
1) Lift-up the vehicle. NOTE:
2) Remove the under cover. Replace the M12 bolt with a new one.
3) Remove the bolt cover. Tightening torque:
T1: 34 N·m (3.5 kgf-m, 25 ft-lb)
T2: 55 N·m (5.6 kgf-m, 41 ft-lb)
T3: 71 N·m (7.2 kgf-m, 52 ft-lb)
T4: 105 N·m (10.7 kgf-m, 77 ft-lb)
(2) (3)
(1) (4)
T2 (4) T3
T4
T1
SU0022
T4
4) Remove the clip. T2 (4) T3
(1) (4)
(2) (3)
SU0032
(1) M8 bolt
(2) M12 bolt (with max)
(3) M12 bolt (with oil)
(4) M10 bolt
SU0023
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).
(6)
(5)
(6)
(4)
(3)
(2)
(1)
(5)
(4)
(3)
(2) (1) SU0024
FS-25
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:
T1: 34 N·m (3.5 kgf-m, 25 ft-lb)
T2: 55 N·m (5.6 kgf-m, 41 ft-lb)
T3: 71 N·m (7.2 kgf-m, 52 ft-lb)
T4: Dark green bolt
105 N·m (10.7 kgf-m, 77 ft-lb)
T4: Except dark green bolt
55 N·m (5.6 kgf-m, 41 ft-lb)
(2) (3)
(1) (4)
T2 (4) T3
T4
T1
T4
T2 (4) T3
(1) (4)
(2) (3)
SU0032
(1) M8 bolt
(2) M12 bolt
(3) M12 bolt
(4) M10 bolt
FS-26
FRONT SUSPENSION
9. 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.
(3) Installation of wrong strut and/or shock absorber Replace with proper parts.
(4) Installation of wrong coil spring Replace with proper parts.
2. POOR RIDE COMFORT

1) Large rebound shock
2) Rocking of the vehicle continues too long after running over bump and/or hump.
3) Large shock in bumping
(1) Breakage of coil spring Replace.
(2) Overinflation pressure of tire Adjust.
(3) Improper wheel arch height Adjust or replace the coil springs with new ones.
(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
(7) Deformation or loss of bushing Replace.
(8) Deformation or damage of helper in strut assembly and/or shock Replace.
absorber
(9) Oil leakage of damper strut and/or shock absorber Replace.
3. NOISE
(1) Wear or damage of damper strut and/or shock absorber component parts Replace.
(2) Loosening of suspension link installing bolt Retighten to the specified torque.
shock absorber
(6) Wear or damage of ball joint Replace.
(7) Deformation of stabilizer clamp Replace.
FS-27
FRONT SUSPENSION
FS-28
REAR SUSPENSION
RS
Page
2. Wheel Alignment .........................................................................................9
3. Rear Stabilizer...........................................................................................10
4. Rear Trailing Link ......................................................................................11
5. Rear Strut..................................................................................................15
6. Lateral link.................................................................................................17
7. Rear Crossmember...................................................................................21
GENERAL DESCRIPTION
REAR SUSPENSION
A: SPECIFICATIONS
Sedan Wagon
Item OUTBACK
Turbo Non-turbo Turbo Non-turbo
−1±2 mm (−0.039±0.079 in)
Toe-in
Each toe-in angle: ±0°07′30”
Wheel arch height 376 mm 381 mm 376 mm 381 mm 386 mm
Thrust angle 0°±20′
20 mm 17 mm
Diameter of stabilizer — —
(0.79 in) (0.67 in)
NOTE:
• Front and rear toe-ins and front camber can be
adjusted. If toe-in or camber tolerance exceeds
specifications, adjust toe-in and camber to the 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.
B4M2250C
(1) Front
A − B = Positive: Toe-in, Negative: Toe-out
α1, α2: Each toe-in angle
RS-2
GENERAL DESCRIPTION
REAR SUSPENSION
RS-3
GENERAL DESCRIPTION
REAR SUSPENSION
B: COMPONENT
1. REAR SUSPENSION
SU0013
RS-4
GENERAL DESCRIPTION
REAR SUSPENSION
(1) Stabilizer (Turbo model) (16) Trailing link bracket Tightening torque: N·m (kgf-m, ft-lb)
(2) Stabilizer bracket (Turbo model) (17) Cap (Protection) T1: 20 (2.0, 14.5)
(3) Stabilizer bushing (Turbo model) (18) Washer T2: 25 (2.5, 18.1)
(4) Clamp (Turbo model) (19) Rear crossmember T3: 45 (4.6, 33.2)
(5) Floating bushing (20) Strut mount cap T4: 55 (5.6, 41)
(6) Stopper (21) Strut mount T5: 70 (7.1, 52)
(7) Stabilizer link (Turbo model) (22) Rubber seat upper T6: 90 (9.2, 66)
(8) Rear lateral link (Turbo model) (23) Dust cover T7: 100 (10.2, 74)
(9) Bushing (C) (24) Coil spring T8: 115 (11.7, 85)
(10) Bushing (A) (25) Helper T9: 130 (13.3, 96)
(11) Front lateral link (26) Rubber seat lower T10: 135 (13.8, 100)
(12) Bushing (B) (27) Damper strut T11: 220 (22.4, 162)
(13) Trailing link rear bushing (28) Self-locking nut
(14) Trailing link (29) Rear differential member rear
(15) Trailing link front bushing (30) Rear lateral link (Non-turbo
model)
RS-5
GENERAL DESCRIPTION
REAR SUSPENSION
C: CAUTION
tion.
points.
formation.
• Before disposing shock absorbers, be sure to
bleed gas completely. Also, do not throw away in
fire.
RS-6
GENERAL DESCRIPTION
REAR SUSPENSION
D: PREPARATION TOOL
1. SPECIAL TOOLS
927380002 ADAPTER Used as an adapter for camber & caster gauge
when measuring camber and caster.
(1) 28199AC000 PLATE
(2) 28199AC010 BOLT
B4M2378A
927720000 INSTALLER & Used for replacing front bushing.
REMOVER
SU0014
927730000 INSTALLER & Used for replacing rear bushing.
REMOVER
SU0015
28099PA100 REMOVER Used for removing DOJ.
SU0016
RS-7
GENERAL DESCRIPTION
REAR SUSPENSION

927710000 INSTALLER & Used for replacing lateral link bushing.
REMOVER
SU0015
92770000 INSTALLER & Used for replacing lateral link bushing.
REMOVER
SU0015
927690000 HELPER SOCKET Used for replacing lateral link bushing.
WRENCH
SU0015

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.
Transmission jack Used for suspension assembly/disassembly.
Bearing puller Used for removing bushings.
RS-8
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
REAR STABILIZER
REAR SUSPENSION
3. Rear Stabilizer B: INSTALLATION

A: REMOVAL
1) Jack-up the rear part of the vehicle, support it NOTE:
with safety stands (rigid racks). • Install the bushing while aligning it with paint
2) Remove the bolt which secures stabilizer link to mark on stabilizer.
rear lateral link. • Ensure that bushing and stabilizer have the
same identification colors when installing.
SU0017
SU0012
3) Remove the bolt and nut which secure stabilizer
to stabilizer bracket. (1) Mark stamped on stabilizer
(2) Bushing identification color
2) Always tighten the rubber bushing location when

wheels are in full contact with the ground and 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
SU0018 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
REAR SUSPENSION
4. Rear Trailing Link B: INSTALLATION

A: REMOVAL
1) Loosen the rear wheel nuts. CAUTION:
2) Jack-up the vehicle, support it with safety stands Always tighten the rubber bushing location
(rigid racks), and then remove the rear wheels. when wheels are in full contact with the ground
3) Remove both the rear parking brake clamp and and vehicle is at curb weight condition.
ABS sensor harness. (Models equipped with ABS) NOTE:
4) Remove the bolt which secures trailing link to Check the wheel alignment and adjust if necessary.
trailing link bracket.
S4M0103B
(1) Trailing link
5) Remove the bolt which secures trailing link to

rear housing.
RS-11
REAR TRAILING LINK
REAR SUSPENSION
C: DISASSEMBLY 2. REAR BUSHING

1. FRONT BUSHING 1) Remove the housing. <Ref. to DS-24, REMOV-
AL, Rear Axle.>
Using the ST, press the front bushing out of place. 2) Using the ST, press the rear bushing out of
ST 927720000 INSTALLER & REMOVER place.
SET ST 927730000 INSTALLER & REMOVER
SET
S4M0358A
S4M0359A
(1) Press
(2) Trailing link (1) Press
(2) Housing
RS-12
REAR TRAILING LINK
REAR SUSPENSION
D: ASSEMBLY 2. REAR BUSHING

1. FRONT BUSHING 1) Using the ST, press the bushing into trailing link.
ST 927730000 INSTALLER & REMOVER
Using the ST, press the bushing into trailing link. SET
SET NOTE:
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 the ST plung- of ST as a lubricant.
er upside down and press it until the plunger
end surface contacts trailing link end surface. SPECIFOED lubricant:
TIRE LUBE: water = 1 : 3
S4M0360A
B4M0224B
(1) Press
(2) Front bushing (1) Press
(3) Trailing link
CAUTION:
Install the front bushing in the proper direction,
as shown in the figure.
S4M0361A
(1) Front
RS-13
REAR TRAILING LINK
REAR SUSPENSION
2) Press the ST plunger until bushing flange pro- 3) Turn the trailing link upside down. Press the ST
trudes beyond trailing link. plunger in the opposite direction that outlines in the
ST 927730000 INSTALLER & REMOVER former procedure until bushing is correctly posi-
SET tioned in trailing link.
SET
B4M0195B
(1) Plunger B4M0196B

(2) Flange
(1) Press
(2) Plunger
4) Install the housing. <Ref. to DS-27, INSTALLA-

TION, Rear Axle.>
E: INSPECTION
Check the trailing links for bends, corrosion or dam-
age.
RS-14
REAR STRUT
REAR SUSPENSION
5. Rear Strut 8) Remove the bolts which secure rear strut to

housing.
A: REMOVAL
1) Depress the brake pedal and secure it in that po-
sition using a wooden block, etc. (Drum brake only)
2) Remove the rear seat cushion and backrest.
(Sedan model)
3) Remove the strut cap of quarter trim. (Wagon
model)
4) Loosen the rear wheel nuts.
5) Jack-up the vehicle, support it with safety stands
(rigid racks) and remove rear wheels.
6) Drum brake models: H4M1070
Remove the brake hose clip. 9) Remove the nuts securing strut mount to body.
Disconnect the brake hose from brake pipe from
strut, and then disconnect the brake pipe from
drum brake.
G4M0399
7) Disc brake models:

Remove the brake hose clip, and then remove the
brake hose from rear strut.
SU0019
(1) Brake hose clip

(2) Brake hose
RS-15
REAR STRUT
REAR SUSPENSION
B: INSTALLATION E: INSPECTION
1) Tighten the self-locking nut used to secure strut Refer to Front Strut as a guide for inspection proce-
mount to vehicle body. dures.
CAUTION: <Ref. to FS-22, INSPECTION, Front Strut.>
Discard the loosened self-locking nut, and re- F: DISPOSAL
place with a new one. Refer to Front Strut as a guide for disposal proce-
Tightening torque: dures. <Ref. to FS-22, DISPOSAL, Front Strut.>
20 N·m (2.0 kgf-m, 14.5 ft-lb)
2) Tighten the bolts which secure rear strut to hous-
ing.
Tightening torque:
220 N·m (22.4 kgf-m, 162 ft-lb)
CAUTION:
Discard the loosened self-locking nut, and re-
3) Disc brake model:
Install the brake hose to lower side of strut, then in-
sert brake hose clip.
Drum brake model:
Connect the brake hose to brake pipe.
Tightening torque:
15 N·m (1.5 kgf-m, 10.8 ft-lb)
Insert the brake hose clip between brake hose and
lower side of strut.
CAUTION:
• Check that the hose clip is positioned proper-
ly.
• Check the brake hose for twisting, or exces-
sive tension.
• Do not subject the ABS sensor harness to ex-
cessive tension. (Model equipped with ABS)
4) Be sure to bleed air from the brake system.
5) Lower the vehicle and tighten wheel nut.
Tightening torque:
90 N·m (9.2 kgf-m, 66 ft-lb)
6) Sedan model:
Install the rear seat backrest and rear seat cushion.
Wagon model:
Install the strut cap to rear quarter trim.
NOTE:
C: DISASSEMBLY
For disassembly of rear strut, refer to procedures
outlined under front strut as a guide. <Ref. to FS-
20, DISASSEMBLY, Front Strut.>
D: ASSEMBLY
Refer to Front Strut as a guide for assembly proce-
dures.
<Ref. to FS-21, ASSEMBLY, Front Strut.>
RS-16
LATERAL LINK
REAR SUSPENSION
6. Lateral link 7) Remove the DOJ from rear differential using tire
lever.
A: REMOVAL (Except for 2.0 L MT model)
1) Loosen the wheel nuts. Lift-up the vehicle and NOTE:
remove wheel. The side spline shaft circlip comes out together
2) Remove the stabilizers. (Turbo model) with the shaft.
3) Remove the ABS sensor harness from trailing
link.
(Models equipped with ABS)
4) Remove the bolt securing trailing link to housing.
S4M0363A
(1) Tire lever
B4M0573B CAUTION:
When removing the DOJ from rear differential,
(1) Rear housing fit tire lever to the bolt as shown in the figure so
(2) Trailing link as not to damage axle shaft holder.
5) Remove the bolts which secure lateral link as-

sembly to rear housing.
6) Remove the DOJ from rear differential using ST.
(2.0 L MT model)
ST 28099PA100 DRIVE SHAFT REMOVER
NOTE:
The side spline shaft circlip comes out together
with the shaft.
S4M0364A
(1) Axle shaft holder
8) Scribe an alignment mark on the rear lateral link

adjusting bolt and crossmember.
9) Remove the bolts securing front and rear lateral
links to crossmember, detach lateral links.
CAUTION:
S4M0362A To loosen the adjusting bolt, always loosen the
nut while holding head of adjusting bolt.
(1) Bolt
(2) DOJ
CAUTION:
Be careful not to damage the side bearing re-
tainer. Always use bolt shown in the figure, as
supporting point for ST during removal.
RS-17
LATERAL LINK
REAR SUSPENSION
B: INSTALLATION
Install in the reverse order of removal. Observe the
following instructions.
• Installation of DOJ to differential: <Ref. to DS-39,
INSTALLATION, Rear Drive Shaft.>
CAUTION:
• Do not allow the DOJ splines to damage side
oil seal.
• Always tighten the rubber bushing location
when wheels are in full contact with the ground
and vehicle is curb weight.
• Tighten the nut when installing adjusting
bolt.
• Replace the self-locking nut and DOJ circlip
with new ones.
NOTE:
C: DISASSEMBLY
Using the ST, press the bushing out of place.
NOTE: S4M0100B
• Using the following table as a guide, verify the
type of bushings. (1) Bushing A
• Select the ST according to type of bushings (2) Bushing B
used.
(3) Bushing C
Bushing ST: INSTALLER & REMOVER SET (4) Front
Bushing A 927700000 (5) Outside of body
Bushing B 927690000
Bushing C 927700000
S4M0365A
(1) Press
(2) Lateral link
RS-18
LATERAL LINK
REAR SUSPENSION
D: ASSEMBLY 2) Press the ST plunger until bushing flange pro-

1) Using the ST, press the bushing into place. trudes beyond lateral link.
CAUTION: NOTE:
Select the ST according to type of bushings Using the same ST as that used during disassem-
used. bly.
NOTE:
• Using the same ST as that used during disas-
sembly.
• If it is difficult to press the bushing into trailing
link, apply water-diluted TIRE LUBE to the inner
surface of ST as a lubricant.
Specified lubricant:
TIRE LUBE: water = 1 : 3
B4M0197B
(1) Press
(2) Plunger
(3) Lateral link
(4) Flange
S4M0366A
(1) Press
(2) Bushing
(3) Lateral link
RS-19
LATERAL LINK
REAR SUSPENSION
3) Turn the lateral link upside down. Press the ST

plunger in opposite direction that outlined in the
former procedure until bushing is correctly posi-
tioned in trailing link.
NOTE:
Using the same ST as that used during dissassem-
bly.
B4M0198B
(1) Press
(2) Plunger
(3) Lateral link
E: INSPECTION
Visually check the lateral links for damage or
bends.
RS-20
REAR CROSSMEMBER
REAR SUSPENSION
7. Rear Crossmember B: INSTALLATION

A: REMOVAL CAUTION:
CAUTION: place it with a new one.
Do not subject the ABS sensor harness to ex- • Always tighten the nut (not adjusting bolt),
cessive tension. (Models equipped with ABS) when tightening adjusting bolt.
1) Separate the front exhaust pipe and rear ex- 1) Install in the reverse order of removal.
haust pipe. 2) For installation and tightening torque of rear dif-
2) Remove the rear exhaust pipe and muffler. ferential;
3) Remove the rear differential. T-type
T-type <Ref. to DI-26, INSTALLATION, Rear Differential
<Ref. to DI-25, REMOVAL, Rear Differential for T- for T-type.>
type.> VA-type
VA-type <Ref. to DI-42, INSTALLATION, Rear Differential
<Ref. to DI-41, REMOVAL, Rear Differential for for VA-type.>
VA-type.> 3) Always tighten the rubber bushing when wheels
4) Place the transmission jack under rear are in full contact with the ground and vehicle is
crossmember. curb weight.
NOTE:
C: INSPECTION
Check the removed parts for wear, damage and
G4M0544
5) Remove the bolts securing crossmember to ve-

hicle body, and then remove the crossmember.
G4M0545
6) Scribe an alignment mark on the rear lateral link

cam bolt and crossmember.
7) Remove the front and rear lateral links by loos-
ening nuts.
RS-21
REAR SUSPENSION
8. General Diagnostic Table

A: INSPECTION
1. IMPROPER VEHICLE POSTURE OR IMPROPER WHEEL ARCH HEIGHT
(1) Permanent distortion or breakage of coil spring Replace.
(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.
2. POOR RIDE COMFORT

1) Large rebound shock
2) Rocking of the vehicle continues too long after running over bump and/or hump.
3) Large shock in bumping
(2) Overinflation pressure of tire Adjust.
(3) Improper wheel arch height Adjust or replace the coil springs with new ones.
(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.
shock absorber
(8) Deformation or damage of helper in strut assembly and/or shock Replace.
absorber
(9) Oil leakage of damper strut and/or shock absorber Replace.
3. NOISE
(1) Wear or damage of damper strut and/or shock absorber component parts Replace.
(2) Loosening of suspension link installing bolt Retighten to the specified torque.
shock absorber
(6) Wear or damage of ball joint Replace.
(7) Deformation of stabilizer clamp Replace.
RS-22
WHEEL AND TIRE SYSTEM
WT
Page
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
GENERAL DESCRIPTION
A: SPECIFICATIONS
S4M0367A
(1) Offset
(2) P.C.D.
Tire size Rim size Rim offset mm (in) P.C.D. mm (in)

185/70R14 88H 14 × 5 1/2JJ
Except 195/60R15 88H 15 × 6JJ
Front and rear OUTBACK 205/50 R16 87V 16 × 6 1/2JJ 55 (2.17)
215/45 R17 87W 17 × 7JJ 100 (3.94) dia.
OUTBACK P205/55 R16 89V 16 × 6 1/2JJ
T125/70 D15 95M 15 × 4T 53 (2.09)
T-Type tire
T135/70 D16 100M 16 × 4T 50 (1.97)
Tire inflation pressure kPa (kg/cm2, psi)

Tire size
Light load Full load
185/70 R14 88H Fr: 220 (2.2, 32) Fr: 220 (2.2, 32)
Except 195/60 R15 88H Rr: 200 (2.0, 29) Rr: 220 (2.2, 32)
Front and rear OUTBACK 205/50 R16 87V Fr: 220 (2.2, 32) Rr: 200 (2.0, 29)
215/45 R17 87W Fr: 230 (2.3, 33) Rr: 220 (2.2, 32)
OUTBACK P205/55 R16 89V Fr: 220 (2.2, 32) Rr: 200 (2.0, 29)
T125/70 D15 95M
T-Type tire 420 (4.2, 60)
T135/70 D16 100M
NOTE:
• “T-type” tire for temporary use is supplied as a spare tire.
• At trailer towing, rear inflation pressure is 250 kPa (2.5 kg/cm2, 36 psi).
WT-2
GENERAL DESCRIPTION
1. SERVICE DATA B: PREPARATION TOOL

Item Axial runout Radial runout 1. GENERAL PURPOSE TOOLS
Steel wheel 1.5 mm (0.059 in)
TOOL NAME REMARKS
Aluminum wheel 1.0 mm (0.039 in)
Air pressure gauge Used for measuring tire air pressure.
2. ADJUSTING PARTS Dial gauge Used for measuring wheel runout.
Wheel balancing Standard Service limit

Dynamic unbalance Less than 5 g (0.18 oz)
Balance weight part number

Weight
(For steel wheel)
723141290 5 g (0.18 oz)
723141300 10 g (0.35 oz)
723141310 15 g (0.53 oz)
723141320 20 g (0.71 oz)
723141330 25 g (0.88 oz)
723141340 30 g (1.06 oz)
723141350 35 g (1.23 oz)
723141360 40 g (1.41 oz)
723141370 45 g (1.59 oz)
723241380 50 g (1.76 oz)
723241580 55 g (1.94 oz)
723241590 60 g (2.12 oz)

Weight
(For aluminum wheel)
23141GA462 5 g (0.18 oz)
23141GA472 10 g (0.35 oz)
23141GA482 15 g (0.53 oz)
23141GA492 20 g (0.71 oz)
23141GA502 25 g (0.88 oz)
23141GA512 30 g (1.06 oz)
23141GA522 35 g (1.23 oz)
23141GA532 40 g (1.41 oz)
23141GA542 45 g (1.59 oz)
23141GA552 50 g (1.76 oz)
— 55 g (1.94 oz)
23141GA572 60 g (2.12 oz)
WT-3
TIRE
2. Tire
A: INSPECTION
1) Take stone, glass, nail etc. off the tread groove.
2) Replace the tire:
CAUTION:
• When replacing a tire, make sure to use only
the same size, construction and load range as
originally installed.
• Avoid mixing radial, belted bias or bias tires
on the vehicle.
(1) When large crack on the side wall, damage
or crack on tread is found.
(2) When the “tread wear indicator” appears as
a solid band across the tread.
S4M0377A
(1) Tread wear indicator

(2) Tire tread
1. TIRE ROTATION
If tires are maintained at the same positions for a
long period of time, uneven wear results. There-
fore, they should be periodically rotated.
This lengthens service life of tires.
CAUTION:
When rotating the tires, replace unevenly worn
or damaged tires with new ones.
B4M1765
WT-4
STEEL WHEEL
3. Steel Wheel C: INSPECTION

1) Deformation or damage on the rim can cause air
A: REMOVAL leakage. Check the rim flange for deformation,
1) Apply parking brake, and position the select le- crack, or damage, and repair or replace as neces-
ver to “P” or “LOW”. sary.
2) Set shop jacks or a lift to the specified point, and 2) Jack-up the vehicle until wheels clear the floor.
support the vehicle with its wheels slightly contact- 3) Slowly rotate the wheel to check rim “runout” us-
ing 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.
G4M0298
B: INSTALLATION
1) Attach the wheel to hub by aligning the wheel Axial runout limit Radial runout limit
bolt hole with hub bolt. 1.5 mm (0.059 in)
2) Temporarily attach the wheel nuts to hub bolts.
(In the case of aluminum wheel, use SUBARU gen-
uine wheel nut for aluminum wheel.)
3) Manually tighten the nuts making sure the wheel
hub hole is aligned correctly to guide portion of hub.
4) Tighten the wheel nuts in a diagonal selection to
specified torque. Use a wheel nut wrench.
Wheel nut tightening torque:
90 N·m (9.1 kgf-m, 65.7 ft-lb)
CAUTION:
• Tighten the wheel nuts in two or three steps G4M0299
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 the figure.
ening of wheel nuts may cause wheels to “jud- 5) If measured runout still exceeds specifications,
der”. replace the wheel.
• Do not depress the wrench with foot; Always
use both hands when tightening.
• Make sure the bolt, nut and nut seating sur-
face 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
ALUMINUM WHEEL
4. Aluminum Wheel
A: REMOVAL
Refer to Steel Wheel for removal procedure of alu-
minum wheels. <Ref. to WT-5, REMOVAL, Steel
Wheel.>
B: INSTALLATION
Refer to Steel Wheel for installation procedure of
aluminum wheels.<Ref. to WT-5, INSTALLATION,
Steel Wheel.>
C: INSPECTION
Refer to Steel Wheel for inspection procedure of
aluminum wheels. <Ref. to WT-5, INSPECTION,
Steel Wheel.>
Rim runout:
Axial runout limit Radial runout limit
1.0 mm (0.039 in)
D: CAUTION
Aluminum wheels are easily scratched. To 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 the aluminum
wheels to contact the shoulder of the road.
3) When installing a tire chain, be sure to install it
properly not to have slack; otherwise it may hit the
wheel while driving.
4) When washing the aluminum wheel, use neutral
synthetic detergent and water. Avoid using the
cleanser including abrasive, hard brushes or an au-
tomatic car washer.
WT-6
WHEEL BALANCING
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 dynamic balancing, measure the 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
Balance weight part number the wheel. Use an appropriate balancer when ad-
Weight justing the wheel balance.
(For steel wheel)
723141290 5 g (0.18 oz) 4) Use genuine balance weights.
723141300 10 g (0.35 oz) CAUTION:
723141310 15 g (0.53 oz) • 55 g (1.94 oz) weight used with the aluminum
723141320 20 g (0.71 oz) wheel is not available.
723141330 25 g (0.88 oz) • Balance weights are available for use with
723141340 30 g (1.06 oz) any of 14- to 16-inch wheels.
723141350 35 g (1.23 oz)
723141360 40 g (1.41 oz)
723141370 45 g (1.59 oz)
723241380 50 g (1.76 oz)
723241580 55 g (1.94 oz)
723241590 60 g (2.12 oz)

Weight
(For aluminum wheel)
23141GA462 5 g (0.18 oz)
23141GA472 10 g (0.35 oz)
23141GA482 15 g (0.53 oz)
23141GA492 20 g (0.71 oz)
23141GA502 25 g (0.88 oz)
23141GA512 30 g (1.06 oz)
23141GA522 35 g (1.23 oz)
23141GA532 40 g (1.41 oz)
23141GA542 45 g (1.59 oz)
23141GA552 50 g (1.76 oz)
— 55 g (1.94 oz)
23141GA572 60 g (2.12 oz) B4M0053B
4) Install the selected weight to the point designat- (1) Weight for aluminum wheel
ed by dynamic balancing. (2) Weight for steel wheel
5) Using dynamic balancing, measure the wheel
balance again. Check that the wheel balance is Service limit: A
correctly adjusted. Weight for steel wheel;
2.16 mm (0.085 in)
Weight for aluminum wheel;
4.5 mm (0.177 in)
WT-7
“T-TYPE” TIRE
6. “T-type” Tire
A: NOTE
“T-type” tire for temporary use is prepared as a
spare tire.
CAUTION:
• Do not use a tire chain with the “T-type” tire.
Because of the smaller tire size, a tire chain will
not fit properly and will result in damage to the
vehicle and the tire.
• Do not drive at a speed greater than 80 km/h
(50 MPH).
• Drive as slowly as possible and avoid pass-
ing over bumps.
B: REPLACEMENT
Refer to Removal and Installation of Steel Wheel
for removal/installation of “T-type” tires. <Ref. to
WT-5, Steel Wheel.>
CAUTION:
Replace with a conventional tire as soon as
possible since the “T-type” tire is only for tem-
porary use.
C: INSPECTION
1) Check the tire inflation pressure.
Specification:
420 kPa (4.2 kg/cm2, 60 psi)
2) Take stones, glass, nails, etc. out of the tread
groove.
3) Check the tires for deformation, cracks, partial
wear, or wear.
CAUTION:
Replace the tire with a new one.
WT-8
FULL WHEEL CAP
7. Full Wheel Cap

A: REMOVAL
Pry off the full wheel cap with a wheel cap remover
inserted between openings on the cap.
SU0007
B: INSTALLATION
Align the valve hole in wheel cap with the valve on
wheel and secure the wheel cap by tapping four
points by hand.
C: INSPECTION
1) Check the wheels for missing wheel caps.
2) Check the pawls of wheel caps for damage or
bend.
3) Check the wheel caps for cracks.
WT-9
GENERAL DIAGNOSTICS TABLE
8. General Diagnostics Table

A: INSPECTION
Front wheel shimmy • Worn or improperly inflated of tire. Replace
• Wheel is out of balance. Adjustment
Abnormal tire wear • Improperly inflated of tire. Replace
Sways/pitches • Worn or improperly inflated of tire. Replace
Wander/pulls • Worn or improperly inflated of tire. Replace
WT-10
DIFFERENTIALS
DI
Page
2. Differential Gear Oil...................................................................................23
3. Front Differential........................................................................................24
4. Rear Differential for T-type........................................................................25
5. Rear Differential for VA-type .....................................................................41
6. Rear Differential Front Oil Seal .................................................................56
7. Rear Differential Side Oil Seal ..................................................................58
8. Rear Differential Member ..........................................................................63
GENERAL DESCRIPTION
DIFFERENTIALS
A: SPECIFICATIONS
When replacing a rear differential assembly, select the correct one according to the following table.
NOTE:
Using the different rear differential assembly causes the drive line and tires to “drag” or emit abnormal noise
when AWD is selected.
1.6 L 2.0 L
MODEL
AT MT AT MT
Rear differential type VA type without LSD T type without LSD
Identification XP XN EG
Type of gear Hypoid gear
Gear ratio (Number of gear
4.444 (40/9) 4.111 (37/9) 3.900 (39/10)
teeth)
Oil capacity 0.82 (0.8 US qt, 0.7 Imp qt)
Rear differential gear oil GL-5
2.5 L 2.0 L Turbo

MT MT
MODEL
AT Except AT Except
Australia Australia
Australia Australia
Rear differential type T type with LSD
LSD type Viscous coupling SURETRAC
Identification EJ ER EJ EF EM
Type of gear Hypoid gear
Gear ratio (Number of gear
4.111 (37/9) 3.700 (37/10) 4.111 (37/9) 3.545 (39/11) 4.444 (40/9)
teeth)
Oil capacity 0.82 (0.8 US qt, 0.7 Imp qt)
Rear differential gear oil GL-5
• Identification • Rear differential gear oil
Recommended oil
CAUTION:
Each oil manufacturer has its base oil and addi-
DR0001
H3M1272A
DI-2
GENERAL DESCRIPTION
DIFFERENTIALS
1. SERVICE DATA
T-type 19 — 26 (1.9 — 2.6, 4.3 — 5.8)
Front and rear bearing preload at companion New bearing
VA-type 12.7 — 32.4 (1.3 — 3.3, 2.9 — 7.3)
flange bolt hole N (kgf, lb)
Used bearing T-type 8 — 16 (0.8 — 1.6, 1.8 — 3.6)
T-type 0.10 — 0.20 (0.0039 — 0.0079)
Side gear backlash mm (in)
VA-type 0.05 — 0.15 (0.0020 — 0.0059)
Side bearing standard width mm (in) 20.00 (0.7874)
T-type 0.10 — 0.20 (0.0039 — 0.0079)
Crown gear to drive pinion backlash mm (in)
VA-type 0.10 — 0.15 (0.0039 — 0.0059)
Crown gear runout on its back surface mm (in) Less than 0.05 (0.0020)
2. ADJUSTING PARTS
• VA-type
Front and rear bearing preload at com- 12.7 — 32.4 N
New bearing
panion flange bolt hole (1.3 — 3.3 kgf, 2.9 — 7.3 lb)
Part No. Length
32288AA040 52.3 mm (2.059 in)
32288AA050 52.5 mm (2.067 in)
31454AA100 52.6 mm (2.071 in)
32288AA060 52.7 mm (2.075 in)
Preload adjusting spacer
31454AA110 52.8 mm (2.079 in)
32288AA070 52.9 mm (2.083 in)
31454AA120 53.0 mm (2.087 in)
32288AA080 53.1 mm (2.091 in)
32288AA090 53.3 mm (2.098 in)
Part No. Thickness
38336AA000 1.500 mm (0.0591 in)
38336AA120 1.513 mm (0.0596 in)
38336AA010 1.525 mm (0.0600 in)
38336AA130 1.538 mm (0.0606 in)
38336AA020 1.550 mm (0.0610 in)
38336AA140 1.563 mm (0.0615 in)
38336AA030 1.575 mm (0.0620 in)
38336AA150 1.588 mm (0.0625 in)
38336AA040 1.600 mm (0.0630 in)
38336AA160 1.613 mm (0.0635 in)
38336AA050 1.625 mm (0.0640 in)
Preload adjusting washer
38336AA170 1.638 mm (0.0645 in)
38336AA060 1.650 mm (0.0650 in)
38336AA180 1.663 mm (0.0655 in)
38336AA070 1.675 mm (0.0659 in)
38336AA190 1.688 mm (0.0665 in)
38336AA080 1.700 mm (0.0669 in)
38336AA200 1.713 mm (0.0674 in)

Impreza 2001 2002 PDF

Uploaded by

Copyright:

Available Formats

You might also like

Impreza 2001 2002 PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Impreza 2001 2002 PDF

Uploaded by

Copyright:

Available Formats

2002 Model Year

PDF Service Manual

ENGINE 1 SECTION (Pub.No.G1840GE2)

ENGINE 2 SECTION (Pub.No.G1840GE3)

TRANSMISSION SECTION (Pub.No.G1840GE4)

CHASSIS SECTION (Pub.No.G1840GE5)

BODY SECTION (Pub.No.G1840GE6)

WIRING SYSTEM SECTION (Pub.No.G1840GE7)

HOW TO USE THIS MANUALS HU

All information, illustration and specifi-

FUJI HEAVY INDUSTRIES LTD. G1840GE1

Applied model: GG***** and GD***** from 2002MY.

The additional manuals below are also available:

The manuals contain the latest information at the

1. How to Use This Manuals

Model Sedan Wagon OUTBACK

Model 1.6 L Non-Turbo 2.0 L Turbo 2.0 L 2.5 L

Model 1.6 L Non-turbo 2.0 L Turbo 2.0 L 2.5 L

Model 1.6 L Non-turbo 2.0 L Turbo 2.0 L 2.5 L

5MT: 5 forward speeds with synchromesh and 1-reverse

Model Turbo 2.0 L, 2.5 L OUTBACK OTHERS

Front Macpherson strut type, Independent, Coil spring

Model 1.6 L Non-turbo 2.0 L, 2.5 L Turbo 2.0 L

Rim size 14 × 51/2JJ 15 × 6JJ 16 × 61/2JJ 17 × 7JJ

Model 1.6 L Non-turbo 2.0 L Turbo 2.0 L 2.5 L

★1: Dual range

1. LHD VEHICLE SA08731G3703

D/R: Dual range

2. RHD VEHICLE SA08731G3704

D/R: Dual range

D/R: Dual range

1. Precaution 7. AIRBAG MODULE

5. LIFTS AND JACKS

Without side sill cover

With side sill cover

Rear Rear differential

Hook for tie-down

Hook for towing

Hook for tie-down Hook for towing

45˚ 45˚ 45˚ 45˚

8. FRONT HOOD STAY INSTALLATION

• When wider hood opening is necessary

9. TRAINING 10.GENERAL SCAN TOOL

Emisson control label Vacuum hose piping label

ID plate (Europe model)

Tire inflation pressure label

Vehicle identification number

Saudi Arabia plate (Saudi Arabia model)

• GCC countries (Saudi Arabia, etc.)

3. MODEL NUMBER PLATE

The engine and transmission type are as follows:

Checks with the Engine Running

Dynamic Test with the Vehicle Running

Checks after Dynamic Test

1. APPEARANCE CHECK 4. CONNECTION OF AIR CONDITIONER

• Vehicles with manual door locks:

• Operate the driver’s side door lock knob to check

9. ACCESSORY CHECK 10.OPERATION CHECK OF HOOD LOCK

Applied model: GG* and GD* from 2002MY.