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1. 2-door Coupe
1. 2-door Coupe
A: DIMENSIONS
Model 2200 2500
AWD AWD
L RS
Overall length mm (in) 4,375 (172.2)
Overall width mm (in) 1,705 (67.1)
Overall height mm (in) 1,410 (55.5)
Compartment Leg room Front Max. mm (in) 1,094 (43.1)
Rear Min. mm (in) 825 (32.5)
Head room Front mm (in) 995 (39.2)
Rear mm (in) 933 (36.7)
Shoulder Front mm (in) 1,335 (52.6)
room Rear mm (in) 1,325 (52.2)
Wheelbase mm (in) 2,520 (99.2)
Tread Front mm (in) 1,460 (57.5) 1,470 (57.9)
Rear mm (in) 1,450 (57.1) 1,460 (57.5)
Minimum road clearance mm (in) 145 (5.7)
B: ENGINE
Model 2200 2500
Engine type Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke gasoline engine
Valve arrangement Overhead camshaft type
Bore x Stroke mm (in) 96.9 x 75.0 (3.815 x 2.953) 99.5 x 79.0 (3.917 x 3.110)
Displacement cm3 (cu in) 2,212 (135) 2,457 (150)
Compression ratio 10.0
Firing order 1—3—2—4
Idle speed at Park/Neutral position rpm 700 650 (MT), 700 (AT)
Maximum output kW (HP)/rpm 106 (142)/5,600 123 (165)/5,600
Maximum torque N.m (kg-m, ft-lb)/rpm 202 (20.6, 149)/3,600 225 (22.9, 166)/4,000
2
SPECIFICATIONS [S1C0] 1-1
1. 2-door Coupe
C: ELECTRICAL
Model 2200 2500
Ignition timing at idling speed BTDC/rpm 15°/700 10° ± 8°/650 (MT), 15° ± 8°/700 (AT)
Spark plug Type and manufacturer CHAMPION: RC10YC4 (Standard)
NGK: BKR6E-11
CHAMPION: RC8YC4
NIPPONDENSO: K20PR-U11
Generator 12V — 75A
Battery Type 55D23L (MT), 65D23L (AT)
Reserve capacity min 99 (MT), 111 (AT) 99 (MT), 118 (AT)
Cold cranking amperes amp. 356 (MT), 420 (AT) 356 (MT), 520 (AT)
3
1-1 [S1D0] SPECIFICATIONS
1. 2-door Coupe
D: TRANSMISSION
Model AWD
Transmission type 5MT* 4AT*
Clutch type DSPD TCC
Gear ratio 1st 3.545 2.785 (2200 cc model)
3.027 (2500 cc model)
2nd 2.111 1.545 (2200 cc model)
1.619 (2500 cc model)
3rd 1.448 1.000
4th 1.088 0.694
5th 0.780 —
Reverse 3.333 2.272
Reduction gear 1st Type of gear — Helical
(Front drive) reduction
Gear ratio — 1.000
Final Type of gear Hypoid Hypoid
reduction
Gear ratio 3.900 (2200 cc model) 4.111 (2200 cc model)
4.111 (2500 cc model) 4.444 (2500 cc model)
Reduction gear Transfer Type of gear Helical —
(Rear drive) reduction
Gear ratio 1.000 —
Final Type of gear Hypoid Hypoid
reduction
Gear ratio 3.900 (2200 cc model) 4.111 (2200 cc model)
4.111 (2500 cc model) 4.444 (2500 cc model)
5MT*: 5-forward speeds with synchromesh and 1-reverse – with center differential and viscous coupling
4AT*: Electronically controlled fully-automatic, 4-forward speeds and 1-reverse – with hydraulically controlled transfer clutch
DSPD: Dry Single Plate Diaphragm
TCC: Torque Converter Clutch
E: STEERING
Type Rack and Pinion
Turns, lock to lock 3.2
Minimum turning circle m (ft) Curb to curb: 10.2 (33.5), Wall to wall: 11.0 (36.1)
F: SUSPENSION
Front Macpherson strut type, Independent, Coil spring
Rear Dual link strut type, Independent, Coil spring
G: BRAKE
Model 2200 2500
Service brake system Dual circuit hydraulic with vacuum suspended power unit
Front Ventilated disc brake
Rear Drum brakes Disc brakes
Parking brake Mechanical on rear brakes
4
SPECIFICATIONS [S1J1] 1-1
1. 2-door Coupe
H: TIRE
Model 2200 2500
AWD AWD
L RS
Size P195/60R15 87H P205/55R16 89V
Type Steel belted radial, Tubeless
I: CAPACITY
Model AWD
5MT 4AT
Fuel tank ȏ (US gal, Imp gal) 60 (15.9, 13.2)
Engine oil Upper level ȏ (US qt, Imp qt) 4.0 (4.2, 3.5)
Lower level ȏ (US qt, Imp qt) 3.0 (3.2, 2.6)
Transmission gear oil ȏ (US qt, Imp qt) 3.5 (3.7, 3.1) —
Automatic transmission fluid ȏ (US qt, Imp qt) — 8.4 (8.9, 7.4) (2200 cc model)
9.3 (9.8, 8.2) (2500 cc model)
AT differential gear oil ȏ (US qt, Imp qt) — 1.2 (1.3, 1.1)
AWD rear differential gear oil ȏ (US qt, Imp qt) 0.8 (0.8, 0.6)
Power steering fluid ȏ (US qt, Imp qt) 0.7 (0.7, 0.6)
Engine coolant ȏ (US qt, Imp qt) 5.8 (6.1, 5.1)
J: WEIGHT
1. U.S. SPEC. VEHICLES
Model 2200 2500
AWD
L RS
5MT 4AT 5MT* 4AT*
Curb weight (C.W.) Front kg (lb) 717 (1,580) 739 (1,630) 742 (1,635) 762 (1,680)
Rear kg (lb) 521 (1,150) 531 (1,170) 526 (1,160) 528 (1,165)
Total kg (lb) 1,238 (2,730) 1,270 (2,800) 1,268 (2,795) 1,290 (2,845)
Gross vehicle weight Front kg (lb) 885 (1,950)
(G V W )
(G.V.W.)
Rear kg (lb) 816 (1,800)
Total kg (lb) 1,701 (3,750)
*: The weight of a vehicle with sunroof is 5 kg (10 lb) larger at the front, 7 kg (15 lb) larger at the rear and 12 kg (25 lb) larger in total.
5
1-1 [S1J2] SPECIFICATIONS
1. 2-door Coupe
*: The weight of a vehicle with sunroof is 5 kg (10 lb) larger at the front, 7 kg (15 lb) larger at the rear and 12 kg (25 lb) larger in total.
6
SPECIFICATIONS [S2B0] 1-1
2. 4-door Sedan
2. 4-door Sedan
A: DIMENSIONS
Model 2200 2500
AWD AWD
L TS RS
Overall length mm (in) 4,375 (172.2)
Overall width mm (in) 1,705 (67.1)
Overall height mm (in) 1,410 (55.5)
Compartment Leg room Front Max. mm (in) 1,094 (43.1)
Rear Min. mm (in) 825 (32.5)
Head room Front mm (in) 995 (39.2)
Rear mm (in) 933 (36.7)
Shoulder Front mm (in) 1,335 (52.6)
room Rear mm (in) 1,315 (51.8)
Wheelbase mm (in) 2,520 (99.2)
Tread Front mm (in) 1,460 (57.5) 1,470 (57.9)
Rear mm (in) 1,450 (57.1) 1,460 (57.5)
Minimum road clearance mm (in) 145 (5.7)
B: ENGINE
Model 2200 2500
Engine type Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke gasoline engine
Valve arrangement Overhead camshaft type
Bore x Stroke mm (in) 96.9 x 75.0 (3.815 x 2.953) 99.5 x 79.0 (3.917 x 3.110)
Displacement cm3 (cu in) 2,212 (135) 2,457 (150)
Compression ratio 10.0
Firing order 1—3—2—4
Idle speed at Park/Neutral position rpm 700 650 (MT), 700 (AT)
Maximum output kW (HP)/rpm 106 (142)/5,600 123 (165)/5,600
Maximum torque N.m (kg-m, ft-lb)/rpm 202 (20.6, 149)/3,600 225 (22.9, 166)/4,000
7
1-1 [S2C0] SPECIFICATIONS
2. 4-door Sedan
C: ELECTRICAL
Model 2200 2500
Ignition timing at idling speed BTDC/rpm 15°/700 10° ± 8°/650 (MT), 15° ± 8°/700 (AT)
Spark plug Type and manufacturer CHAMPION: RC10YC4 (Standard)
NGK: BKR6E-11
CHAMPION: RC8YC4
NIPPONDENSO: K20PR-U11
Generator 12V — 75A
Battery Type 55D23L (MT), 65D23L (AT)
Reserve capacity min 99 (MT), 111 (AT)
Cold cranking amperes amp. 356 (MT), 420 (AT)
8
SPECIFICATIONS [S2G0] 1-1
2. 4-door Sedan
D: TRANSMISSION
Model AWD
Transmission type 5MT* 4AT*
Clutch type DSPD TCC
Gear ratio 1st 3.545 2.785 (2200 cc model)
3.027 (2500 cc model)
2nd 2.111 1.545 (2200 cc model)
1.619 (2500 cc model)
3rd 1.448 1.000
4th 1.088 0.694
5th 0.780 —
Reverse 3.333 2.272
Reduction gear 1st Type of gear — Helical
(Front drive) reduction
Gear ratio — 1.000
Final Type of gear Hypoid Hypoid
reduction
Gear ratio 3.900 (2200 cc model) 4.111 (2200 cc model)
4.111 (2500 cc model) 4.444 (2500 cc model)
Reduction gear Transfer Type of gear Helical —
(Rear drive) reduction
Gear ratio 1.000 —
Final Type of gear Hypoid Hypoid
reduction
Gear ratio 3.900 (2200 cc model) 4.111 (2200 cc model)
4.111 (2500 cc model) 4.444 (2500 cc model)
5MT*: 5-forward speeds with synchromesh and 1-reverse – with center differential and viscous coupling
4AT*: Electronically controlled fully-automatic, 4-forward speeds and 1-reverse – with hydraulically controlled transfer clutch
DSPD: Dry Single Plate Diaphragm
TCC: Torque Converter Clutch
E: STEERING
Type Rack and Pinion
Turns, lock to lock 3.2
Minimum turning circle m (ft) Curb to curb: 10.2 (33.5), Wall to wall: 11.0 (36.1)
F: SUSPENSION
Front Macpherson strut type, Independent, Coil spring
Rear Dual link strut type, Independent, Coil spring
G: BRAKE
Model 2200 2500
Service brake system Dual circuit hydraulic with vacuum suspended power unit
Front Ventilated disc brake
Rear Drum brakes Disc brakes
Parking brake Mechanical on rear brakes
9
1-1 [S2H0] SPECIFICATIONS
2. 4-door Sedan
H: TIRE
Model 2200 2500
AWD AWD
L TS RS
Size P195/60R15 87H P205/55R16 89V
Type Steel belted radial, Tubeless
I: CAPACITY
Model AWD
5MT 4AT
Fuel tank ȏ (US gal, Imp gal) 60 (15.9, 13.2)
Upper level ȏ (US qt, Imp qt) 4.0 (4.2, 3.5)
Engine oil
Lower level ȏ (US qt, Imp qt) 3.0 (3.2, 2.6)
Transmission gear oil ȏ (US qt, Imp qt) 3.5 (3.7, 3.1) —
8.4 (8.9, 7.4) (2200 cc model)
Automatic transmission fluid ȏ (US qt, Imp qt) —
9.3 (9.8, 8.2) (2500 cc model)
AT differential gear oil ȏ (US qt, Imp qt) — 1.2 (1.3, 1.1)
AWD rear differential gear oil ȏ (US qt, Imp qt) 0.8 (0.8, 0.6)
Power steering fluid ȏ (US qt, Imp qt) 0.7 (0.7, 0.6)
Engine coolant ȏ (US qt, Imp qt) 5.8 (6.1, 5.1)
J: WEIGHT
1. U.S. SPEC. VEHICLES
Model 2200 2500
AWD
L RS
5MT 4AT 5MT* 4AT*
Curb weight (C.W.) Front kg (lb) 719 (1,585) 744 (1,640) 744 (1,640) 764 (1,685)
Rear kg (lb) 521 (1,150) 528 (1,165) 526 (1,160) 529 (1,165)
Total kg (lb) 1,240 (2,735) 1,272 (2,805) 1,270 (2,800) 1,293 (2,850)
Gross vehicle weight Front kg (lb) 885 (1,950)
(G V W )
(G.V.W.)
Rear kg (lb) 816 (1,800)
Total kg (lb) 1,701 (3,750)
*: The weight of a vehicle with sunroof is 5 kg (10 lb) larger at the front, 7 kg (15 lb) larger at the rear and 12 kg (25 lb) larger in total.
10
SPECIFICATIONS [S2J2] 1-1
2. 4-door Sedan
*: The weight of a vehicle with sunroof is 5 kg (10 lb) larger at the front, 7 kg (15 lb) larger at the rear and 12 kg (25 lb) larger in total.
11
1-1 [S3A0] SPECIFICATIONS
3. Sport Wagon
3. Sport Wagon
A: DIMENSIONS
Model 2200
AWD
Brighton L OUTBACK
Overall length mm (in) 4,375 (172.2)
Overall width mm (in) 1,705 (67.1)
Overall height mm (in) 1,410 (55.5) 1,430 (56.3)
Compartment Leg room Front Max. mm (in) 1,094 (43.1)
Rear Min. mm (in) 825 (32.5)
Head room Front mm (in) 995 (39.2)
Rear mm (in) 950 (37.4)
Shoulder Front mm (in) 1,335 (52.6)
room Rear mm (in) 1,315 (51.8)
Wheelbase mm (in) 2,520 (99.2)
Tread Front mm (in) 1,460 (57.5)
Rear mm (in) 1,450 (57.1)
Minimum road clearance mm (in) 145 (5.7) 165 (6.5)
B: ENGINE
Model 2200
Engine type Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke gasoline engine
Valve arrangement Overhead camshaft type
Bore x Stroke mm (in) 96.9 x 75.0 (3.815 x 2.953)
Displacement cm3 (cu in) 2,212 (135.0)
Compression ratio 10.0
Firing order 1—3—2—4
Idle speed at Park/Neutral position rpm 700
Maximum output kW (HP)/rpm 106 (142)/5,600
Maximum torque N.m (kg-m, ft-lb)/rpm 202 (20.6, 149)/3,600
12
SPECIFICATIONS [S3C0] 1-1
3. Sport Wagon
C: ELECTRICAL
Model 2200
Ignition timing at idling speed BTDC/rpm 15°/700
Spark plug Type and manufacturer CHAMPION: RC10YC4 (Standard)
NGK: BKR6E-11
CHAMPION: RC8YC4
NIPPONDENSO: K20PR-U11
Generator 12V — 75A
Battery Type 55D23L (MT), 65D23L (AT)
Reserve capacity min 99 (MT), 111 (AT)
Cold cranking amperes amp. 356 (MT), 420 (AT)
13
1-1 [S3D0] SPECIFICATIONS
3. Sport Wagon
D: TRANSMISSION
Model AWD
Transmission type 5MT* 4AT*
Clutch type DSPD TCC
Gear ratio 1st 3.545 2.785
2nd 2.111 1.545
3rd 1.448 1.000
4th 1.088 0.694
5th 0.780 —
Reverse 3.333 2.272
Reduction ggear 1st Type of gear — Helical
(F t d
(Front drive)
i ) reduction
d ti
Gear ratio — 1.000
Final Type of gear Hypoid Hypoid
reduction
d ti
Gear ratio 3.900 4.111
Reduction ggear Transfer Type of gear Helical —
(R
(Rear drive)
di ) reduction
d ti
Gear ratio 1.000 —
Final Type of gear Hypoid Hypoid
reduction
d ti
Gear ratio 3.900 4.111
5MT*: 5-forward speeds with synchromesh and 1-reverse – with center differential and viscous coupling
4AT*: Electronically controlled fully-automatic, 4-forward speeds and 1-reverse – with hydraulically controlled transfer clutch
DSPD: Dry Single Plate Diaphragm
TCC: Torque Converter Clutch
E: STEERING
Type Rack and Pinion
Turns, lock to lock 3.2
Minimum turning circle m (ft) Curb to curb: 10.2 (33.5), Wall to wall: 11.0 (36.1)
F: SUSPENSION
Front Macpherson strut type, Independent, Coil spring
Rear Dual link strut type, Independent, Coil spring
G: BRAKE
Model 2200
Service brake system Dual circuit hydraulic with vacuum suspended power unit
Front Ventilated disc brake
Rear Drum brake
Parking brake Mechanical on rear brakes
H: TIRE
Model 2200
AWD
Brighton L OUTBACK
Size P195/60R15 87H P205/60R15 90S
P205/60R15 90H
Type Steel belted radial, Tubeless
14
SPECIFICATIONS [S3J2] 1-1
3. Sport Wagon
I: CAPACITY
Model AWD
5MT 4AT
Fuel tank ȏ (US gal, Imp gal) 60 (15.9, 13.2)
Upper level ȏ (US qt, Imp qt) 4.0 (4.2, 3.5)
Engine oil
Lower level ȏ (US qt, Imp qt) 3.0 (3.2, 2.6)
Transmission gear oil ȏ (US qt, Imp qt) 3.5 (3.7, 3.1) —
Automatic transmission fluid ȏ (US qt, Imp qt) — 8.4 (8.9, 7.4)
AT differential gear oil ȏ (US qt, Imp qt) — 1.2 (1.3, 1.1)
AWD rear differential gear oil ȏ (US qt, Imp qt) 0.8 (0.8, 0.6)
Power steering fluid ȏ (US qt, Imp qt) 0.7 (0.7, 0.6)
Engine coolant ȏ (US qt, Imp qt) 5.8 (6.1, 5.1)
J: WEIGHT
1. U.S. SPEC. VEHICLES
Model 2200
AWD
L OUTBACK
5MT 4AT 5MT 4AT
Curb weight (C.W.) Front kg (lb) 721 (1,590) 741 (1,635) 730 (1,610) 751 (1,655)
Rear kg (lb) 565 (1,245) 565 (1,245) 567 (1,250) 576 (1,270)
Total kg (lb) 1,286 (2,835) 1,306 (2,880) 1,297 (2,860) 1,327 (2,925)
Gross vehicle weight Front kg (lb) 885 (1,950)
(G V W )
(G.V.W.)
Rear kg (lb) 907 (2,000)
Total kg (lb) 1,792 (3,950)
15
1-3 [G1A0] GENERAL INFORMATION
1. General Precautions
2
GENERAL INFORMATION [G1E2] 1-3
1. General Precautions
9) Do not use petrol, kerosene, diesel fuel, gas when engine is operating at low speeds
oil, thinners or solvents for washing skin. since this may cause vehicle to jump off test
10)If skin disorders develop, obtain medical machine.
advice. D Avoid abrupt braking after tests.
11)Where practicable, degrease components D In order to prevent the vehicle from slip-
prior to handling. ping due to vibration, do not place any
12)Where there is a risk of eye contact, eye wooden blocks or similar items between the
protection should be worn, for example, chemi- safety stands and the vehicle.
cal goggles or face shields; in addition an eye D Since the rear wheels will also be rotating,
wash facility should be provided. do not place anything near them. Also, make
3. ENVIRONMENTAL PROTECTION PRE- sure that nobody goes in front of the vehicle.
CAUTIONS 1) Position vehicle so that front wheels are
It is illegal to pour used oil on to the ground, placed between rollers of speedometer test
down sewers or drains, or into water courses. machine.
The burning of used engine oil in small space 2) Jack up vehicle until rear wheels clear the
heaters or boilers is not recommended unless floor, and support with safety stands.
emission control equipment is fitted. If in doubt,
check with the Local Authority.
Dispose of used oil through authorized waste
disposal contractors, licensed waste disposal
sites, or to the waste oil reclamation trade. If in
doubt, contact the Local Authority for advice on
disposal facilities.
D: HANDLING AN AT VEHICLE
1) The engine cannot be started by pushing
the vehicle, and also the vehicle cannot be
B1H0001A
moved by operating the starter motor.
2) Be sure to release the accelerator pedal be-
fore shifting from the “R” to the “N” range and 3) Start engine with shift lever set in 2nd gear
from the “N” to the “D” range, or vise versa even (for safety considerations). Perform speedom-
when the vehicle is stopped. eter tests.
3) Do not maintain the vehicle in a stall opera- 2. SPEEDOMETER TEST (Free roller meth-
tion for more than five seconds as this may over- od)
heat the clutch excessively. WARNING:
4) When the speedometer malfunctions, a ve- D Secure a rope or wire to the front towing
hicle-speed signal will no longer be emitted. Im- hook to prevent the lateral runout of front
mediately have it repaired. wheels.
5) Use only genuine SUBARU AT fluid in the D Do not abruptly depress/release clutch
transmission. pedal or accelerator pedal during tests even
when engine is operating at low speeds
E: FULL-TIME AWD MT MODELS since this may cause vehicle to jump off test
1. SPEEDOMETER TEST (Jack-up method) machine.
D Avoid abrupt braking after tests.
WARNING:
D Secure a rope or wire to the front towing 1) Position vehicle so that front wheels are
hook to prevent the lateral runout of front placed between rollers of test machine.
wheels. 2) Scribe alignment mark corresponding with
D Do not abruptly depress/release clutch centerline of rear wheels on floor.
pedal or accelerator pedal during tests even
3
1-3 [G1E3] GENERAL INFORMATION
1. General Precautions
B1H0003
4
GENERAL INFORMATION [G1E6] 1-3
1. General Precautions
6. TOWING
1) Loading vehicle onto dolly or flat-bed truck
CAUTION:
D Transport vehicle using a dolly or flat-bed
truck whenever possible.
D Move shift lever to “1st” position and ap-
ply parking brake.
B1H0006
5
1-3 [G1F1] GENERAL INFORMATION
1. General Precautions
B1H0008 S1H0013A
B1H0009
6
GENERAL INFORMATION [G1F2] 1-3
1. General Precautions
B1H0006
B1H0010
7
1-3 [G200] GENERAL INFORMATION
2. Precaution for Supplemental Restraint System (Airbag)
8
GENERAL INFORMATION [G3A2] 1-3
3. Vehicle Identification Numbers (V.I.N.)
9
1-3 [G3B0] GENERAL INFORMATION
3. Vehicle Identification Numbers (V.I.N.)
H1H0493C
10
GENERAL INFORMATION [G400] 1-3
4. Identification Number and Label Locations
H1H0455A
B1H0309A B1H0287A
B1H0286A
11
1-3 [G5A1] GENERAL INFORMATION
5. Recommended Fuel, Lubricants, Sealants and Adhesives
5. Recommended Fuel, Lubri- Many gasolines are now blended with materials
cants, Sealants and Adhesives called oxygenates. Use of these fuels can also
help keep the air cleaner. SUBARU approves
A: FUEL the use of oxygenated blend fuels, such as
MTBE (Methyl Tertiary Butyl Ether) or ethanol
1. FUEL OCTANE RATING
(ethyl or grain alcohol). These blended fuels
SUBARU engines are designed to use only un- should contain no more than 15% MTBE or 10%
leaded gasoline with an octane rating of 87 AKI ethanol for the proper operation of your
or higher. [This octane rating is the average of SUBARU.
the Research Octane and Motor Octane num- In addition, some gasoline suppliers are now
bers and is commonly referred to as the Anti- producing reformulated gasolines, which are
Knock Index (AKI).] Using a gasoline with a low- designed to reduce vehicle emissions.
er octane rating can cause persistent and SUBARU approves the use of reformulated
heavy knocking, which can damage the en- gasoline.
gine. Do not be concerned if SUBARU vehicle If you are not sure what the fuel contains, you
sometimes knocks lightly when you drive up a should ask your service station operators if their
hill or when you accelerate. See your dealer or gasolines contain detergents and oxygenates
a qualified service technician if you use a gaso- and if they have been reformulated to reduce
line with the specified octane rating and vehicle emissions.
SUBARU vehicle knocks heavily or persistently. As additional guidance, only use fuels suited for
2. UNLEADED GASOLINE your vehicle as explained below.
D Fuel should be unleaded and have an octane
The neck of the fuel filler pipe is designed to ac- rating no lower than that specified in this manu-
cept only an unleaded gasoline filler nozzle. al.
Under no circumstances should leaded gaso- D Methanol (methyl or wood alcohol) is some-
line be used since it will damage the emission times mixed with unleaded gasoline. Methanol
control system and may impair driveability and can be used in your vehicle ONLY if it does not
fuel economy. exceed 5% of the fuel mixture AND if it is ac-
3. GASOLINE FOR CALIFORNIA-CERTI- companied by sufficient quantities of the prop-
FIED LEV er cosolvents and corrosion inhibitors required
If SUBARU vehicle is a California-certified Low to prevent damage to the fuel system. Do not
use fuel containing methanol EXCEPT under
Emission Vehicle (LEV) as indicated on the
underhood tune-up label, it is designed to opti- these conditions.
D If undesirable driveability problems are ex-
mize engine and emission control system per-
formance with gasolines that meet California perienced and you suspect they may be fuel re-
specifications. lated, try a different brand of gasoline before
seeking service at your SUBARU dealer.
D Fuel system damage or driveability problems
B: FUELS CONTAINING ALCOHOL which result from the use of improper fuel are
Your use of gasoline with detergent additives not covered under the SUBARU Limited War-
will help prevent deposits from forming in your ranty.
engine and fuel system. This helps keep your
engine in tune and your emission control sys- CAUTION:
Take care not to spill fuel during refueling.
tem working properly, and is a way of doing your
Fuels containing alcohol may cause paint
part for cleaner air.
damage.
12
GENERAL INFORMATION [G5CO] 1-3
5. Recommended Fuel, Lubricants, Sealants and Adhesives
C: LUBRICANTS
Lubricants Specifications Remarks
13
1-3 [G5D0] GENERAL INFORMATION
5. Recommended Fuel, Lubricants, Sealants and Adhesives
D: FLUID
CAUTION:
D Each oil manufacturer has its base oil and additives. Thus, do not mix two or more brands
(Except engine oil).
D When replenishing oil, it does not matter if the oil to be added is a different brand from
that in the engine; however, use oil having the API classification and SAE viscosity No. des-
ignated by SUBARU.
NOTE:
If vehicle is used in desert areas with very high temperatures or for other heavy duty applications,
the following viscosity oils may be used:
API classification: SJ or SH
SAE Viscosity No: 30, 40, 10W-50, 20W-40, 20W-50
B1H0439C
14
GENERAL INFORMATION [G5G0] 1-3
5. Recommended Fuel, Lubricants, Sealants and Adhesives
E: COOLANT
CAUTION:
· Avoid using any coolant or only water other than this designated type to prevent corrosion.
· SUBARU’s engine is aluminum alloy, and so special care is necessary.
· To prevent cooling system leaks, always add Genuine Subaru Cooling System Conditioner
(Part No. SOA635071) whenever the coolant is replaced.
Coolant Specifications
Lowest antici- SUBARU Specification gravity
pated atmo- coolant-to- Freezing
spheric tem- *water ratio at 10˚C at 20˚C at 30˚C at 40˚C at 50˚C point
perature (Volume) % (50˚F) (68˚F) (86˚F) (104˚F) (122˚F)
Above –30˚C –36˚C
50 — 50 1.084 1.079 1.074 1.068 1.062
(–22˚F) (–33˚F)
Above –15˚C
30 — 70 1.053 1.049 1.044 1.039 1.034 –16˚C (3˚F)
(5˚F)
*: It is recommended that distilled water be used.
F: SEALANTS
Recommended Application Equivalent
Three Bond 1105
Rear differential oil drain plug, retainer bolt, etc. Dow Corning's No. 7038
(P/N 004403010)
Matching surface of oil pump, transmission
Three Bond 1215
case, etc. Flywheel and drive plate tightening Dow Corning's No. 7038
(P/N 004403007)
Sealant bolts, etc.
Starcalking B-33A Sealing against water and dust entry through
Butyl Rubber Sealant
(P/N 000018901) weatherstrips, grommets, etc.
Three Bond 1102
Steering gear box adjust screw —
(P/N 004403006)
G: ADHESIVES
Weatherstrips and other rubber parts, plastics
Cemedine 5430L 3M's EC-1770 EC-1368
and textiles except soft vinyl parts.
Soft vinyl parts, and other parts subject to gaso-
3M's EC-776 EC-847
Cemedine 540 line, grease or oil, e.g. trim leather, door inner
EC-1022 (Spray Type)
Adhesive remote cover, etc.
Bonding metals, glass, plastic and rubber parts.
Cemedine 3000 Armstrong's Eastman 910
Repairing slightly torn weatherstrips, etc.
Essex Chemical Crop's Ure-
Windshield to body panel. Sunstar 580
thane E
15
replacement page for MSA5T0010A
Bulletin Number:18-74-04; Date: 01/15/04 Page 16
1-3 [G6A0] GENERAL INFORMATION
6. Tightening Torque of Standard Bolts and Nuts
B: BODY
Unit: N.m (kg-m, ft-lb)
Dia.
(mm) 4T 7T 9T
1.7 — 2.6
4 — —
(0.17 — 0.27, 1.2 — 2.0)
2.9 — 5.9
5 — —
(0.30 — 0.60, 2.2 — 4.3)
5.4 — 9.3
6 — —
(0.55 — 0.95, 4.0 — 6.9)
12.7 — 22.6 22.6 — 42.2 31.4 — 51.0
8
(1.30 — 2.30, 9.4 — 16.6) (2.30 — 4.30, 16.6 — 31.1) (3.20 — 5.20, 23.1 — 37.6)
27.5 — 47.1 51.0 — 86.3 62.8 — 107.9
10
(2.80 — 4.80, 20.3 — 34.7) (5.20 — 8.80, 37.6 — 63.7) (6.40 — 11.00, 46.3 — 79.6)
52.0 — 85.3 88.3 — 156.9 117.7 — 196.1
G1H0041 12
(5.30 — 8.70, 38.3 — 62.9) (9.00 — 16.00, 65.1 — 115.7) (12.00 — 20.00, 86.8 — 144.7)
1.2 — 2.2
4 — —
(0.12 — 0.22, 0.9 — 1.6)
2.5 — 4.4
5 — —
(0.25 — 0.45, 1.8 — 3.3)
4.4 — 7.4
6 — —
(0.45 — 0.75, 3.3 — 5.4)
9.8 — 17.7 17.7 — 31.4 23.5 — 39.2
7
(1.10 — 1.80, 7.2 — 13.0) (1.80 — 3.20, 13.0 — 23.1) (2.40 — 4.00, 17.4 — 28.9)
22.6 — 36.3 37.3 — 66.7 48.1 — 83.4
10
(2.30 — 3.70, 16.6 — 26.8) (3.80 — 6.80, 27.5 — 49.2) (4.90 — 8.50, 35.4 — 61.5)
39.2 — 64.7 68.6 — 117.7 88.3 — 147.1
G1H0042 12
(4.00 — 6.60, 28.9 — 47.7) (7.00 — 12.00, 50.6 — 86.8) (9.00 — 15.00, 65.1 — 108.5)
16
GENERAL INFORMATION [G7B0] 1-3
7. Lifting, Towing and Tie-down Points
A: GARAGE JACK
G1H0043
H1H0443A
17
1-3 [G7B0] GENERAL INFORMATION
7. Lifting, Towing and Tie-down Points
H1H0457A
18
GENERAL INFORMATION [G7C0] 1-3
7. Lifting, Towing and Tie-down Points
G1H0048
H1H0458A
G1H0367
19
1-3 [G8A0] GENERAL INFORMATION
8. Front Hood Stay Installation
H1H0444
H1H0445
20
1-4 [G100] PRE-DELIVERY INSPECTION
1. List of Pre-delivery Inspection
2
PRE-DELIVERY INSPECTION [G100] 1-4
1. List of Pre-delivery Inspection
3
1-4 [G100] PRE-DELIVERY INSPECTION
1. List of Pre-delivery Inspection
4
PRE-DELIVERY INSPECTION [G2A2] 1-4
2. Pre-road Test Inspection
H1H0467
5
1-4 [G2B1] PRE-DELIVERY INSPECTION
2. Pre-road Test Inspection
G1H0005
H1H0468
2) Again operate the key plate to ensure the
door unlocks.
1) First open the door completely and then
close it fully by operating the inside handle from NOTE:
the driver’s seat. Replace the lock cylinder if it malfunctions.
2) Repeat the preced step two or three times to When the door lock seems to be operating
see how the door opens and closes. Pay atten- slowly, lubricate the moving parts with grease or
tion to the operating effort, any abnormal noise oil.
and positive operation. 3) Sit in the driver seat, close the door com-
3) Operate the outer handle from the outside pletely, and move the lock lever to lock the door.
and check how the door opens and closes. Then, pull the inside door handle to ensure the
Also, check that there is an uniform clearance door will not open.
between the door and car body without any
grade difference.
NOTE:
D To examine the closed state and sinking of
the door, observe from the front right-hand door.
D If the striker drags during opening when the
outer handle is pulled, adjust by relocating the
striker.
S1H0061A
6
PRE-DELIVERY INSPECTION [G2D1] 1-4
2. Pre-road Test Inspection
CHECK POINTS
1. Trunk lid, rear gate and fuel lid “open-
close” operation
2. Operation of trunk lid and rear gate
(release and lock)
3. Fitting of trunk lid, rear gate and fuel
lid
4. Operation of trunk lid opener cancel
lever
7
1-4 [G2E1] PRE-DELIVERY INSPECTION
2. Pre-road Test Inspection
G1H0010
G1H0011
(1) Brake fluid is not oozing or leaking from
the brake fluid lines.
(2) The connectors and clamps are not
loose.
(3) There is no possibility of the pipes and
hoses contacting the body or other me-
8
PRE-DELIVERY INSPECTION [G2G1] 1-4
2. Pre-road Test Inspection
9
1-4 [G2H1] PRE-DELIVERY INSPECTION
2. Pre-road Test Inspection
B1H0118
B1H0410A
10
PRE-DELIVERY INSPECTION [G2H3] 1-4
2. Pre-road Test Inspection
B1H0037D
B1H0293A
B1H0036D
11
1-4 [G2I0] PRE-DELIVERY INSPECTION
2. Pre-road Test Inspection
12
PRE-DELIVERY INSPECTION [G2N2] 1-4
2. Pre-road Test Inspection
D Do not clean the wiper blades with gaso- M: REAR WINDOW WASHER AND
line or a solvent, such as paint thinner or WIPER
benzene. This will cause deterioration of the
wiper blades. CHECK POINTS
1. Quantity of washer fluid
NOTE: 2. Direction and quantity of washer fluid
D Before operating the wipers, be sure to eject sprayed
washer fluid onto the window. If the window is 3. Operation of rear window washer and
dry, the wipers’ operating speed and angle of wiper
operation will be different from when it is wet.
D If the position at which washer fluid is ejected N: WHEEL NUTS FOR LOOSENESS
is wrong: Using an eyeleteer or similar tool, ad- AND TIRE INFLATION PRESSURE
just the direction of the nozzle, be careful not to
damage the nozzle hole. CHECK POINTS
D Grease, wax, insects or other material on the 1. Wheel nut tightening torque
windshield or the wiper blades results in jerky 2. Tire inflation pressure and tire specifi-
wiper operation and unclear frontal view. If you cation
can not get clear view after operating the wind- 3. Damage to tire and rim
shield washer or wiper operation is jerky, clean 1. CHECK THE WHEEL NUT TIGHTENING
the outer surface of the windshield and wiper TORQUE
blades with a neutral detergent. NOTE:
Wiper blades, windshield and rear window
D When checking the wheel nuts, be sure to use
should be cleaned with sponge, soft cloth or
a torque wrench, and tighten the nuts to the
mild-abrasive cleaner.
specified torque.
After cleaning, rinse the windshield and wiper
D After inspecting and adjusting the tire pres-
blades with clean water. The windshield is clear sure, be sure to put the valve cap back.
if beads do not form when you rinse the wind-
shield with water. Tightening torque:
88 ± 10 N.m (9 ± 1 kg-m, 65 ± 7 ft-lb)
2. CHECK THE TIRE INFLATION PRESSURE
AND TIRE SPECIFICATION
CAUTION:
Check that all tires are adjusted to the speci-
fied tire inflation pressure.
Tire inflation pressure
Tire size kPa (kg/cm2, psi)
Front Rear
P195/60R15 87H 220 (2.2, 32) 200 (2.0, 29)
P205/55R16 87V 220 (2.2, 32) 200 (2.0, 29)
P205/60R15 90S*
220 (2.2, 32) 200 (2.0, 29)
P205/60R15 90H*
*: OUTBACK model only
13
1-4 [G2O1] PRE-DELIVERY INSPECTION
2. Pre-road Test Inspection
O: SEAT ADJUSTER AND SEAT 2) The anchor installation points are covered
BELTS with caps. Remove the cap at the desired an-
chor installation points.
CHECK POINTS
1. Front and rear seats, and their facing
materials
2. Front seat operation
3. Rear seat folding operation
4. Seat belts and their fit
5. Installing procedure for child anchor
1. MANUAL THREE-POINT TYPE
The seat belt warning light on the instrument
panel comes on for approximately six seconds
with the ignition switch “ON”.
And the warning chime sounds if the driver’s H1H0469B
seat belt is not fastened.
Make sure that the warning system works nor-
mally.
2. INSTALLING PROCEDURE FOR CHILD
ANCHOR
CAUTION:
D Be sure to install the plate anchor set in
the correct direction.
D Before tightening the plate anchor set,
position the plate in the pawl of the cover. Do
not allow the cover base to be caught be-
tween the plate anchor and spacer.
H1H0470A
D Always use a genuine top strap anchor.
When top strap anchor is used for rear seat: 3) Install the anchor at the installation point.
1) For Canada models, the anchor set is inside Tighten the bolt so that the anchor is completely
the glove box. Take it out and check that its secured.
components are assembled as shown in figure. 4) Attach the cover to the anchor plate.
5) Attach the hook of the top strap to the an-
chor.
G1H0020
14
PRE-DELIVERY INSPECTION [G2S2] 1-4
2. Pre-road Test Inspection
S1H0055A
15
1-4 [G2T1] PRE-DELIVERY INSPECTION
2. Pre-road Test Inspection
S1H0067A
T: INSTALLATION OF STEERING
COMPONENTS
CHECK POINTS
1. Installation of universal joints
2. Steering gear box for looseness, play,
or backlash, and boots for damage G1H0051
16
PRE-DELIVERY INSPECTION [G2Y0] 1-4
2. Pre-road Test Inspection
S1H0044A
H1H0474A
17
[G3A0] PRE-DELIVERY INSPECTION
3. Road Test Inspection
18
PRE-DELIVERY INSPECTION [G3D2] 1-4
3. Road Test Inspection
1. CHECK THE FOOT AND PARKING (4) If there is no free play between clevis
BRAKES’ OPERATION pin and clevis, turn brake switch adjusting
CAUTION: nut until the clearance between stopper and
Be sure to perform this test in a safe area. screw of brake switch becomes 0.3 mm
(0.01 in).
1) Drive on a dry, level, paved road, and apply (5) After adjustment, make sure there is no
normal braking. Look for uneven or improper brake dragging.
operation, or pulling to one side.
2) Press the brake pedal in two or three times, 4) Pull the parking brake lever completely out,
and keep it fully depressed. Make sure that the and check its operation. Also check the ratchet
brake can be kept that way for at least five se- for normal functioning.
conds. Also check for air in the brake system, Check the parking brake lever stroke. If it is out
or brake fluid leakage. of specification, adjust it by turning adjusting
3) Perform the adjustment of operating rod as- nut at parking brake lever.
sembly as follows: Standard parking brake lever stroke:
(1) Be sure engine is off. (No vacuum is ap- 7 — 8 notches/196 N (20 kg, 44 lb)
plied to brake booster).
(2) There should be play between brake
booster clevis and pin at brake pedal instal-
ling portion.
[Depress brake pedal pad with a force of
less than 10 N (1 kg, 2 lb) to a stroke of 1 to
3 mm (0.04 to 0.12 in).]
B1H0030B
B1H0029A
19
[G3D3] PRE-DELIVERY INSPECTION
3. Road Test Inspection
(2) If it is out of specification, adjust it by 3) Remove the wheel chocks, and return the
turning adjusting nut on engine side end of shift lever to neutral, then check the gear shift-
clutch cable at release fork. ing mechanism for excessive play.
4) Drive the car at various speeds. While de-
Fork lever free play allowance:
pressing the clutch pedal completely, move the
2 — 4 mm (0.08 — 0.16 in)
gear shift lever into each position, and check for
any unusual play or unusual resistance.
4. OPERATION OF SELECTOR LEVER (AU-
TOMATIC TRANSMISSION MODELS)
1) Check the operation of shift lock system and
key interlock.
Ensure that select lever is shifted from “P” to any
other position only after brake pedal is de-
pressed.
Also ensure that ignition key is removed from
key cylinder only when select lever is set to “P”
B1H0177B position.
2) Place the selector lever in each position,
and make sure that the pointer indicates the
Tightening torque:
position of each range correctly.
5.4 — 9.3 N.m
(0.55 — 0.95 kg-m, 4.0 — 6.9 ft-lb)
2) Hydraulic clutch type
Inspection of the clutch free play is not required.
3. CHECK THE OPERATION OF CLUTCH
AND GEAR SHIFTING
CAUTION:
D Be sure to perform this test in a safe area.
D Do not repeat this test.
1) With the engine idling and the shift lever in
neutral, gradually depress the clutch pedal, to G1H0059
see if it generates any abnormal noise.
NOTE: 5. OPERATION OF STARTER INTERLOCK
Carefully compare a normal clutch’s operating (MANUAL TRANSMISSION MODELS)
sounds to the clutch being tested.
Ensure that engine starts only when after clutch
2) Pull the parking brake lever completely out, pedal is depressed.
and place wheel chocks under the tires. Then
depress the clutch pedal completely, and place
the shift lever in 5th speed.
Raise engine rpm a little, gradually engage the
clutch, and see if the engine stalls.
If the engine stalls, it means that the clutch is not
slipping.
20
PRE-DELIVERY INSPECTION [G3D10] 1-4
3. Road Test Inspection
6. OPERATION OF STEERING AND POSI- 2) Depress the accelerator pedal, and make
TION OF STEERING WHEEL sure that the engine rpm increase smoothly and
1) Check the steering wheel for free play. that the vehicle accelerates smoothly.
3) While driving, turn the steering wheel right
Steering wheel free play: and left to test the vehicle’s stability and re-
0 — 17 mm (0 — 0.67 in) sponse.
CAUTION:
Be sure to perform this test in a safe area.
10. CHECK THE OPERATION OF THE
CRUISE CONTROL ACCORDING TO “OWN-
ER’S MANUAL”
CAUTION:
Be sure to conduct driving tests using a
chassis dynamometer with front wheels set
in operation, or tests on an authorized race
course or similar place.
B4M0133A
21
1-4 [G4A0] PRE-DELIVERY INSPECTION
4. Post-road Test Inspection
B1H0294A
22
PRE-DELIVERY INSPECTION [G4F0] 1-4
4. Post-road Test Inspection
23
1-4 [G4F0] PRE-DELIVERY INSPECTION
4. Post-road Test Inspection
24
1-5 [G100] PERIODIC MAINTENANCE SERVICES
1. Schedule of Inspection and Maintenance Services
R: Replace
I: Inspect, correct or replace if necessary.
P: Perform
(I) or (P): Recommended service for safe vehicle operation
2
PERIODIC MAINTENANCE SERVICES [G100] 1-5
1. Schedule of Inspection and Maintenance Services
NOTE:
1) When the vehicle is used under severe driving conditions such as those mentioned be-
low*, the engine oil and filter should be changed every 6,000 km (3,750 miles) or 3.5 months.
2) When the vehicle is used in extremely cold or hot weather areas, contamination of the
filter may occur and filter replacement should be performed more often.
3) When the vehicle is frequently operated under severe driving conditions, replacement
should be performed every 24,000 km (15,000 miles).
4) When the vehicle is frequently operated under severe driving conditions, such as moun-
tain driving replacement should be performed every 24,000 km (15,000 miles).
5) When the vehicle is used in high humidity areas or in mountainous areas, change the
brake fluid every 24,000 km (15,000 miles) or 15 months, whichever occurs first.
6) When the vehicle is used under severe driving conditions such as those mentioned be-
low*, inspection should be performed every 12,000 km (7,500 miles) or 7.5 months, whichev-
er occurs first.
7) This inspection is not required to maintain emission warranty eligibility and it does not
affect the manufacturer’s obligations under EPA’s in-use compliance program.
8) When the vehicle is used in extremely dusty conditions, the air cleaner element should
be replaced more often.
9) ATF filter is maintenance free part. ATF filter needs replacement, when it has physically
damaged or ATF leaked.
D * Examples of severe driving conditions:
D Repeated short distance driving. (Items 3, 12 and 13 only)
D Driving on rough and/or muddy roads. (Items 12, 13 and 16 only)
D Driving in dusty conditions.
D Driving in extremely cold weather. (Items 3 and 16 only)
D Driving in areas where roads salts or other corrosive materials are used. (Items 6, 12, 13, 14
and 16 only)
D Living in coastal areas. (Items 6, 12, 13, 14 and 16 only)
D Towing a trailer. (Items 3, 4, 9, 10, 12 and 13 only)
3
[G2A0] PERIODIC MAINTENANCE SERVICES
2. Drive Belt(s) [Except Camshaft] (Inspect drive belt tension)
A: INSPECTION B: REPLACEMENT
1) Replace belts, if cracks, fraying or wear is 1. V-BELT COVER
found. 1) Remove V-belt cover.
2) Check drive belt tension and adjust it if nec-
essary by changing generator installing posi-
tion and/or idler pulley installing position.
Belt tension
(A)
replaced: 7 — 9 mm (0.276 — 0.354 in)
reused: 9 — 11 mm (0.354 — 0.433 in)
(B)*
replaced: 7.5 — 8.5 mm
(0.295 — 0.335 in)
reused: 9.0 — 10.0 mm (0.354 — 0.394 in)
*: There is no belt (B) on models without an air conditioning. H1H0458
4
PERIODIC MAINTENANCE SERVICES [G2B3] 1-5
2. Drive Belt(s) [Except Camshaft] (Inspect drive belt tension)
H1H0459
B1H0310A
5
1-5 [G3A0] PERIODIC MAINTENANCE SERVICES
3. Camshaft Drive Belt (Timing Belt)
S1H0115A
B1H0121
4) Remove four bolts holding shroud to radia-
tor.
2) Disconnect radiator main fan motor connec-
tor and sub fan motor connector.
G1H0068
S1H0116A
6
PERIODIC MAINTENANCE SERVICES [G3A0] 1-5
3. Camshaft Drive Belt (Timing Belt)
B1H0296A
H1H0458
B1H0297A
7
1-5 [G3B0] PERIODIC MAINTENANCE SERVICES
3. Camshaft Drive Belt (Timing Belt)
B1H0298
B1H0300A
H1H0502
B: INSTALLATION
To install, reverse order of removal procedures.
<Ref. to 2-3 [W2C0].>
8
PERIODIC MAINTENANCE SERVICES [G4A0] 1-5
4. Engine Oil
4. Engine Oil
MAINTENANCE INTERVAL
[Number of months or km (miles), whichever occurs first]
Months 3 7.5 15 22.5 30 37.5 45 52.5 60 67.5 75 82.5 90 97.5 105 112.5 120
1,000
4.8 12 24 36 48 60 72 84 96 108 120 132 144 156 168 180 192
km
1,000
3 7.5 15 22.5 30 37.5 45 52.5 60 67.5 75 82.5 90 97.5 105 112.5 120
miles
R R R R R R R R R R R R R R R R R
G1H0397 B1H0118
3) Tighten engine oil drain plug after draining The proper viscosity helps car get good cold
engine oil. and hot starting by reducing viscous friction
Tightening torque: and thus increasing cranking speed.
9
[G4B0] PERIODIC MAINTENANCE SERVICES
4. Engine Oil
G1H0397
G1H0013
10
PERIODIC MAINTENANCE SERVICES [G5A0] 1-5
5. Engine Oil Filter
A: REPLACEMENT
1) Remove oil filter with ST.
ST 498547000 OIL FILTER WRENCH
G1H0072
11
[G6A1] PERIODIC MAINTENANCE SERVICES
6. Replace Engine Coolant and Inspect Cooling and Heating System, Hoses and Connections
A: REPLACEMENT
1. REPLACEMENT OF COOLANT
WARNING:
The radiator is of the pressurized type. Do
not attempt to open the radiator cap immedi-
ately after the engine has been stopped.
1) Lift up the vehicle.
2) Fit vinyle tube to drain pipe.
S1H0118A
12
PERIODIC MAINTENANCE SERVICES [G6A3] 1-5
6. Replace Engine Coolant and Inspect Cooling and Heating System, Hoses and Connections
er neck. Next, add coolant into reservoir tank up 3. PROCEDURE TO ADJUST THE CON-
to “FULL” level. CENTRATION OF THE COOLANT
13)Securely install radiator and reservoir tank To adjust the concentration of the coolant ac-
caps. cording to temperature, find the proper fluid
2. RELATIONSHIP OF SUBARU COOLANT concentration in the above diagram and re-
CONCENTRATION AND FREEZING TEM- place the necessary amount of coolant with an
PERATURE undiluted solution of SUBARU genuine coolant
The concentration and safe operating tempera- (concentration 50).
ture of the SUBARU coolant is shown in the dia- The amount of coolant that should be replaced
gram. Measuring the temperature and specific can be determined using the diagram.
gravity of the coolant will provide this informa- [Example]
tion. Assume that the coolant concentration must be
[Example] increased from 30% to 40%. Find point A, where
If the coolant temperature is 25°C (77°F) and its the 30% line of coolant concentration intersects
specific gravity is 1.054, the concentration is with the 40% curve of the necessary coolant
35% (point A), the safe operating temperature concentration, and read the scale on the verti-
is –14°C (7°F) (point B), and the freezing tem- cal axis of the graph at height A. The quantity of
perature is –20°C (–4°F) (point C). coolant to be drained is 3.0 liters (3.2 US qt, 2.6
Imp qt). Drain 3.0 liters (3.2 US qt, 2.6 Imp qt)
of coolant from the cooling system and add 3.0
liters (3.2 US qt, 2.6 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.
B1H0110A
M1H0065
13
[G6B0] PERIODIC MAINTENANCE SERVICES
6. Replace Engine Coolant and Inspect Cooling and Heating System, Hoses and Connections
G1H0079
14
PERIODIC MAINTENANCE SERVICES [G7A0] 1-5
7. Replace Fuel Filter and Inspect Fuel System, Lines and Connections
G1H0081
15
[G7B1] PERIODIC MAINTENANCE SERVICES
7. Replace Fuel Filter and Inspect Fuel System, Lines and Connections
G1H0081
B: INSPECTION
1. FUEL PIPING AND CONNECTIONS
Check fuel piping and connections for leakage,
scratches, swelling and corrosion.
16
PERIODIC MAINTENANCE SERVICES [G8A0] 1-5
8. Air Cleaner Element
A: REPLACEMENT
Do not attempt to clean the air cleaner element.
The filter paper of the element is wetted with a
special non-inflammable slow-evaporating vis-
cous liquid. It is resistant to cold weather and
has a long service life. Dirt adhering to this filter
paper forms porous laminations with the vis-
cous liquid, which function as a filtration layer to
reduce dust penetration into the filter paper. If
this filter paper is cleaned, the filtration layer
thus formed will be lost along with the viscous
liquid.
B1H0290
17
1-5 [G9A0] PERIODIC MAINTENANCE SERVICES
9. Spark Plugs
9. Spark Plugs
MAINTENANCE INTERVAL
[Number of months or km (miles), whichever occurs first]
Months 3 7.5 15 22.5 30 37.5 45 52.5 60 67.5 75 82.5 90 97.5 105 112.5 120
1,000
4.8 12 24 36 48 60 72 84 96 108 120 132 144 156 168 180 192
km
1,000
3 7.5 15 22.5 30 37.5 45 52.5 60 67.5 75 82.5 90 97.5 105 112.5 120
miles
R R R R
A: REPLACEMENT NOTE:
If torque wrench is not available, tighten spark
1) Remove intake duct and intake chamber.
plug until gasket contacts cylinder head; then
2) Remove washer tank and put it aside.
tighten further 1/4 to 1/2 turns.
3) Disconnect spark plug cord.
4) Remove spark plug with a plug-wrench.
B1H0291
18
PERIODIC MAINTENANCE SERVICES [G10A1] 1-5
10. Transmission/Differential (Front and rear) Lubricants (Gear oil)
10. Transmission/Differential
(Front and rear) Lubricants (Gear
oil)
MAINTENANCE INTERVAL
[Number of months or km (miles), whichever occurs first]
Months 3 7.5 15 22.5 30 37.5 45 52.5 60 67.5 75 82.5 90 97.5 105 112.5 120
1,000
4.8 12 24 36 48 60 72 84 96 108 120 132 144 156 168 180 192
km
1,000
3 7.5 15 22.5 30 37.5 45 52.5 60 67.5 75 82.5 90 97.5 105 112.5 120
miles
I I I
B1H0410A
G1H0088
19
1-5 [G11A1] PERIODIC MAINTENANCE SERVICES
11. Automatic Transmission Fluid
B1H0294A
B1H0295A
2. ATF FILTER
2) Reinstall drain plug after draining ATF, and
tighten it to the specified torque. NOTE:
ATF filter is maintenance free part. ATF filter
Tightening torque: needs replacement, when it has physically
25 ± 2 N.m (2.5 ± 0.2 kg-m, 18.1 ± 1.4 ft-lb) damaged or ATF leaked.
3) Fill ATF up to the middle of the “COLD” side
For the replacement procedures of the ATF fil-
on level gauge by using the gauge hole. ter, refer to “AUTOMATIC TRANSMISSION AND
Recommended fluid: DIFFERENTIAL” section. <Ref. to 3-2 [W600].>
Dexron II, IIE or Dexron III type automat-
ic transmission fluid
22
PERIODIC MAINTENANCE SERVICES [G12A0] 1-5
12. Brake Fluid
23
1-5 [G12A0] PERIODIC MAINTENANCE SERVICES
12. Brake Fluid
CAUTION:
Add brake fluid as necessary while perform-
ing the air bleed operation, in order to pre-
vent the tank from running short of brake
fluid.
9) After completing the bleeding operation,
hold brake pedal depressed and tighten screw
and install bleeder cap.
Tightening torque:
7 — 9 N.m (0.7 — 0.9 kg-m, 5.1 — 6.5 ft-lb)
10)Bleed air from each wheel cylinder using the
same procedures as described in the immedi-
ately preceding five steps.
11)Depress brake pedal with a force of approxi-
mately 294 N (30 kg, 66 lb) and hold it there for
approximately 20 seconds. At this time check
pedal to see if it makes any unusual movement.
Visually inspect bleeder screws and brake pipe
joints to make sure that there is no fluid leakage.
12)Install wheels, and drive car for a short dis-
tance between 2 to 3 km (1 to 2 miles) to make
sure that brakes are operating properly.
24
PERIODIC MAINTENANCE SERVICES [G13A1] 1-5
13. Disc Brake Pads and Discs/Front and Rear Axle Boots and Axle Shaft Joint Portions
A: INSPECTION
1. DISC BRAKE PAD AND DISC
1) Jack up vehicle and support with rigid
racks. Then remove wheels.
2) Visually check pad thickness through
inspection hole of disc brake assembly.
Replace pad if necessary.
H1H0464A
25
[G13A2] PERIODIC MAINTENANCE SERVICES
13. Disc Brake Pads and Discs/Front and Rear Axle Boots and Axle Shaft Joint Portions
CAUTION:
When replacing a pad, always replace the
pads for both the left and right wheels at the
same time. Also replace pad clips if they are
twisted or worn.
G1H0097
B1H0057A
G1H0099
26
PERIODIC MAINTENANCE SERVICES [G14A1] 1-5
14. Brake Linings and Drums
B1H0165
CAUTION:
D Always replace both leading and trailing G1H0101
brake shoes for the left and right wheels at
the same time.
D When either the left or the right brake
assembly is replaced, always replace the
leading shoe and trailing shoe of the other.
D The cotter pin, once removed, cannot be
reused.
27
[G14A2] PERIODIC MAINTENANCE SERVICES
14. Brake Linings and Drums
2. PARKING BRAKE (REAR DISC BRAKE) 4) When the shoe return spring tension is ex-
1) Inspect brake shoes for damage or de- cessively weakened, replace it, taking care to
formation and check brake linings for wear. identify upper and lower springs.
CAUTION: B: ADJUSTMENT
Always replace both primary and secondary
brake shoes for the left and right wheels at 1. REAR DRUM BRAKE
the same time. The main brake is adjusted automatically, and
so there is no need to adjust it.
Brake lining thickness excluding back metal
Standard value: 3.2 mm (0.126 in) 2. PARKING BRAKE (REAR DISC BRAKE)
Wear limit: 1.5 mm (0.059 in) 1) Remove rear cover (rubber) installed at
back plate.
2) Turn adjuster toward arrow mark (upward)
until it is locked slightly, by using slot-type
screwdriver as shown in illustration.
G1H0102
G1H0103
28
PERIODIC MAINTENANCE SERVICES [G15B1] 1-5
15. Inspect Brake Lines and Check Operation of Parking and Service Brake System
A: INSPECTION NOTE:
When the brake fluid level in the reservoir tank
1. BRAKE LINE
is lower than the specified limit, the brake fluid
1) Check scratches, swelling, corrosion and/or warning light on the combination meter will
traces of fluid leakage on brake hoses or pipe come on.
joints.
2) Check the possibility of adjacent parts inter- B: CHECKING
fering with brake pipes/hoses during driving,
and loose connections/clamps. 1. SERVICE BRAKE
3) Check any trace of fluid leakage, scratches, 1) Check the free play of brake pedal with a
etc. on master cylinder, wheel cylinder. force of less than 10 N (1 kg, 2 lb).
Brake pedal free play:
1 — 3 mm (0.04 — 0.12 in)
If the free play is out of specifications above,
adjust the brake pedal as follows:
(1) Be sure engine is off. (No vacuum is
applied to brake booster.)
(2) There should be play between brake
booster clevis and pin at brake pedal instal-
ling portion.
[Depress brake pedal pad with a force of
less than 10 N (1 kg, 2 lb) to a stroke of 1 to
G1H0009
3 mm (0.04 to 0.12 in).]
(3) Depress the surface of brake pad by
hand.
(4) If there is no free play between clevis
pin and clevis, turn brake switch adjusting
nut until the clearance between stopper and
screw of brake switch becomes 0.3 mm
(0.01 in).
G1H0010
29
[G15B2] PERIODIC MAINTENANCE SERVICES
15. Inspect Brake Lines and Check Operation of Parking and Service Brake System
G1H0104
B1H0030B
30
PERIODIC MAINTENANCE SERVICES [G15B3] 1-5
15. Inspect Brake Lines and Check Operation of Parking and Service Brake System
G1H0106
31
[G16A1] PERIODIC MAINTENANCE SERVICES
16. Clutch Operation
32
PERIODIC MAINTENANCE SERVICES [G16A2] 1-5
16. Clutch Operation
S1H0044A
B1H0178A
33
1-5 [G17A1] PERIODIC MAINTENANCE SERVICES
17. Steering and Suspension System
B4M0133A
34
PERIODIC MAINTENANCE SERVICES [G17A4] 1-5
17. Steering and Suspension System
3. GEARBOX
1) With wheels placed on a level surface, turn
steering wheel 90° in both the left and right
directions.
While wheel is being rotated, reach under
vehicle and check for looseness in gearbox.
Tightening torque:
47 — 71 N.m
(4.8 — 7.2 kg-m, 35 — 52 ft-lb)
G1H0110
35
1-5 [G17A5] PERIODIC MAINTENANCE SERVICES
17. Steering and Suspension System
3) Check lock nut on the tie-rod end for tight- 6. POWER STEERING FLUID FOR LEAKS
ness. If it is loose, retighten it to the specified Inspect the underside of oil pump and gearbox
torque. for power steering system, hoses, piping and
Tightening torque: their couplings for fluid leaks.
78 — 88 N.m (8 — 9 kg-m, 58 — 65 ft-lb) If fluid leaks are found, correct them by retigh-
tening their fitting bolts (or nuts) and/or replac-
5. POWER STEERING FLUID LEVEL
ing their parts.
1) Place vehicle with engine “off” on the flat
NOTE:
and level surface.
D Wipe the leakage fluid off after correcting
2) Check the fluid level by removing filler cap
fluid leaks, or a wrong diagnosis is taken later.
of oil pump.
D Also pay attention to clearances between
(1) Check at temperature 21°C (70°F) of
fluid temperature, read the fluid level on the hoses (or pipings) and other parts when
inspecting fluid leaks.
“COLD” side.
(2) Check at temperature 60°C (140°F) of 7. HOSES OF OIL PUMP FOR DAMAGES
fluid temperature, read the fluid level on the Check pressure hose and return hose of oil
“HOT” side. pump for crack, swell or damage. Replace
hose with new one if necessary.
NOTE:
Prevent hoses from revolving and/or turning
when installing hoses.
G1H0436
36
PERIODIC MAINTENANCE SERVICES [G17A11] 1-5
17. Steering and Suspension System
G1H0117
B1H0166
37
1-5 [G17A12] PERIODIC MAINTENANCE SERVICES
17. Steering and Suspension System
B1H0109A B1H0107A
B1H0108A
38
PERIODIC MAINTENANCE SERVICES [G17A18] 1-5
17. Steering and Suspension System
39
1-5 [G17A18] PERIODIC MAINTENANCE SERVICES
17. Steering and Suspension System
D Crossmember
D Strut
D Rear suspension
D Crossmember
D Lateral links
D Trailing link
D Strut
D 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 pre-
vention measure as required.
40
PERIODIC MAINTENANCE SERVICES [G18A2] 1-5
18. Front and Rear Wheel Bearing Lubricant
A: INSPECTION
1. FRONT WHEEL BEARING
NOTE:
Inspect the condition of front wheel bearing
grease.
1) Jack up the front of vehicle.
2) While holding front wheel by hand, swing it
in and out to check bearing free play.
3) Loosen wheel nuts and remove front wheel.
4) If bearing free play exists, attach a dial
B1H0062A
gauge to hub and measure axial displacement
in axial direction.
Service limit: 2. REAR WHEEL BEARING
Straight-ahead position within 0.05 mm NOTE:
(0.0020 in) Inspect the condition of rear wheel bearing
5) Remove bolts and self-locking nuts, and ex- grease.
tract transverse link from front crossmember. 1) Jack up the rear of vehicle.
6) While lightly hammering spring pin which 2) While holding rear wheel by hand, swing it
secures S.F.J. to transmission spindle, remove in and out to check bearing free play.
it. 3) Loosen wheel nuts and remove rear wheel.
7) Extract S.F.J. from transmission spindle. 4) If bearing free play exists in step 2) above,
<Ref. to 4-2 [W1A0].> attach a dial gauge to hub and measure axial
8) While supporting front drive shaft horizontal- displacement in axial direction.
ly with one hand, turn hub with the other to
check for noise or binding. Service limit:
If hub is noisy or binds, disassemble front axle Straight-ahead position within 0.05 mm
and check condition of oil seals, bearing, etc. (0.0020 in)
5) Turn hub by hand to check for noise or bind-
ing. If hub is noisy or binds, disassemble rear
axle and check condition of oil seals, bearings,
etc.
6) Remove bolts and self-locking nuts, and re-
move front lateral link from cross member.
41
1-5 [G18A2] PERIODIC MAINTENANCE SERVICES
18. Front and Rear Wheel Bearing Lubricant
B1H0064A
42
PERIODIC MAINTENANCE SERVICES [G19A0] 1-5
19. Supplemental Restraint System (Airbag)
A: INSPECTION
Check the airbag system in accordance with
the result of the self-diagnosis. <Refer to 5-5
[T4A0].>
1) Ensure that airbag connectors are con-
nected. If not, properly connect (also double
lock the connector). When the ignition switch is
turned ON with the connector(s) disconnected,
the airbag warning light blinks to identify the
fault.
2) Turn the ignition switch ON, and connect the
airbag diagnosis terminal of the service con-
nector (located below lower cover) to the
ground terminal.
3) The warning light blinks to indicate a trouble
code (a fault is identified). When the airbag sys-
tem is in good order (no trouble codes are
stored in the memory), the warning light blinks
on and off at 0.6 second intervals (as long as the
diagnosis terminal is connected to the ground
terminal).
4) When the warning light indicates a trouble
code, check the airbag system in accordance
with the troubleshooting procedure. <Ref. to
5-5 [T4A0].>
H1H0508
43
1-5 [G20A0] PERIODIC MAINTENANCE SERVICES
20. Valve Clearance
A: INSPECTION
For the inspection procedures of the valve clea-
race on SOHC models, refer to “ON-CAR SER-
VICE”. <Ref. to 2-2 [W800].>
44
[G100] SPECIAL TOOLS
1. Engine Tools
1. Engine Tools
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
498267800 CYLINDER HEAD Used for replacing valve guides.
TABLE Used for removing and installing valve
springs.
B1H0304
498457000 ENGINE STAND Used with ENGINE STAND (499817000).
ADAPTER RH
G1H0128
498457100 ENGINE STAND Used with ENGINE STAND (499817000).
ADAPTER LH
G1H0129
498497100 CRANKSHAFT Used for stopping rotation of flywheel when
STOPPER loosening and tightening crankshaft pulley bolt,
etc.
B1H0194
498747100 PISTON GUIDE Used for installing piston in cylinder.
For 2200 cc engine.
B1H0195
2
SPECIAL TOOLS [G100] 1-6
1. Engine Tools
B1H0195
498857100 VALVE OIL SEAL Used for press-fitting of intake and exhaust
GUIDE valve guide oil seals.
B1H0197
499017100 PISTON PIN GUIDE Used for installing piston pin, piston and
connecting rod.
B1H0198
499037100 CONNECTING ROD Used for removing and installing connecting rod
BUSHING REMOVER bushing.
& INSTALLER
B1H0199
499097700 PISTON PIN Used for removing piston pin.
REMOVER ASSY
B1H0200
3
[G100] SPECIAL TOOLS
1. Engine Tools
B1H0201
499207400 CAMSHAFT Used for removing and installing camshaft
SPROCKET sprocket (right side).
WRENCH
B1H0305
499587700 CAMSHAFT OIL Used for installing cylinder head plug.
SEAL INSTALLER
B1H0203
499587200 CRANKSHAFT OIL Used for installing crankshaft oil seal.
SEAL INSTALLER Used with CRANKSHAFT OIL SEAL GUIDE
(499597100).
B1H0204
499597000 CAMSHAFT OIL Used for installing camshaft oil seal.
SEAL GUIDE Used with CAMSHAFT OIL SEAL
INSTALLER (499587500).
H1H0494
4
SPECIAL TOOLS [G100] 1-6
1. Engine Tools
H1H0495
499718000 VALVE SPRING Used for removing and installing valve spring.
REMOVER
G1H0142
499767700 VALVE GUIDE Used for installing intake valve guides.
ADJUSTER
H1H0496
499767800 VALVE GUIDE Used for installing exhaust valve guides.
ADJUSTER
H1H0496
499767200 VALVE GUIDE Used for removing valve guides.
REMOVER
B1H0205
5
[G100] SPECIAL TOOLS
1. Engine Tools
B1H0206
499817000 ENGINE STAND Stand used for engine disassembly and
assembly.
Used with ENGINE STAND ADAPTER RH
(498457000) & LH (498457100).
G1H0146
499977300 CRANK PULLEY Used for stopping rotation of crankshaft
WRENCH pulley when loosening and tightening crank-
shaft pulley bolts.
For 2200 cc engine.
B1H0274
499987500 CRANKSHAFT Used for rotating crankshaft.
SOCKET
G1H0148
498547000 OIL FILTER WRENCH Used for removing and installing oil filter.
B1H0208
6
SPECIAL TOOLS [G100] 1-6
1. Engine Tools
B1H0207
499497000 TORX PLUS Used for removing and installing camshaft cap.
B1H0286
499587500 OIL SEAL INSTALLER Used for installing front camshaft oil seal.
B1H0203
7
1-6 [G200] SPECIAL TOOLS
2. Manual Transmission and Differential Tools
B1H0209
399411700 ACCENT BALL Used for installing reverse shifter rail arm.
INSTALLER
B1H0210
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)
B1H0135A
399780104 WEIGHT Used for measuring preload on roller bearing.
B1H0211
498077000 5TH DRIVEN GEAR Used for removing roller bearing of drive pinion
REMOVER shaft.
G1H0156
8
SPECIAL TOOLS [G200] 1-6
2. Manual Transmission and Differential Tools
G1H0157
498147000 DEPTH GAUGE Used for adjusting main shaft axial end play.
B1H0136
498247001 MAGNET BASE Used for measuring backlash between side
gear and pinion, and hypoid gear.
Used with DIAL GAUGE (498247100).
B1H0137
498247100 DIAL GAUGE Used for measuring backlash between side
gear and pinion, and hypoid gear.
Used with MAGNET BASE (498247001).
G1H0160
498427100 STOPPER Used for removing and installing drive pinion
shaft assembly lock nut.
B1H0213
9
1-6 [G200] SPECIAL TOOLS
2. Manual Transmission and Differential Tools
G1H0163
498937000 TRANSMISSION Used for removing and installing transmission
HOLDER main shaft lock nut.
G1H0164
499277100 BUSH 1-2 Used for installing 1st driven gear thrust plate
INSTALLER and 1st-2nd driven gear bush.
G1H0165
499277200 INSTALLER Used for press-fitting the 2nd driven gear, roller
bearings, & 5th driven gear onto the driven
shaft (AWD).
B1H0214
499747100 CLUTCH DISC GUIDE Used when installing clutch disc to flywheel.
G1H0167
10
SPECIAL TOOLS [G200] 1-6
2. Manual Transmission and Differential Tools
G1H0168
499787000 WRENCH ASSY Used for removing and installing differential side
retainer.
G1H0169
499827000 PRESS Used for installing speedometer oil seal.
G1H0171
499857000 5TH DRIVEN GEAR Used for removing 5th driven gear.
REMOVER
G1H0172
499877000 RACE 4-5 INSTALLER Used for installing 4th needle bearing race
and ball bearing onto transmission main
shaft.
Used with REMOVER (899714110).
G1H0173
11
1-6 [G200] SPECIAL TOOLS
2. Manual Transmission and Differential Tools
G1H0174
499927100 HANDLE Used for fitting transmission main shaft.
G1H0175
499937100 TRANSMISSION Stand used for transmission disassembly and
STAND assembly.
B1H0215
499987003 SOCKET WRENCH Used for removing and installing driven pinion
(35) lock nut and main shaft lock nut.
B1H0216
499987300 SOCKET WRENCH Used for removing and installing driven gear
(50) assembly lock nut.
G1H0178
12
SPECIAL TOOLS [G200] 1-6
2. Manual Transmission and Differential Tools
B1H0217
899864100 REMOVER Used for removing parts on transmission main
shaft and drive pinion.
B1H0218
899884100 HOLDER Used for tightening lock nut on sleeve.
B1H0219
899904100 REMOVER Used for removing and installing straight pin.
B1H0220
899988608 SOCKET WRENCH Used for removing and installing drive pinion
(27) lock nut.
B1H0216
13
1-6 [G200] SPECIAL TOOLS
2. Manual Transmission and Differential Tools
G1H0184
398497701 ADAPTER Used for installing roller bearing onto
differential case.
Used with INSTALLER (499277100).
B1H0222
499587000 INSTALLER Used for installing driven gears to driven shaft.
G1H0330
899824100 PRESS Used for installing speedometer shaft oil seal.
G1H0328
498517000 REPLACER Used for removing drive pinion thrust plate and
roller bearing race.
G1H0379
14
SPECIAL TOOLS [G200] 1-6
2. Manual Transmission and Differential Tools
B1H0074
899984103 SOCKET WRENCH Used for removing and installing drive pinion
(35) lock nut.
B1H0216
498497100 CRANKSHAFT Used for stopping rotation of flywheel when
STOPPER loosening tightening bolt, etc.
B1H0194
498057300 INSTALLER Used for installing extension oil seal.
G1H0188
498077400 SYNCHRONIZER Used for removing synchronizer cone of
CONE REMOVER main shaft.
For 2500 cc engine.
G1H0157
15
1-6 [G200] SPECIAL TOOLS
2. Manual Transmission and Differential Tools
B1H0285
16
SPECIAL TOOLS [G300] 1-6
3. Automatic Transmission and Differential Tools
B1H0138
498057300 INSTALLER Used for installing extension oil seal.
G1H0188
498077000 REMOVER Used for removing differential taper roller
bearing.
G1H0156
498575400 OIL PRESSURE Used for measuring oil pressure.
GAUGE ASSY
B1H0139
498897200 ADAPTER Used on oil pump housing when measuring re-
verse clutch pressure and line pressure.
G1H0194
17
1-6 [G300] SPECIAL TOOLS
3. Automatic Transmission and Differential Tools
B1H0227
499257300 GUIDE Used for installing transfer outer snap ring.
Used with INSTALLER (499247400).
B1H0228
499787000 WRENCH ASSY Used for removing and installing differential side
retainer.
G1H0169
398437700 DRIFT Used for installing converter case oil seal.
G1H0200
398497701 INSTALLER Used for installing converter case oil seal.
B1H0222
18
SPECIAL TOOLS [G300] 1-6
3. Automatic Transmission and Differential Tools
B1H0140
498255400 PLATE Used for measuring backlash of hypoid gear.
B1H0285
399893600 PLIER Used for removing and installing clutch spring.
B1H0142
498247001 MAGNET BASE Used for measuring gear backlash.
Used with DIAL GAUGE (498247100).
B1H0137
498247100 DIAL GAUGE Used for measuring gear backlash.
Used with MAGNET BASE (498247001).
G1H0160
19
1-6 [G300] SPECIAL TOOLS
3. Automatic Transmission and Differential Tools
G1H0379
398623600 SEAT Used for removing snapring of transfer clutch
piston.
B1H0231
499095500 REMOVER ASSY Used for removing axle shaft.
B1H0232
499247300 INSTALLER Used for removing axle shaft.
Used with REMOVER (499095500).
G1H0209
499267300 STOPPER PIN Used for installing inhibitor switch.
G1H0210
20
SPECIAL TOOLS [G300] 1-6
3. Automatic Transmission and Differential Tools
G1H0211
499787500 ADAPTER ASSY Used for removing and installing drive pinion
lock nut.
B1H0169
899524100 PULLER SET Used for removing reduction gear.
B1H0135B
498897700 ADAPTER SET Used with PRESSURE GAUGE.
G1H0214
398643600 GAUGE Used for measuring total end play, extention
end play and drive pinion hight.
B1H0233
21
1-6 [G300] SPECIAL TOOLS
3. Automatic Transmission and Differential Tools
B1H0234
499577000 GAUGE Used for measuring the transmission case
mating surface to the reduction gear end
surface.
B1H0068
498937110 HOLDER Used for removing and installing drive pinion
lock nut.
G1H0207
499737000 PULLER Used for removing driven gear assembly.
B1H0284
499737100 PULLER SET Used for removing reduction drive gear assem-
bly.
B1H0281
22
SPECIAL TOOLS [G300] 1-6
3. Automatic Transmission and Differential Tools
G1H0157
498677100 COMPRESSOR Used for installing 2-4 brake snap ring.
B1H0282
498437000 HIGH CLUTCH Used for installing high clutch piston.
PISTON GUIDE
B1H0283
498437100 LOW CLUTCH Used for installing low clutch piston.
PISTON GUIDE
B1H0283
498545400 FILTER WRENCH Used for removing and installing ATF filter.
B1H0289
23
1-6 [G400] SPECIAL TOOLS
4. Rear Differential Tools (AWD Models)
B1H0230
398477702 DRIFT Used for press-fitting the bearing cone of differ-
ential carrier (front).
B1H0235
398217700 ATTACHMENT SET Stand for rear differential carrier disassembly
and assembly.
B1H0143
498447120 DRIFT Used for installing front oil seal.
B1H0236
498427200 FLANGE WRENCH Used for stopping rotation of companion flange
when loosening and tightening self-lock nut.
G1H0222
24
SPECIAL TOOLS [G400] 1-6
4. Rear Differential Tools (AWD Models)
B1H0237
399780104 WEIGHT Used for installing front bearing cone, pilot
bearing, companion flange.
B1H0211
899580100 INSTALLER Used for press-fitting the front bearing cone,
pilot bearing.
B1H0238
899904100 STRAIGHT PIN Used for driving out differential pinion shaft lock
REMOVER pin.
B1H0220
498247001 MAGNET BASE Used for measuring backlash between side
gear and pinion, and hypoid gear.
Used with DIAL GAUGE (498247100).
B1H0137
25
1-6 [G400] SPECIAL TOOLS
4. Rear Differential Tools (AWD Models)
G1H0160
499705401 PULLER ASSY Used for removing oil seal and side bearing
cup.
B1H0138
28099PA090 OIL SEAL PROTEC- Used for installing rear drive shaft into rear
TOR differential.
For protecting oil seal.
G1H0303
398507704 BLOCK Used for adjusting pinion height and preload.
B1H0242
398177700 INSTALLER Used for installing rear bearing cone.
For T-type.
B1H0223
26
SPECIAL TOOLS [G400] 1-6
4. Rear Differential Tools (AWD Models)
B1H0239
398477703 DRIFT 2 Used for press-fitting the bearing race (rear)
of differential carrier.
For T-type.
B1H0235
398437700 DRIFT Used for installing said oil seal.
For T-type.
G1H0200
398507702 DUMMY SHAFT Used for adjusting pinion height and preload.
For T-type.
B1H0240
398507703 DUMMY COLLAR Used for adjusting pinion height and preload.
For T-type.
B1H0241
27
1-6 [G400] SPECIAL TOOLS
4. Rear Differential Tools (AWD Models)
G1H0379
398487700 DRIFT Used for press-fitting the side bearing cone.
For T-type.
B1H0224
398507701 GAUGE Used for adjusting pinion height.
For T-type.
B1H0156
399527700 PULLER SET Used for extracking side bearing cone.
(1) BOLT (899521412)
(2) PULLER (399527702)
(3) HOLDER (399527703)
(4) ADAPTER (398497701)
(5) BOLT (899520107)
(6) NUT (021008000)
For T-type.
B1H0135A
398227700 WEIGHT Used for installing side bearing.
Used with GAUGE (398237700).
For T-type.
B1H0243
28
SPECIAL TOOLS [G400] 1-6
4. Rear Differential Tools (AWD Models)
S1H0033
28099PA100 DRIVE SHAFT Used for removing rear drive shaft from rear
REMOVER differential.
For T-type.
G1H0338
498175500 INSTALLER Used for installing rear bearing cone.
For VA-type.
B1H0223
399780111 WRENCH ASSY Used for removing and installing side oil seal
holder.
For VA-type.
G1H0169
498447100 DRIFT Used for installing oil seal.
For VA-type.
G1H0200
29
1-6 [G400] SPECIAL TOOLS
4. Rear Differential Tools (AWD Models)
H1H0498
498485400 DRIFT Used for installing side bearing cone.
For VA-type.
B1H0224
498505501 GAUGE Used for adjusting pinion height.
For VA-type.
B1H0156
498447110 BEARING OUTER Used for press-fitting the bearing race (front)
RACE DRIFT of differential carrier.
For VA-type.
B1H0235
498447150 DUMMY SHAFT Used for adjusting pinion height and preload.
For VA-type.
B1H0193
30
SPECIAL TOOLS [G400] 1-6
4. Rear Differential Tools (AWD Models)
B1H0241
498515500 REPLACER Used for removing rear bearing cone.
For VA-type.
G1H0379
899524100 PULLER SET Used for removing side bearing cone.
For VA-type.
B1H0135B
899874100 INSTALLER Used for installing companion flange.
For VA-type.
H1H0497
499705404 SEAT Used for removing side bearing race.
Used with PULLEY ASSY (499705401).
For VA-type.
H1H0498
31
1-6 [G400] SPECIAL TOOLS
4. Rear Differential Tools (AWD Models)
B1H0138
32
SPECIAL TOOLS [G500] 1-6
5. Suspension Tools
5. Suspension Tools
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
927380000 ADAPTER Used as an adapter for camber & caster gauge
when measuring camber and caster.
(1) 28199AC000 PLATE
(2) 28199AC010 BOLT
B1H0144A
927680000 INSTALLER & Used for replacing transverse link bushing
REMOVER (Front).
B1H0244
927690000 INSTALLER & Used for replacing lateral link bushing (12 dia).
REMOVER
B1H0245
927700000 INSTALLER & Used for replacing lateral link bushing (14 dia).
REMOVER
B1H0245
927720000 INSTALLER & Used for replacing trailing link bushing.
REMOVER
B1H0246
33
[G500] SPECIAL TOOLS
5. Suspension Tools
B1H0245
927760000 STRUT MOUNT Used for disassembling and assembling strut
SOCKET mount.
B1H0247
34
SPECIAL TOOLS [G600] 1-6
6. Wheels and Axles Tools
B1H0145
925091000 BAND TIGHTENING Used for tightening boot band.
TOOL
B1H0146A
926470000 AXLE SHAFT Used for removing front axle shaft.
PULLER
H1H0503
927060000 HUB REMOVER Used for removing front hub.
Used with HUB STAND (927080000).
G1H0250
927100000 BEARING PULLER Used for disassembling and assembling
front housing bearing.
Used with HOUSING STAND (927400000).
G1H0252
35
[G600] SPECIAL TOOLS
6. Wheels and Axles Tools
B1H0249
927390000 ADAPTER Used as an adapter for AXLE SHAFT
INSTALLER (922431000).
B1H0250
927400000 HOUSING STAND Used for disassembling and assembling
front housing bearing.
Used with BEARING PULLER (927100000).
B1H0251
927410000 OIL SEAL INSTALLER Used for installing oil seal into front housing.
Used with HOUSING STAND (927400000).
G1H0256
927420000 HUB REMOVER Used for removing rear hub.
Used with HUB STAND (927080000).
B1H0252
36
SPECIAL TOOLS [G600] 1-6
6. Wheels and Axles Tools
B1H0251
927440000 BEARING REMOVER Used for disassembling and assembling rear
housing bearing.
Used with HOUSING STAND (927430000).
B1H0254
927120000 HUB INSTALLER Used for installing hub.
Used with HUB STAND (927080000).
B1H0255
927450000 HUB INSTALLER Used for pressing rear hub into housing
assembly.
Used with HUB STAND (927080000).
B1H0256
927460000 OIL SEAL INSTALLER Used for installing outer bearing and sub
bearing into housing.
Used with HOUSING STAND (927430000).
B1H0257
37
[G600] SPECIAL TOOLS
6. Wheels and Axles Tools
G1H0303
28099PA100 DRIVE SHAFT Used for removing rear drive shaft from rear
REMOVER differential.
G1H0338
927080000 HUB STAND Used for disassembling and assembling hub
bolt in hub.
Used for removing front and rear hub.
B1H0248
28099AC000 BOOT BAND PLIER Used for tightening boot band.
B1H0272
38
SPECIAL TOOLS [G700] 1-6
7. Steering System Tools
B1H0147
926200000 STAND Used when inspecting characteristic of gearbox
assembly and disassembling it.
Vise this tool and secure gearbox assembly
using gearbox clamp.
G1H0263
34099AC010 ADAPTER HOSE A Used with PRESSURE GAUGE (925711000).
B1H0172A
34099AC020 ADAPTER HOSE B Used with PRESSURE GAUGE (925711000).
B1H0185A
926230000 SPANNER For the lock nut when adjusting backlash of
gearbox.
Measurement of rotating resistance of gear-
box assembly.
G1H0265
39
[G700] SPECIAL TOOLS
7. Steering System Tools
B1H0261
926370000 INSTALLER A Used for installing valve assembly into valve
housing assembly.
Used with STAND BASE (927630000).
G1H0267
926390001 COVER & REMOVER Used for assembling rack assembly.
ASSY
H1H0476A
926400000 GUIDE Right side of rack when installing rack bush.
Used with GUIDE (927660000).
B1H0069
927660000 GUIDE Right side of rack when installing rack bush.
Used with GUIDE (926400000).
B1H0070
40
SPECIAL TOOLS [G700] 1-6
7. Steering System Tools
B1H0262
927630000 STAND BASE Used for assembling power steering gearbox.
G1H0273
926360000 INSTALLER A Used as a guide to install oil seal.
Used with INSTALLER B (927620000).
B1H0263
34099FA110 INSTALLER Used for installing oil seal.
G1H0275
927610000 INSTALLER Used for installing valve housing oil seal.
S1H0030
41
[G700] SPECIAL TOOLS
7. Steering System Tools
S1H0031
34199AE050 REMOVER OIL SEAL Used for removing oil seal.
S1H0054
34099AA000 INSTALLER Used for installing oil seal and shaft of oil pump.
B1H0259
34099AA020 INSTALLER Used for installing shaft of oil pump.
B1H0260
34099AC030 INSTALLER A Used for installing retaining ring.
Used with INSTALLER B (34099AC040).
H1H0513
42
SPECIAL TOOLS [G700] 1-6
7. Steering System Tools
H1H0514
43
1-6 [G800] SPECIAL TOOLS
8. Brake Tools
8. Brake Tools
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
926460000 WHEEL CYLINDER Used for installing cup onto wheel cylinder
3/4” ADAPTER piston (Size 3/4 in).
B1H0148
44
SPECIAL TOOLS [G900] 1-6
9. Body Tools
9. Body Tools
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
41099AA010 ENGINE SUPPORT Used for supporting engine.
BRACKET
B1H0264
41099AA020 ENGINE SUPPORT Used for supporting engine.
B1H0265
925580000 PULLER Used for removing trim clip.
B1H0266
925610000 WRENCH Used for adjusting door assembly.
B1H0267
927780000 REMOVER Used for removing and installing trunk torsion
bar.
B1H0268
45
1-6 [G900] SPECIAL TOOLS
9. Body Tools
H1H0492
46
SPECIAL TOOLS [G1000] 1-6
10. Supplemental Restraint System Tools
G1H0284
98299FC010 TEST HARNESS F Used for checking the supplemental restraint
system.
S1H0002
98299FA030 TEST HARNESS H Used for checking the supplemental restraint
system.
S1H0101
98299FC041 TEST HARNESS I 2 Used for checking the supplemental restraint
(Newly adopted system.
tool)
B1H0469
98299PA030 DEPLOYMENT TOOL Used for deploying the air bag module.
G1H0287
47
1-6 [G1000] SPECIAL TOOLS
10. Supplemental Restraint System Tools
G1H0389
98299FC030 ADAPTER A Used for deploying the air bag module.
(DEPLOYMENT) Used with DEPLOYMENT TOOL
(98299PA030).
S1H0028
48
SPECIAL TOOLS [G1100] 1-6
11. Select Monitor and Cartridge
S1H0070
22771AA020 SELECT MONITOR Troubleshooting for electrical systems.
KIT English: 22771AA020 (With printer)
22771AA030 (Without printer)
German: 22771AA040 (With printer)
22771AA070 (Without printer)
French: 22771AA050 (With printer)
22771AA080 (Without printer)
Spanish: 22771AA060 (With printer)
22771AA090 (Without printer)
S1H0027
49
EMISSION CONTROL SYSTEM
AND VACUUM FITTING 2-1
Page
W SERVICE PROCEDURE ...................................................................................2
1. Front Catalytic Converter ............................................................................2
2. Rear Catalytic Converter.............................................................................4
3. Canister .......................................................................................................5
4. Purge Control Solenoid Valve .....................................................................5
5. Fuel Temperature Sensor............................................................................7
6. Fuel Tank Pressure Sensor.........................................................................9
7. Pressure Control Solenoid Valve ..............................................................10
8. Main Fuel Level Sensor ............................................................................12
9. Air Filter .....................................................................................................13
10. Sub Fuel Level Sensor..............................................................................14
11. Vent Valve .................................................................................................15
12. Shut Valve .................................................................................................17
13. Drain Valve ................................................................................................18
2-1 [W1A0] SERVICE PROCEDURE
1. Front Catalytic Converter
B2M0055
B2M0054
B2M0014
B2M0313
B2M0312
2
SERVICE PROCEDURE [W1B0] 2-1
1. Front Catalytic Converter
9) Separate front and rear catalytic converter 3) Install front exhaust pipe to cylinder heads.
assembly from front exhaust pipe. Tightening torque:
30±5 N·m (3.1±0.5 kg-m, 22.4±3.6 ft-lb)
S2M0923
B2M0054
B2M0055
S2M0923
5) Tighten bolt which holds front and rear catalytic
2) Install front and rear catalytic converter assem- converter assembly to hanger bracket.
bly. Tightening torque:
Temporarily tighten bolt which installs center 35±5 N·m (3.6±0.5 kg-m, 26.0±3.6 ft-lb)
exhaust pipe to hanger bracket.
B2M0313
B2M0313
3
2-1 [W2A0] SERVICE PROCEDURE
2. Rear Catalytic Converter
B: INSTALLATION
Install rear catalytic converter. <Ref. to 2-1
[W1B0].>
B2M0312
B2M0014
S2M0922
G6M0095
4
SERVICE PROCEDURE [W4A0] 2-1
4. Purge Control Solenoid Valve
S2M0950
G6M0095
3) Remove canister from body.
2) Remove air cleaner case and air intake duct.
(2200 cc California spec. vehicles) <Ref. to 2-7
[W1A0].>
S2M0142
S2M0142
S2M0940
5
2-1 [W4A0] SERVICE PROCEDURE
4. Purge Control Solenoid Valve
S2M0055 B2M1893A
S2M0056
B2M2384B
6
SERVICE PROCEDURE [W5A0] 2-1
5. Fuel Temperature Sensor
5. Fuel Temperature Sensor 5) Move clips, and then disconnect fuel delivery
hose (A), return hose (B) and jet pump hose (C).
A: REMOVAL 6) Disconnect quick connector, and then discon-
nect fuel delivery hose (A). <Ref. to 2-8 [W7A0].>
1) Release fuel pressure. <Ref. to 2-8 [W1B0].>
2) Open fuel filler lid, and remove fuel filler cap.
S2M0060A
S2M0061
G6M0095
4) Disconnect connector from fuel pump. 8) Take off fuel pump assembly from fuel tank.
B2M0956
S2M0172
7
2-1 [W5B0] SERVICE PROCEDURE
5. Fuel Temperature Sensor
S2M0855
S2M0063A
NOTE:
Fuel temperature sensor is a unit with fuel pump.
If replacing it, replace as a fuel pump.
8
SERVICE PROCEDURE [W6A0] 2-1
6. Fuel Tank Pressure Sensor
S2M1153
H2M2535
B2M1774
S2M1152A
B2M1776
S2M0169A
9
2-1 [W7A0] SERVICE PROCEDURE
7. Pressure Control Solenoid Valve
10) Move clip, and disconnect pressure hose from 7. Pressure Control Solenoid
fuel tank.
Valve
A: REMOVAL AND INSTALLATION
1) Disconnect battery ground cable.
B2M1778
B2M1779
B2M1776
S2M0876A
10
SERVICE PROCEDURE [W7A0] 2-1
7. Pressure Control Solenoid Valve
4) Remove bolt which installs pressure control 9) Disconnect vacuum hose from pressure control
solenoid valve holding bracket on body. solenoid valve.
H2M2530 B2M1785
5) Disconnect connector from pressure control 10) Installation is in the reverse order of removal.
solenoid valve. Tightening torque:
17.6±5 N·m (1.8±0.5 kg-m, 13.0±3.6 ft-lb)
B2M1782
B2M1783
B2M1786
11
2-1 [W8A0] SERVICE PROCEDURE
8. Main Fuel Level Sensor
8. Main Fuel Level Sensor 5) Move clips, and then disconnect fuel delivery
hose (A), return hose (B) and jet pump hose (C).
A: REMOVAL 6) Disconnect quick connector, and then discon-
nect fuel delivery hose (A). <Ref. to 2-8 [W7A0].>
1) Release fuel pressure. <Ref. to 2-8 [W1B0].>
2) Open fuel flap lid, and remove fuel filler cap.
S2M0060A
S2M0061
G6M0095
8) Take off fuel pump assembly from fuel tank.
4) Disconnect connector from fuel pump. 9) Disconnect connector from fuel pump bracket.
S2M0172 S2M0145
H2M3206
12
SERVICE PROCEDURE [W9A0] 2-1
9. Air Filter
G6M0095
H2M3206
S2M0063A
B2M1788
S2M0876A
13
2-1 [W10A0] SERVICE PROCEDURE
10. Sub Fuel Level Sensor
6) Remove nut which installs air filter and drain 10. Sub Fuel Level Sensor
valve brackets on body, and remove them as a
unit. A: REMOVAL AND INSTALLATION
1) Release fuel pressure. <Ref. to 2-8 [W1B0].>
2) Open fuel flap lid, and remove fuel filler cap.
B2M1790
B2M1791A
G2M0863
B2M1790
S2M0151
14
SERVICE PROCEDURE [W11A0] 2-1
11. Vent Valve
6) Remove bolts which install sub fuel level sensor 11. Vent Valve
on fuel tank.
A: REMOVAL AND INSTALLATION
1) Release fuel pressure. <Ref. to 2-8 [W1B0].>
2) Open fuel flap lid, and remove fuel filer cap.
S2M0152
H2M2535
S2M0153
S2M0152A
G2M0345
S2M0169A
15
2-1 [W11A0] SERVICE PROCEDURE
11. Vent Valve
S2M1153
B2M1794A
S2M1154
S2M1155
16
SERVICE PROCEDURE [W12A0] 2-1
12. Shut Valve
B2M1796
H2M2535
B2M1797
B2M1797
G6M0095
B2M1756
17
2-1 [W13A0] SERVICE PROCEDURE
13. Drain Valve
13. Drain Valve 6) Remove bolt which installs air filter and drain
valve brackets on body.
A: REMOVAL AND INSTALLATION
1) Disconnect battery ground cable.
B2M1790
B2M1799
B2M1780
8) Installation is in the reverse order of removal.
Tightening torque:
4) Disconnect connector from drain valve.
22.5±7 N·m (2.3±0.7 kg-m, 16.6±5.1 ft-lb)
B2M1788
B2M1790
5) Disconnect evaporation hoses from drain valve.
B2M1798A
18
ON-CAR SERVICES 2-2
Page
W SERVICE PROCEDURE ...................................................................................2
1. Foreword .....................................................................................................2
2. Ignition Timing .............................................................................................2
3. Engine Idle Speed.......................................................................................3
4. Engine Compression ...................................................................................4
5. Intake Manifold Vacuum..............................................................................5
6. Engine Oil Pressure ....................................................................................5
7. Valve Clearance ..........................................................................................7
2-2 [W100] SERVICE PROCEDURE
1. Foreword
S2M0239
2
SERVICE PROCEDURE [W3A0] 2-2
3. Engine Idle Speed
3. Engine Idle Speed (8) Start the engine, and read engine idle
speed.
A: MEASUREMENT
1) Before checking idle speed, check the follow-
ing:
(1) Ensure that air cleaner element is free from
clogging, ignition timing is correct, spark plugs
are in good condition, and that hoses are con-
nected properly.
(2) Ensure that malfunction indicator light
(CHECK ENGINE light) does not illuminate.
2) Warm-up the engine.
S2M0098
3) Stop the engine, and turn ignition switch to
OFF. 5) When using tachometer (Secondary pick-up
4) When using SUBARU SELECT MONITOR; type).
(1) Attach the pick-up clip to No. 1 cylinder
NOTE:
spark plug cord.
For detailed operation procedures, refer to the
(2) Start the engine, and read engine idle
SUBARU SELECT MONITOR OPERATION speed.
MANUAL.
NOTE:
(1) Insert the cartridge to SUBARU SELECT I When using the OBD-II general scan tool, care-
MONITOR. <Ref. to 1-6 [G1100].> fully read its operation manual.
I This ignition system provides simultaneous igni-
tion for #1 and #2 plugs. It must be noted that
some tachometers may register twice that of actual
engine speed.
S2M0286A
3
2-2 [W4A0] SERVICE PROCEDURE
4. Engine Compression
S2M0539
4
SERVICE PROCEDURE [W6A0] 2-2
6. Engine Oil Pressure
5. Intake Manifold Vacuum 3) Keep the engine at the idle speed and read the
vacuum gauge indication.
A: MEASUREMENT By observing the gauge needle movement, the
internal condition of the engine can be diagnosed
1) Warm-up the engine. as described below.
2) Disconnect the brake vacuum hose and install
the vacuum gauge to the hose fitting on the mani- Vacuum pressure (at idling, A/C “OFF”):
fold. Less than −60.0 kPa (−450 mmHg, −17.72
inHg)
S2M0945A
H6M0402
G6M0095
5
2-2 [W6A0] SERVICE PROCEDURE
6. Engine Oil Pressure
(2) Remove V-belt cover 5) Connect oil pressure gauge hose to cylinder
block.
6) Connect battery ground cable.
B2M0017
(3) Loosen lock bolt and slider bolt, and remove G6M0095
front side V-belt.
7) Start the engine, and measure oil pressure.
G2M0286
S2M0242
(4) Remove generator lock bolt.
(5) Remove bolt which install generator on Oil pressure:
bracket. 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:
I If oil pressure is out of specification, check
oil pump, oil filter and lubrication line. <Ref. to
2-4 ENGINE LUBRICATION SYSTEM.>
I If oil pressure warning light is turned ON and
oil pressure is in specification, replace oil pres-
sure switch. <Ref. to 2-4 ENGINE LUBRICA-
H2M1499 TION SYSTEM.>
NOTE:
3) Disconnect connector from oil pressure switch.
The specified data is based on an engine oil tem-
4) Remove oil pressure switch from engine cylin- perature of 80°C (176°F).
der block. <Ref. to 2-4 [W3A0].>
8) After measuring oil pressure, install oil pressure
switch. <Ref. to 2-4 [W3B0].>
Tightening torque:
25±3 N·m (2.5±0.3 kg-m, 18.1±2.2 ft-lb)
9) Install generator and V-belt in the reverse order
of removal, and adjust the V-belt deflection. <Ref.
to 1-5 [G2A0].>
G2M0091
6
SERVICE PROCEDURE [W7A0] 2-2
7. Valve Clearance
B2M2012
G6M0095
B2M2013
S2M0931
B2M2018
B2M2031
B2M2019
7
2-2 [W7A0] SERVICE PROCEDURE
7. Valve Clearance
(5) Remove clips of air cleaner upper cover (10) Disconnect blow-by hose from rocker
(Except 2200 cc California spec. vehicles). cover (RH).
(6) Remove air intake duct and air cleaner
upper cover as a unit (Except 2200 cc Califor-
nia spec. vehicles).
B2M2015
B2M2016
S2M0179
(16) Remove rocker cover bolts, then remove
rocker cover (RH).
(9) Disconnect spark plug cords from spark
plugs (#1 and #3 cylinders).
B2M2017
B2M2014
7) When inspecting #2 and #4 cylinders:
(1) Disconnect battery cables, and then
remove battery and battery carrier.
8
SERVICE PROCEDURE [W7A0] 2-2
7. Valve Clearance
(2) Disconnect front window washer motor con- (7) Disconnect blow-by hose form rocker cover
nector. (LH).
(3) Disconnect rear gate glass washer motor
connector. (Wagon only)
B2M2025
S2M0546
(8) Lift-up the vehicle.
(9) Remove under cover (LH).
(4) Disconnect rear gate glass washer hose (10) Place suitable container under the vehicle.
from washer motor, then plug connection with a (11) Remove rocker cover bolts, then remove
suitable cap. (Wagon only) rocker cover (LH).
(5) Remove the two bolts which hold washer
tank, then secure the tank away from working
area.
B2M2026
B2M2024
B2M2027A
9
2-2 [W7B0] SERVICE PROCEDURE
7. Valve Clearance
9) Measure #1 cylinder valve clearance by using 1) Set #1 cylinder piston to top dead center of
thickness gauge. compression stroke by rotating crankshaft pulley
CAUTION: clockwise.
I Insert the thickness gauge in at as horizon- NOTE:
tal a direction as a possible with respect to the When arrow mark on camshaft sprocket (LH)
valve stem end face. comes exactly to the top, #1 cylinder piston is
I Measure exhaust valve clearances while lift- brought to the top dead center of the compression
ing-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)
B2M2027A
B2M2029A
10
SERVICE PROCEDURE [W7B0] 2-2
7. Valve Clearance
4) Turn crankshaft two complete rotations until #1 6) Similar to adjustment procedures used for #1
cylinder piston is again set to top dead center on cylinder, adjust #2, #3 and #4 cylinder valve clear-
compression stroke. ances.
5) Ensure that valve clearances are within speci- NOTE:
fications. If necessary, re-adjust valve clearances. I Be sure to set cylinder pistons to their respective
top dead centers on the compression stroke before
adjusting valve clearances.
I To set #3, #2 and #4 cylinder pistons to their top
dead centers on the compression stroke, turn
crankshaft pulley clockwise 90° at a time starting
with arrow mark on left-hand camshaft sprocket
facing up.
B2M2029A
11
2-2 SERVICE PROCEDURE
MEMO:
12
ENGINE 2-3
Page
S SPECIFICATIONS AND SERVICE DATA..........................................................2
1. Specifications ..............................................................................................2
2. Service Data................................................................................................3
C COMPONENT PARTS .......................................................................................7
1. Timing Belt ..................................................................................................7
2. Cylinder Head and Camshaft......................................................................8
3. Cylinder Head and Valve Assembly............................................................9
4. Cylinder Block ...........................................................................................10
5. Crankshaft and Piston ...............................................................................11
6. Valve Rocker Assembly.............................................................................12
W SERVICE PROCEDURE .................................................................................13
1. General Precautions..................................................................................13
2. Timing Belt ................................................................................................14
3. Valve Rocker Assembly.............................................................................29
4. Camshaft ...................................................................................................34
5. Cylinder Head............................................................................................42
6. Cylinder Block ...........................................................................................53
K DIAGNOSTICS.................................................................................................76
1. Engine Trouble in General ........................................................................76
2. Engine Noise .............................................................................................83
2-3 [S100] SPECIFICATIONS AND SERVICE DATA
1. Specifications
1. Specifications
Model 2200 cc 2500 cc
Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke gaso-
Type
line engine
Valve arrangement Belt driven, single over-head camshaft, 4-valve/cylinder
Bore x Stroke mm (in) 96.9 × 75.0 (3.815 × 2.953) 99.5 × 79.0 (3.917 × 3.110)
Displacement cm3 (cu in) 2,212 (135) 2,457 (150)
Compression ratio 9.7
Compression pres-
sure (at 200 — 300 kPa (kg/cm2, psi) 1,079 — 1,275 (11.0 — 13.0, 156 — 185)
rpm)
Number of piston rings Pressure ring: 2, Oil ring: 1
Engine
Opening 2° BTDC 1° BTDC
Intake valve timing
Closing 50° ABDC 51° ABDC
Opening 46° BBDC 50° BBDC
Exhaust valve timing
Closing 6° 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±50 (A/C switch ON)
AT]
Firing order 1→3→2→4
Ignition timing BTDC/rpm 14°±8°/700 (MT), 20°±8°/700 (AT)
2
SPECIFICATIONS AND SERVICE DATA [S200] 2-3
2. Service Data
2. Service Data
NOTE:
STD: Standard, I.D.: Inner Diameter, O.D.: Outer Diameter, OS: Oversize, US: Undersize
Belt
ten-
Protrusion of adjuster rod 5.2 — 6.2 mm (0.205 — 0.244 in)
sioner
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)
ten- Clearance between spacer and bush
sioner 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)
Valve STD 0.020 — 0.054 mm (0.0008 — 0.0021 in)
rocker Clearance between shaft and arm
arm Limit 0.10 mm (0.0039 in)
Bend limit 0.020 mm (0.0008 in)
STD 0.030 — 0.090 mm (0.0012 — 0.0035 in)
Thrust clearance
Limit 0.11 mm (0.0043 in)
STD 38.732 — 38.832 mm (1.5249 — 1.5288 in)
Intake
Limit 38.632 mm (1.5209 in)
Cam lobe height (2200 cc)
STD 39.257 — 39.357 mm (1.5455 — 1.5495 in)
Exhaust
Limit 39.157 mm (1.5416 in)
Cam-
STD 39.485 — 39.585 mm (1.5545 — 1.5585 in)
shaft Intake
Limit 39.385 mm (1.5506 in)
Cam lobe height (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 0.118 mm (0.0046 in)
Surface warpage limit 0.05 mm (0.0020 in)
Cylinder
Surface grinding limit 0.3 mm (0.012 in)
head
Standard height 127.5 mm (5.02 in)
Refacing angle 90°
STD 1.0 mm (0.039 in)
Valve Intake
Limit 1.7 mm (0.067 in)
set 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
Intake 20.0 — 20.5 mm (0.787 — 0.807 in)
guide Protrusion above head
Exhaust 16.5 — 17.0 mm (0.650 — 0.669 in)
3
2-3 [S200] SPECIFICATIONS AND SERVICE DATA
2. Service Data
4
SPECIFICATIONS AND SERVICE DATA [S200] 2-3
2. Service Data
5
2-3 [S200] SPECIFICATIONS AND SERVICE DATA
2. Service Data
6
COMPONENT PARTS [C100] 2-3
1. Timing Belt
1. Timing Belt
H2M2924A
(1) Belt cover No. 2 (RH) (9) Belt idler (No. 2) Tightening torque: N·m (kg-m, ft-lb)
(2) Timing belt guide (MT vehicles (10) Automatic belt tension adjuster
T1: 5±1 (0.5±0.1, 3.6±0.7)
only) ASSY
T2: 9.8±1.0 (1.0±0.1, 7.2±0.7)
(3) Crankshaft sprocket (Except (11) Belt idler No. 2
T3: 25±3 (2.5±0.3, 18.1±2.2)
2200 cc California spec. (12) Camshaft sprocket No. 2
vehicles) (13) Timing belt T4: 39±4 (4.0±0.4, 28.9±2.9)
(4) Crankshaft sprocket (2200 cc (14) Front belt cover T5: 78±5 (8.0±0.5, 57.9±3.6)
California spec. vehicles) (15) Belt cover (LH) T6: 127±5 (13.0±0.5, 94±3.6)
(5) Belt cover No. 2 (LH) (16) Crankshaft pulley (2200 cc T7: 177±5 (18.0±0.5, 130.2±3.6)
(6) Camshaft sprocket No. 1 model)
(7) Belt idler (No. 1) (17) Crankshaft pulley (2500 cc
(8) Tensioner bracket model)
7
2-3 [C200] COMPONENT PARTS
2. Cylinder Head and Camshaft
B2M1954A
(1) Rocker cover (RH) (10) Cylinder head gasket (19) Stud bolt
(2) Intake valve rocker ASSY (11) Cylinder head (LH)
(3) Exhaust valve rocker ASSY (12) Camshaft (LH) Tightening torque: N·m (kg-m, ft-lb)
(4) Camshaft cap (RH) (13) Camshaft cap (LH) T1: <Ref. to 2-3 [W5E1].>
(5) Oil seal (14) Oil filler cap T2: 5±1 (0.5±0.1, 3.6±0.7)
(6) Camshaft (RH) (15) Gasket T3: 10±2 (1.0±0.2, 7.2±1.4)
(7) Plug (16) Oil filler pipe T4: 18±2 (1.8±0.2, 13.0±1.4)
(8) Spark plug pipe gasket (17) O-ring T5: 25±2 (2.5±0.2, 18.1±1.4)
(9) Cylinder head (RH) (18) Rocker cover (LH)
8
COMPONENT PARTS [C300] 2-3
3. Cylinder Head and Valve Assembly
B2M1955A
(1) Exhaust valve (5) Intake valve oil seal (9) Exhaust valve guide
(2) Intake valve (6) Valve spring (10) Exhaust valve spring seat
(3) Intake valve guide (7) Retainer (11) Exhaust valve oil seal
(4) Intake valve spring seat (8) Retainer key
9
2-3 [C400] COMPONENT PARTS
4. Cylinder Block
4. Cylinder Block
B2M1957A
(1) Oil pressure switch (12) Cylinder block (LH) Tightening torque: N·m (kg-m, ft-lb)
(2) Cylinder block (RH) (13) Water pump
T1: 5 (0.5, 3.6)
(3) Service hole plug (14) Baffle plate
T2: 6.4 (0.65, 4.7)
(4) Gasket (15) Oil filter connector
T3: 10 (1.0, 7)
(5) Oil separator cover (16) Oil strainer
(6) Water by-pass pipe (17) Gasket T4: 25±2 (2.5±0.2, 18.1±1.4)
(7) Oil pump (18) Oil pan T5: 47±3 (4.8±0.3, 34.7±2.2)
(8) Front oil seal (19) Drain plug T6: 69±7 (7.0±0.7, 50.6±5.1)
(9) Rear oil seal (20) Metal gasket T7: First 12±2 (1.2±0.2, 8.7±1.4)
(10) O-ring (21) Oil level gauge guide Second 12±2 (1.2±0.2,
(11) Service hole cover 8.7±1.4)
10
COMPONENT PARTS [C500] 2-3
5. Crankshaft and Piston
B2M1958A
(1) Flywheel (MT) (9) Piston pin (17) Crankshaft bearing #1, #3
(2) Ball bearing (MT) (10) Circlip (18) Crankshaft bearing #2, #4
(3) Reinforcement (AT) (11) Connecting rod bolt (19) Crankshaft bearing #5
(4) Drive plate (AT) (12) Connecting rod
(5) Top ring (13) Connecting rod bearing Tightening torque: N·m (kg-m, ft-lb)
(6) Second ring (14) Connecting rod cap T1: 44±2 (4.5±0.2, 32.5±1.4)
(7) Oil ring (15) Crankshaft T2: 72±3 (7.3±0.3, 52.8±2.2)
(8) Piston (16) Woodruff key
11
2-3 [C600] COMPONENT PARTS
6. Valve Rocker Assembly
B2M1956A
(1) Intake valve rocker arm (6) Intake rocker shaft Tightening torque: N·m (kg-m, ft-lb)
(2) Valve rocker nut (7) Exhaust rocker shaft
T1: 5±1 (0.5±0.1, 3.6±0.7)
(3) Valve rocker adjust screw (8) Exhaust valve rocker arm
T2: 10±1 (1.0±0.1, 7.2±0.7)
(4) Spring
T3: 25±2 (2.5±0.2, 18.1±1.4)
(5) Rocker shaft support
12
SERVICE PROCEDURE [W1A0] 2-3
1. General Precautions
B2M2582A
13
2-3 [W2A1] SERVICE PROCEDURE
2. Timing Belt
2. Timing Belt
A: REMOVAL
1. CRANKSHAFT PULLEY AND BELT
COVER
H2M2925A
(1) Front side V-belt (4) Crankshaft Pulley (2200 cc (6) Belt cover (LH)
(2) Rear side V-belt (With A/C model) (7) Front belt cover (2500 cc model)
model) (5) Crankshaft pulley (2500 cc
(3) Crankshaft pulley bolt model)
B2M2584
B2M2585
14
SERVICE PROCEDURE [W2A2] 2-3
2. Timing Belt
B2M2587A
B2M2586B
H2M2393B
2. TIMING BELT
B2M2588B
15
2-3 [W2A2] SERVICE PROCEDURE
2. Timing Belt
1) Remove timing belt guide. (MT vehicles only) 2) If alignment mark (a) and/or arrow mark (which
indicates rotation direction) on timing belt fade
away, put new marks before removing timing belt
as shown in figure:
S2M0294
B2M2589A
B2M2590A
16
SERVICE PROCEDURE [W2A3] 2-3
2. Timing Belt
(2) Using white paint, put alignment and/or 3) Remove belt idler (No. 2).
arrow marks on timing belts in relation to the 4) Remove belt idler No. 2.
sprockets.
B2M2593
B2M2591
5) Remove timing belt.
Specified data:
Z1: 44 tooth length
Z2: 40.5 tooth
B2M2594
B2M2592A
B2M2595B
17
2-3 [W2A4] SERVICE PROCEDURE
2. Timing Belt
1) Remove belt idler (No. 1). 2) Remove automatic belt tension adjuster assem-
bly.
B2M2596
H2M2375
H2M2926A
1) Remove camshaft sprocket No. 2. To lock 2) Remove camshaft sprocket No. 1. To lock
camshaft, use ST. camshaft, use ST.
ST 499207100 CAMSHAFT SPROCKET ST 499207400 CAMSHAFT SPROCKET
WRENCH WRENCH
H2M2377A B2M2599A
18
SERVICE PROCEDURE [W2B2] 2-3
2. Timing Belt
S2M0414B
19
2-3 [W2B3] SERVICE PROCEDURE
2. Timing Belt
H2M2381A
20
SERVICE PROCEDURE [W2C1] 2-3
2. Timing Belt
C: INSTALLATION
1. CAMSHAFT AND CRANKSHAFT
SPROCKET
H2M2926B
(1) Tensioner bracket (5) Camshaft sprocket No. 1 Tightening torque: N·m (kg-m, ft-lb)
(2) Belt cover No. 2 (RH) (6) Camshaft sprocket No. 2
T1: 5±1 (0.5±0.1, 3.6±0.7)
(3) Belt cover No. 2 (LH)
T2: 25±3 (2.5±0.3, 18.1±2.2)
(4) Crankshaft sprocket
T3: 78±5 (8.0±0.5, 57.9±3.6)
H2M2380 B2M2600B
S2M0414B
B2M2601
21
2-3 [W2C1] SERVICE PROCEDURE
2. Timing Belt
B2M2599A
H2M2377A
22
SERVICE PROCEDURE [W2C2] 2-3
2. Timing Belt
B2M2595A
(1) Automatic belt tension adjuster (2) Belt idler (No. 1) Tightening torque: N·m (kg-m, ft-lb)
ASSY
T: 39±4 (4.0±0.4, 28.9±2.9)
1) Preparation for installation of automatic belt (2) Slowly move the adjuster rod down with a
tension adjuster assembly; pressure of 294 N (30 kg, 66 lb) until the
CAUTION: adjuster rod is aligned with the stopper pin hole
I Always use a vertical type pressing tool to in the cylinder.
move the adjuster rod down.
I Do not use a lateral type vise.
I Push adjuster rod vertically.
I Be sure to slowly move the adjuster rod
down applying a pressure of 294 N (30 kg, 66
lb).
I Press-in the push adjuster rod gradually tak-
ing more than three minutes.
I Do not allow press pressure to exceed 9,807
N (1,000 kg, 2,205 lb).
I Press the adjuster rod as far as the end sur- H2M2382
face of the cylinder. Do not press the adjuster (3) With a 2 mm (0.08 in) dia. stopper pin or a
rod into the cylinder. Doing so may damage the 2 mm (0.08 in) (nominal) dia. hex bar wrench
cylinder. inserted into the stopper pin hole in the cylinder,
I Do not release press pressure until stopper secure the adjuster rod.
pin is completely inserted.
(1) Attach the automatic belt tension adjuster
assembly to the vertical pressing tool.
H2M2383A
23
2-3 [W2C2] SERVICE PROCEDURE
2. Timing Belt
H2M2384
B2M2596
24
SERVICE PROCEDURE [W2C3] 2-3
2. Timing Belt
3. TIMING BELT
B2M2588A
(a) Alignment mark (4) Timing belt guide (MT vehicles Tightening torque: N·m (kg-m, ft-lb)
(1) Timing belt only)
T1: 9.8±1.0 (1.0±0.1, 7.2±0.7)
(2) Belt idler No. 2
T2: 39±4 (4.0±0.4, 28.9±2.9)
(3) Belt idler (No. 2)
B2M2603A
B2M2602A
25
2-3 [W2C3] SERVICE PROCEDURE
2. Timing Belt
3) Install belt idler (No. 2). (2) Check and adjust clearance between timing
belt and timing belt guide.
Clearance:
1.0±0.5 mm (0.039±0.020 in)
B2M2593
H2M2415
H2M2387A
S2M0294
26
SERVICE PROCEDURE [W2C4] 2-3
2. Timing Belt
H2M2925B
(1) Front belt cover (5) Crankshaft pulley bolt Tightening torque: N·m (kg-m, ft-lb)
(2) Belt cover (LH) (6) Rear side V-belt (With A/C
T1: 5±1 (0.5±0.1, 3.6±0.7)
(3) Crankshaft pulley (2200 cc model)
T2: 127±5 (13.0±0.5, 94±3.6)
model) (7) Front side V-belt
T3: 177±5 (18.0±0.5, 130.2±3.6)
(4) Crankshaft pulley (2500 cc
model)
B2M2586A
27
2-3 [W2C4] SERVICE PROCEDURE
2. Timing Belt
H2M2393A
28
SERVICE PROCEDURE [W3A0] 2-3
3. Valve Rocker Assembly
B2M2604A
1) Disconnect PCV hose and remove rocker (2) Equally loosen bolts (e) through (h) all the
cover. way, being careful that knock pin is not gouged.
2) Removal of valve rocker assembly
(1) Remove bolts (a) through (b) in alphabetical
sequence.
CAUTION:
Leave two or three threads of bolt (a) engaged
to retain valve rocker assembly.
B2M2605A
B2M2605A
B2M2606
29
2-3 [W3B0] SERVICE PROCEDURE
3. Valve Rocker Assembly
B: DISASSEMBLY
B2M2607A
(1) Bolt (4) Intake valve rocker arm (7) Exhaust valve rocker arm
(2) Intake valve rocker shaft (5) Spring (8) Valve rocker nut
(3) Rocker shaft support (6) Exhaust valve rocker shaft (9) Valve rocker adjust screw
30
SERVICE PROCEDURE [W3C2] 2-3
3. Valve Rocker Assembly
B2M0072
B2M0073
31
2-3 [W3D0] SERVICE PROCEDURE
3. Valve Rocker Assembly
D: ASSEMBLY
B2M2607B
(1) Valve rocker adjust screw (5) Rocker shaft support Tightening torque: N·m (kg-m, ft-lb)
(2) Valve rocker nut (6) Intake valve rocker shaft
T: 5±1 (0.5±0.1, 3.6±0.7)
(3) Intake valve rocker arm (7) Exhaust valve rocker arm
(4) Spring (8) Exhaust valve rocker shaft
32
SERVICE PROCEDURE [W3E0] 2-3
3. Valve Rocker Assembly
E: INSTALLATION
B2M2604B
(1) Spark plug pipe gasket (4) Rocker cover Tightening torque: N·m (kg-m, ft-lb)
(2) Intake valve rocker ASSY
T1: 5±1 (0.5±0.1, 3.6±0.7)
(3) Exhaust valve rocker ASSY
T2: 25±2 (2.5±0.2, 18.1±1.4)
1) Installation of valve rocker assembly 2) Adjust the valve clearances. <Ref. to 2-2
(1) Temporarily tighten bolts (a) through (d) [W7B0].>
equally as shown in figure. 3) Install rocker cover and connect PCV hose.
CAUTION:
Do not allow valve rocker assembly to gouge
knock pins.
(2) Tighten bolts (e) through (h) to specified
torque.
(3) Tighten bolts (a) through (d) to specified
torque.
Tightening torque:
25±2 N·m (2.5±0.2 kg-m, 18.1±1.4 ft-lb)
B2M2605A
33
2-3 [W4A1] SERVICE PROCEDURE
4. Camshaft
4. Camshaft
A: REMOVAL
1. RELATED PARTS
Remove timing belt, camshaft sprockets and
related parts. <Ref. to 2-3 [W2A0].>
2. CAMSHAFT (LH)
B2M2610A
1) Remove camshaft position sensor. (2) Remove bolts (a) through (b) in alphabetical
CAUTION: sequence.
Do not damage the camshaft position sensor.
2) Remove oil level gauge guide attaching bolt.
3) Remove oil level gauge guide.
4) Remove camshaft position sensor support.
5) Remove camshaft cap.
(1) Remove valve rocker assembly.
<Ref. to 2-3 [W3A0].>
B2M2612A
B2M2606
34
SERVICE PROCEDURE [W4A3] 2-3
4. Camshaft
(3) Equally loosen bolts (c) through (j) all the (5) Remove camshaft cap.
way in alphabetical sequence.
B2M2613
B2M2612A
6) Remove camshaft (LH).
(4) Remove bolts (k) through (p) in alphabetical 7) Remove oil seal.
sequence using ST. 8) Remove plug from rear side of camshaft (LH).
ST 499497000 TORX PLUS
CAUTION:
I Do not remove oil seal unless necessary.
I Do not scratch journal surface when remov-
ing oil seal.
B2M2612A
3. CAMSHAFT (RH)
B2M2614A
35
2-3 [W4B1] SERVICE PROCEDURE
4. Camshaft
(1) Remove valve rocker assembly RH. (5) Remove camshaft cap.
<Ref. to 2-3 [W3A0].>
B2M2613
B2M2615
2) Remove camshaft (RH).
(2) Remove bolts (a) through (b) in alphabetical 3) Remove oil seal.
sequence. 4) Remove plug from rear side of camshaft (RH).
CAUTION:
I Do not remove oil seal unless necessary.
I Do not scratch journal surface when remov-
ing oil seal.
B: INSPECTION
1. CAMSHAFT
1) Measure the bend, and repair or replace if nec-
essary.
B2M2612A
Limit:
(3) Equally loosen bolts (c) through (j) all the 0.020 mm (0.0008 in)
way in alphabetical sequence.
B2M2617
B2M2612A
2) Check journal for damage and wear. Replace if
(4) Remove bolts (k) through (p) in alphabetical faulty.
sequence using ST. 3) Measure outside diameter of camshaft journal
ST 499497000 TORX PLUS and inside diameter of cylinder head journal, and
determine the difference between the two (= oil
clearance). If oil clearance exceeds specifications,
replace camshaft or cylinder head as necessary.
B2M2612A
36
SERVICE PROCEDURE [W4B2] 2-3
4. Camshaft
Unit: mm (in)
Standard 0.055 — 0.090 (0.0022 — 0.0035 )
Clearance at journal
Limit 0.118 (0.0046)
Camshaft journal O.D. 31.928 — 31.945 (1.2570 — 1.2577)
Journal hole I.D. 32.000 — 32.018 (1.2598 — 1.2605)
I 2500 cc
Unit: mm (in)
Item Standard Limit
39.485 — 39.585
Intake 39.385 (1.5506)
(1.5545 — 1.5585)
39.257 — 39.357 B2M2618A
Exhaust 39.157 (1.5416)
(1.5455 — 1.5495)
Cam base circle diameter A:
IN: 34.0 mm (1.339 in)
EX: 34.0 mm (1.339 in)
B2M1209A
37
2-3 [W4C1] SERVICE PROCEDURE
4. Camshaft
C: INSTALLATION
1. CAMSHAFT (LH)
B2M2610B
(1) Camshaft (LH) (3) Plug (5) Oil level gauge guide
(2) Camshaft cap (4) Oil seal (6) Bolt
S2M1199A
B2M2612A
38
SERVICE PROCEDURE [W4C1] 2-3
4. Camshaft
(3) Install valve rocker assembly. (6) Tighten bolts (o) through (v) in alphabetical
<Ref. to 2-3 [W3E0].> sequence.
Tightening torque:
10±2 N·m (1.0±0.2 kg-m, 7.2±1.4 ft-lb)
B2M2606
B2M2621B
B2M2621C
S2M1122A
39
2-3 [W4C2] SERVICE PROCEDURE
4. Camshaft
2. CAMSHAFT (RH)
B2M2614A
S2M1199A
B2M2612A
40
SERVICE PROCEDURE [W4C2] 2-3
4. Camshaft
(3) Install valve rocker assembly. (6) Tighten bolts (o) through (v) in alphabetical
<Ref. to 2-3 [W3E0].> sequence.
Tightening torque:
10±2 N·m (1.0±0.2 kg-m, 7.2±1.4 ft-lb)
B2M2615
B2M2621B
ST 499427000 TORX PLUS 3) Apply a coat of grease to oil seal lips and install
Tightening torque: oil seal (A) on camshaft using ST1 and ST2.
18±2 N·m (1.8±0.2 kg-m, 13.0±1.4 ft-lb) CAUTION:
Use a new oil seal.
ST1 499597000 OIL SEAL GUIDE
ST2 499587500 OIL SEAL INSTALLER
B2M2621C
S2M1123A
41
2-3 [W4C3] SERVICE PROCEDURE
5. Cylinder Head
B2M2627A
42
SERVICE PROCEDURE [W5A2] 2-3
5. Cylinder Head
B2M2628A
B2M2628A
43
2-3 [W5B0] SERVICE PROCEDURE
5. Cylinder Head
B: DISASSEMBLY
B2M2629A
(1) Valve rocker ASSY (6) Spark plug pipe gasket (11) Valve spring seat
(2) Camshaft cap (7) Retainer key (12) Valve guide
(3) Camshaft (8) Retainer (13) Valve
(4) Oil seal (9) Valve spring
(5) Plug (10) Oil seal
1) Remove valve rocker assembly, camshaft cap 5) Set ST on valve spring. Compress valve spring
and camshaft. <Ref. to 2-3 [W3A0].> and remove the valve spring retainer key. Remove
2) Remove oil seal. each valve and valve spring.
3) Remove plug. ST 499718000 VALVE SPRING REMOVER
4) Place cylinder head on ST. CAUTION:
ST 498267800 CYLINDER HEAD TABLE I Mark each valve to prevent confusion.
I Use extreme care not to damage the lips of
the intake valve oil seals and exhaust valve oil
seals.
B2M2630A
44
SERVICE PROCEDURE [W5C2] 2-3
5. Cylinder Head
B2M0074
G2M0148
45
2-3 [W5C3] SERVICE PROCEDURE
5. Cylinder Head
3. VALVE GUIDE (1) Place cylinder head on ST1 with the com-
bustion chamber upward so that valve guides
1) Check the clearance between valve guide and
enter the holes in ST1.
stem. The clearance can be checked by measur-
(2) Insert ST2 into valve guide and press it
ing the outside diameter of valve stem and the
down to remove valve guide.
inside diameter of valve guide with outside and
ST1 498267800 CYLINDER HEAD TABLE
inside micrometers respectively.
ST2 499767400 VALVE GUIDE REMOVER
Clearance between the valve guide and valve
stem:
Standard
Intake 0.035 — 0.062 mm (0.0014 —
0.0024 in)
Exhaust 0.040 — 0.067 mm (0.0016 —
0.0026 in)
Limit
0.15 mm (0.0059 in)
Valve guide inner diameter:
6.000 — 6.012 mm (0.2362 — 0.2367 in) G2M0150
B2M0387A
B2M0076A
46
SERVICE PROCEDURE [W5C3] 2-3
5. Cylinder Head
(5) Put new valve guide, coated with sufficient (7) Ream the inside of valve guide with ST.
oil, in cylinder, and insert ST1 into valve guide. Gently rotate the reamer clockwise while press-
Press in until the valve guide upper end is flush ing it lightly into valve guide, and return it also
with the upper surface of ST2. rotating clockwise. After reaming, clean valve
ST1 499767400 VALVE GUIDE REMOVER guide to remove chips.
Intake side: CAUTION:
ST2 499767700 VALVE GUIDE ADJUSTER I Apply engine oil to the reamer when ream-
Exhaust side: ing.
ST2 499767800 VALVE GUIDE ADJUSTER I If the inner surface of the valve guide is torn,
the edge of the reamer should be slightly
ground with an oil stone.
I If the inner surface of the valve guide
becomes lustrous and the reamer does not
chips, use a new reamer or remedy the reamer.
ST 499767400 VALVE GUIDE REAMER
B2M2632A
B2M0077A
47
2-3 [W5C4] SERVICE PROCEDURE
5. Cylinder Head
G2M0154
G2M0153
48
SERVICE PROCEDURE [W5C6] 2-3
5. Cylinder Head
B2M2633A
49
2-3 [W5D0] SERVICE PROCEDURE
5. Cylinder Head
D: ASSEMBLY
B2M2629B
head.
50
SERVICE PROCEDURE [W5E1] 2-3
5. Cylinder Head
(5) Compress valve spring and fit valve spring (6) After installing, tap valve spring retainers
retainer key. lightly with wooden hammer for better seating.
2) Install plug.
3) Install camshaft, camshaft cap and valve rocker
assembly.
<Ref. to 2-3 [W3C0].>
4) Install plug using ST.
ST 499587100 OIL SEAL INSTALLER
5) Install oil seal using ST.
ST 499587500 OIL SEAL INSTALLER
B2M2634A
E: INSTALLATION
1. CYLINDER HEAD
B2M2627B
51
2-3 [W5E2] SERVICE PROCEDURE
5. Cylinder Head
B2M2628B
52
SERVICE PROCEDURE [W6A1] 2-3
6. Cylinder Block
A: REMOVAL
1. RELATED PARTS
1) Remove timing belt, camshaft sprockets and
related parts.
<Ref. to 2-3 [W2A0].>
2) Remove cylinder heads. <Ref. to 2-3 [W5A0].>
B2M2638
53
2-3 [W6A2] SERVICE PROCEDURE
6. Cylinder Block
B2M1767A
(1) Clutch housing cover (MT (4) Oil separator cover (8) Oil pan
vehicles only) (5) Water by-pass pipe (9) Oil strainer
(2) Flywheel (MT vehicles only) (6) Water pump (10) Baffle plate
(3) Drive plate (AT vehicles only) (7) Oil pump (11) Oil filter
54
SERVICE PROCEDURE [W6A2] 2-3
6. Cylinder Block
2) Remove flywheel (MT vehicles only) or drive (3) Insert a oil pan cutter blade between cylin-
plate (AT vehicles only). der block-to-oil pan clearance and remove oil
Using ST, lock crankshaft. pan.
ST 498497100 CRANKSHAFT STOPPER CAUTION:
Do not use a screwdriver or similar tool in
place of oil pan cutter.
G2M0776
G2M0163
B2M0706A
CAUTION:
Be careful not to scratch the mating surface of
cylinder block and oil pump.
G2M0162
55
2-3 [W6B1] SERVICE PROCEDURE
6. Cylinder Block
B: DISASSEMBLY
1. PISTON PIN AND CYLINDER BLOCK CONNECTING BOLT
B2M1180A
(1) Service hole plug (3) Circlip (5) Service hole cover
(2) Gasket (4) Piston pin
1) Remove service hole cover and service hole 2) Rotate crankshaft to bring #1 and #2 pistons to
plugs using hexagon wrench [14 mm (0.55 in)]. bottom dead center position, then remove piston
circlip through service hole of #1 and #2 cylinders.
B2M2620
G2M0165
56
SERVICE PROCEDURE [W6B2] 2-3
6. Cylinder Block
3) Draw out piston pin from #1 and #2 pistons 4) Similarly remove piston pins from #3 and #4
using ST. pistons.
ST 499097700 PISTON PIN REMOVER 5) Remove bolts which connect cylinder block on
CAUTION: the side of #2 and #4 cylinders.
Be careful not to confuse original combination 6) Back off bolts which connect cylinder block on
of piston, piston pin and cylinder. the side of #1 and #3 cylinders two or three turns.
G2M0166
2. CYLINDER BLOCK
B2M2408A
57
2-3 [W6B3] SERVICE PROCEDURE
6. Cylinder Block
4) Remove crankshaft together with connecting 6) Draw out each piston from cylinder block using
rod. wooden bar or hammer handle.
5) Remove crankshaft bearings from cylinder
CAUTION:
block using hammer handle.
Do not confuse combination of piston and cyl-
CAUTION: inder.
Do not confuse combination of crankshaft
bearings. Press bearing at the end opposite to
locking lip.
3. CRANKSHAFT AND PISTON
B2M1320I
58
SERVICE PROCEDURE [W6C2] 2-3
6. Cylinder Block
G2M0170
H2M1732A
59
2-3 [W6C3] SERVICE PROCEDURE
6. Cylinder Block
4) How to measure the outer diameter of each (1) If the value of taper, out-of-roundness, or
piston cylinder- to-piston clearance measured exceeds
Measure the outer diameter of each piston at the the specified limit or if there is any damage on
height shown in the figure. (Thrust direction) the cylinder wall, rebore it to use an oversize
CAUTION: piston.
Measurement should be performed at a tem- CAUTION:
perature of 20°C (68°F). When any of the cylinders needs reboring, all
Piston grade point H: other cylinders must be bored at the same
2200 cc: 40.0 mm (1.575 in) time, and use oversize pistons. Do not perform
2500 cc: 37.0 mm (1.457 in) boring on one cylinder only, nor use an over-
size piston for one cylinder only.
Piston outer diameter:
(2) If the cylinder inner diameter exceeds the
2200 cc: limit after boring and honing, replace the crank-
Standard case.
A: 96.885 — 96.895 mm (3.8144 — 3.8148 in) CAUTION:
B: 96.875 — 96.885 mm (3.8140 — 3.8144 in) Immediately after reboring, the cylinder diam-
eter may differ from its real diameter due to
0.25 mm (0.0098 in) oversize temperature rise. Thus, pay attention to this
97.125 — 97.135 mm (3.8238 — 3.8242 in) when measuring the cylinder diameter.
0.50 mm (0.0197 in) oversize Limit of cylinder enlarging (boring):
97.375 — 97.385 mm (3.8337 — 3.8340 in) 0.5 mm (0.020 in)
2500 cc:
3. PISTON AND PISTON PIN
Standard
1) Check pistons and piston pins for damage,
A: 99.485 — 99.495 mm (3.9167 — 3.9171 in)
cracks, and wear and the piston ring grooves for
B: 99.475 — 99.485 mm (3.9163 — 3.9167 in) wear and damage. Replace if defective.
0.25 mm (0.0098 in) oversize 2) Measure the piston-to-cylinder clearance at
99.725 — 99.735 mm (3.9262 — 3.9266 in) each cylinder. <Ref. to 2-3 [W6C2].> If any of the
clearances is not to specification, replace the pis-
0.50 mm (0.0197 in) oversize ton or bore the cylinder to use an oversize piston.
99.975 — 99.985 mm (3.9360 — 3.9364 in)
B2M1305A
60
SERVICE PROCEDURE [W6C4] 2-3
6. Cylinder Block
G2M0623
G2M0624
B2M0084A
2) Squarely place piston ring and oil ring in
cylinder, and measure the piston ring gap with a
4) Check circlip installation groove on the piston thickness gauge.
for burr. If necessary, remove burr from the groove
so that piston pin can lightly move. Unit: mm (in)
Standard Limit
0.20 — 0.35
Top ring 1.0 (0.039)
(0.0079 — 0.0138)
Piston Second 0.37 — 0.52
1.0 (0.039)
ring gap ring (0.0146 — 0.0205)
Oil ring 0.20 — 0.50
1.0 (0.039)
rail (0.0079 — 0.0197)
B2M0420A
61
2-3 [W6C5] SERVICE PROCEDURE
6. Cylinder Block
3) Measure the clearance between piston ring and 2) Check for bend or twist using a connecting rod
piston ring groove with a thickness gauge. aligner. Replace connecting rod if the bend or twist
CAUTION: exceeds the limit.
Before measuring the clearance, clean the pis- Limit of bend or twist per 100 mm (3.94 in) in
ton ring groove and piston ring. length:
0.10 mm (0.0039 in)
Unit: mm (in)
Standard Limit
0.040 — 0.080
Clearance Top ring (0.0016 — 0.15 (0.0059)
between pis- 0.0031)
ton ring and
0.030 — 0.070
piston ring Second
(0.0012 — 0.15 (0.0059)
groove ring
0.0028)
B2M1402A
5. CONNECTING ROD
B2M1005A
1) Replace connecting rod, if the large or small
end thrust surface is damaged.
3) Install connecting rod fitted with bearing to
crankshaft and measure the side clearance (thrust
clearance). Replace connecting rod if the side
clearance exceeds the specified limit.
Connecting rod side clearance:
Standard
0.070 — 0.330 mm (0.0028 — 0.0130 in)
Limit
0.4 mm (0.016 in)
G2M0176
62
SERVICE PROCEDURE [W6C5] 2-3
6. Cylinder Block
5) Measure the oil clearance on individual con- 6) Inspect bushing at connecting rod small end,
necting rod bearings by means of plastigauge. If and replace if worn or damaged. Also measure the
any oil clearance is not within specification, replace piston pin clearance at the connecting rod small
the defective bearing with a new one of standard end.
size or undersize as necessary. (See the table Clearance between piston pin and bushing:
below.) Standard
Connecting rod oil clearance: 0 — 0.022 mm (0 — 0.0009 in)
I 2200 cc Limit
Standard 0.030 mm (0.0012 in)
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
Bearing (Thickness at cen-
crank pin
ter)
1.492 — 1.501 51.984 — 52.000
Standard
(0.0587 — 0.0591) (2.0466 — 2.0472)
0.03 (0.0012) 1.510 — 1.513 51.954 — 51.970 B2M0085
undersize (0.0594 — 0.0596) (2.0454 — 2.0461)
0.05 (0.0020) 1.520 — 1.523 51.934 — 51.950
undersize (0.0598 — 0.0600) (2.0446 — 2.0453)
0.25 (0.0098) 1.620 — 1.623 51.734 — 51.750
undersize (0.0638 — 0.0639) (2.0368 — 2.0374)
Connecting rod oil clearance:
I 2500 cc
Standard
0.020 — 0.046 mm (0.0008 — 0.0018 in)
Limit
0.050 mm (0.0020 in) B2M0084A
G2M0177
63
2-3 [W6C6] SERVICE PROCEDURE
6. Cylinder Block
6. CRANKSHAFT AND CRANKSHAFT 3) Inspect the crank journal and crank pin for
BEARING wear. If not to specifications, replace bearing with
an undersize one, and replace or recondition
1) Clean crankshaft completely and check for
crankshaft as necessary. When grinding crank
cracks by means of red lead check etc., and
replace if defective. journal or crank pin, finish them to the specified
2) Measure the crankshaft bend, and correct or dimensions according to the undersize bearing to
replace if it exceeds the limit. be used.
CAUTION: Crank pin and crank journal:
If a suitable V-block is not available, install #1 Out-of-roundness
and #5 crankshaft bearing on cylinder block, 0.030 mm (0.0012 in) or less
position crankshaft on these bearings and Taper limit
measure crankshaft bend using a dial gauge. 0.07 mm (0.0028 in)
Grinding limit
Crankshaft bend limit:
0.035 mm (0.0014 in) 0.250 mm (0.0098 in)
G2M0179
G2M0178
Unit: mm (in)
Crank journal diameter
Crank pin diameter
#1, #3 #2, #4, #5
59.992 — 60.008 59.992 — 60.008 51.984 — 52.000
Journal O.D.
(2.3619 — 2.3625) (2.3619 — 2.3625) (2.0466 — 2.0472)
Standard Bearing size
1.998 — 2.011 2.000 — 2.013 1.492 — 1.501
(Thickness at cen-
(0.0787 — 0.0792) (0.0787 — 0.0793) (0.0587 — 0.0591)
ter)
59.962 — 59.978 59.962 — 59.978 51.954 — 51.970
Journal O.D.
(2.3607 — 2.3613) (2.3607 — 2.3613) (2.0454 — 2.0461)
0.03 (0.0012)
Bearing size
undersize 2.017 — 2.020 2.019 — 2.022 1.510 — 1.513
(Thickness at cen-
(0.0794 — 0.0795) (0.0795 — 0.0796) (0.0594 — 0.0596)
ter)
59.942 — 59.958 59.942 — 59.958 51.934 — 51.950
Journal O.D.
(2.3599 — 2.3605) (2.3599 — 2.3605) (2.0446 — 2.0453)
0.05 (0.0020)
Bearing size
undersize 2.027 — 2.030 2.029 — 2.032 1.520 — 1.523
(Thickness at cen-
(0.0798 — 0.0799) (0.0799 — 0.0800) (0.0598 — 0.0600)
ter)
59.742 — 59.758 59.742 — 59.758 51.734 — 51.750
Journal O.D.
(2.3520 — 2.3527) (2.3520 — 2.3527) (2.0368 — 2.0374)
0.25 (0.0098)
Bearing size
undersize 2.127 — 2.130 2.129 — 2.132 1.620 — 1.623
(Thickness at cen-
(0.0837 — 0.0839) (0.0838 — 0.0839) (0.0638 — 0.0639)
ter)
O.D. ... Outer Diameter
64
SERVICE PROCEDURE [W6D1] 2-3
6. Cylinder Block
4) Measure the thrust clearance of crankshaft at 5) Inspect individual crankshaft bearings for signs
center bearing. If the clearance exceeds the limit, of flaking, seizure, melting, and wear.
replace bearing. 6) Measure the oil clearance on each crankshaft
Crankshaft thrust clearance: bearing by means of plastigauge. If the measure-
Standard ment is not within the specification, replace defec-
0.030 — 0.115 mm (0.0012 — 0.0045 in) tive bearing with an undersize one, and replace or
Limit recondition crankshaft as necessary.
0.25 mm (0.0098 in)
Unit: mm (in)
Crankshaft oil clearance
0.010 — 0.030
Standard
(0.0004 — 0.0012)
Limit 0.040 (0.0016)
H2M2939A
D: ASSEMBLY
1. CRANKSHAFT AND PISTON
B2M1320J
(1) Connecting rod bearing (5) Second ring Tightening torque: N·m (kg-m, ft-lb)
(2) Connecting rod (6) Top ring
T: 44±2 (4.5±0.2, 32.5±1.4)
(3) Connecting rod cap (7) Circlip
(4) Oil ring
65
2-3 [W6D1] SERVICE PROCEDURE
6. Cylinder Block
B2M2635B
S2M1012B
S2M1009B
66
SERVICE PROCEDURE [W6D1] 2-3
6. Cylinder Block
(6) Position the lower rail gap at (E) or (F) in the 5) Install circlip.
figure. Install circlips in piston holes located opposite ser-
vice holes in cylinder block, when positioning all
CAUTION:
pistons in the corresponding cylinders.
I Ensure ring gaps do not face the same direc-
tion. CAUTION:
I Ensure ring gaps are not within the piston Use new circlips.
skirt area.
B2M1403A
B2M2636B
CAUTION:
Piston front mark faces towards the front of the
engine.
S2M1012B
B2M2800B
S2M1013B
67
2-3 [W6D2] SERVICE PROCEDURE
6. Cylinder Block
2. CYLINDER BLOCK
B2M2407A
(1) Crankshaft bearing (4) Rear oil seal Tightening torque: N·m (kg-m, ft-lb)
(2) Crankshaft
T1: 25±2 (2.5±0.2, 18.1±1.4)
(3) Cylinder block
T2: 47±3 (4.8±0.3, 34.7±2.2)
1) Install ST to cylinder block, then install crank- 3) Apply fluid packing to the mating surface of #1
shaft bearings. and #3 cylinder block, and position it on #2 and #4
ST 499817000 ENGINE STAND cylinder block.
CAUTION: Fluid packing:
Remove oil in the mating surface of bearing THREE BOND 1215 or equivalent
and cylinder block before installation. Also CAUTION:
apply a coat of engine oil to crankshaft pins. Do not allow fluid packing to jut into O-ring
2) Position crankshaft on the #2 and #4 cylinder grooves, oil passages, bearing grooves, etc.
block.
G2M0185
68
SERVICE PROCEDURE [W6D2] 2-3
6. Cylinder Block
4) Temporarily tighten 10 mm cylinder block con- 7) Install rear oil seal using ST1 and ST2.
necting bolts in alphabetical sequence shown in ST1 499597100 OIL SEAL GUIDE
figure. ST2 499587200 OIL SEAL INSTALLER
B2M0088D G2M0186
B2M0088D
B2M0089F
69
2-3 [W6D3] SERVICE PROCEDURE
6. Cylinder Block
B2M1322E
1) Installing piston
(1) Turn cylinder block so that #1 and #2 cylin-
ders face upward.
(2) Using ST1, turn crankshaft so that #1 and
#2 connecting rods are set at bottom dead cen-
ter.
ST1 499987500 CRANKSHAFT SOCKET
(3) Apply a coat of engine oil to pistons and
cylinders and insert pistons in their cylinders
using ST2.
G2M0189
ST2 498747100 PISTON GUIDE
(2) Apply a coat of engine oil to piston pin and
insert piston pin into piston and connecting rod
through service hole.
(3) Install circlip.
CAUTION:
Use new circlips.
S2M0306A
70
SERVICE PROCEDURE [W6D3] 2-3
6. Cylinder Block
B2M2625
B2M2620
71
2-3 [W6D4] SERVICE PROCEDURE
6. Cylinder Block
B2M1323E
(1) Piston (5) Service hole plug Tightening torque: N·m (kg-m, ft-lb)
(2) Piston pin (6) Service hole cover
T1: 6.4 (0.65, 4.7)
(3) Circlip
T2: 69±7 (7.0±0.7, 50.6±5.1)
(4) Gasket
72
SERVICE PROCEDURE [W6E1] 2-3
6. Cylinder Block
E: INSTALLATION
1. OIL PUMP AND WATER PUMP
B2M1767B
(1) Baffle plate (8) Oil pump Tightening torque: N·m (kg-m, ft-lb)
(2) Oil strainer (9) Water pump
T1: 5 (0.5, 3.6)
(3) Oil pan (10) Water by-pass pipe
T2: 6.4 (0.65, 4.7)
(4) Oil separater cover (11) Oil filter
T3: 10 (1.0, 7)
(5) Drive plate (AT vehicles only)
(6) Flywheel (MT vehicles only) T4: 72±3 (7.3±0.3, 52.8±2.2)
(7) Clutch housing cover (MT T5: First 12±2 (1.2±0.2, 8.7±1.4)
vehicles only) Second 12±2 (1.2±0.2,
8.7±1.4)
73
2-3 [W6E1] SERVICE PROCEDURE
6. Cylinder Block
4) Apply fluid packing to matching surfaces and 6) Install flywheel or drive plate.
install oil pan. To lock crankshaft, use ST.
Fluid packing: ST 498497100 CRANKSHAFT STOPPER
THREE BOND 1215 or equivalent
G2M0084
G2M0161
S2M0235
74
SERVICE PROCEDURE [W6E2] 2-3
6. Cylinder Block
(2) Apply fluid packing to matching surface of 10) Install water by-pass pipe for heater.
oil pump. 11) Install oil filter using ST.
Fluid packing: ST 498187300 OIL FILTER WRENCH
THREE BOND 1215 or equivalent
B2M2611A
S2M0739A
(3) Apply a coat of engine oil to the inside of the 2. RELATED PARTS
oil seal. 1) Install cylinder head, valve rocker assembly
and rocker cover.
<Ref. to 2-3 [W5E0].>
2) Install timing belt and camshaft sprocket.
<Ref. to 2-3 [W2C0].>
3) Install water pipe. <Ref. to 2-5 [W8B0].>
4) Install intake manifold. <Ref. to 2-7 [W4D0].>
S2M0118A
H2M1568B
75
2-3 [K100] DIAGNOSTICS
1. Engine Trouble in General
76
DIAGNOSTICS [K100] 2-3
1. Engine Trouble in General
77
2-3 [K100] DIAGNOSTICS
1. Engine Trouble in General
78
DIAGNOSTICS [K100] 2-3
1. Engine Trouble in General
79
2-3 [K100] DIAGNOSTICS
1. Engine Trouble in General
80
DIAGNOSTICS [K100] 2-3
1. Engine Trouble in General
81
2-3 [K100] DIAGNOSTICS
1. Engine Trouble in General
82
DIAGNOSTICS [K200] 2-3
2. Engine Noise
2. Engine Noise
Type of sound Condition Possible cause
I Valve mechanism is defective.
I Incorrect valve clearance
Sound increases as engine
Regular clicking sound I Worn valve rocker
speed increases.
I Worn camshaft
I Broken valve spring
I Worn crankshaft main bearing
Oil pressure is low.
I Worn connecting rod bearing (big end)
Heavy and dull clank
I Loose flywheel mounting bolts
Oil pressure is normal.
I Damaged engine mounting
I Ignition timing advanced
High-pitched clank (Spark Sound is noticeable when I Accumulation of carbon inside combustion chamber
knock) accelerating with an overload. I Wrong spark plug
I Improper gasoline
Sound is reduced when fuel
Clank when engine speed is injector connector of noisy cyl- I Worn crankshaft main bearing
medium (1,000 to 2,000 rpm). inder is disconnected. I Worn bearing at crankshaft end of connecting rod
(NOTE*)
Sound is reduced when fuel
I Worn cylinder liner and piston ring
injector connector of noisy cyl-
I Broken or stuck piston ring
Knocking sound when engine inder is disconnected. I 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 I Unusually worn valve lifter
fuel injector connector is dis- I Worn cam gear
connected in turn. (NOTE*) I Worn camshaft journal bore in crankcase
Squeaky sound — I Insufficient generator lubrication
Rubbing sound — I Defective generator brush and rotor contact
Gear scream when starting I Defective ignition starter switch
—
engine I Worn gear and starter pinion
Sound like polishing glass with I Loose drive belt
—
a dry cloth I Defective engine coolant pump shaft
I Loss of compression
Hissing sound — I Air leakage in air intake system, hoses, connections or
manifolds
I Loose timing belt
Timing belt noise —
I Belt contacting case/adjacent part
Valve tappet noise — I 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 2-7 [T3D0].> and INSPECTION MODE <Ref. to 2-7 [T3E0].> after con-
necting fuel injector connector.
83
2-3 DIAGNOSTICS
MEMO:
84
ENGINE LUBRICATION SYSTEM 2-4
Page
S SPECIFICATIONS AND SERVICE DATA..........................................................2
1. Specifications ..............................................................................................2
C COMPONENT PARTS .......................................................................................3
1. Lubrication System......................................................................................3
W SERVICE PROCEDURE ...................................................................................4
1. Oil Pump......................................................................................................4
2. Oil Pan and Oil Strainer ..............................................................................8
3. Oil Pressure Switch...................................................................................14
K DIAGNOSTICS.................................................................................................16
1. Engine Lubrication System Trouble in General ........................................16
2-4 [S100] SPECIFICATIONS AND SERVICE DATA
1. Specifications
1. Specifications
Lubrication method Forced lubrication
Pump type Trochoid type
Inner rotor 9
Number of teeth
Outer rotor 10
Outer rotor diameter × thickness 78 × 9 mm (3.07 × 0.35 in)
Tip clearance between inner and outer STANDARD 0.04 — 0.14 mm (0.0016 — 0.0055 in)
rotor LIMIT 0.18 mm (0.0071 in)
Side clearance between inner rotor and STANDARD 0.02 — 0.07 mm (0.0008 — 0.0028 in)
pump case LIMIT 0.15 mm (0.0059 in)
Case clearance between outer rotor and STANDARD 0.10 — 0.175 mm (0.0039 — 0.0069 in)
Oil pump pump case LIMIT 0.20 mm (0.0079 in)
- pressure 98 kPa (1.0 kg/cm2, 14 psi) or more
600 rpm Discharge 2200 cc 4.2 (4.4 US qt, 3.7 Imp qt)/min.
- quantity
Capacity at 2500 cc 4.6 (4.9 US qt, 4.0 Imp qt)/min.
80°C - pressure 294 kPa (3.0 kg/cm2, 43 psi) or more
(176°F) 42.0 (11.10 US gal, 9.24 Imp gal)/
5,000 rpm Discharge 2200 cc
- quantity min.
2500 cc 47.0 (12.4 US gal, 10.3 Imp gal)/min.
2200 cc 490 kPa (5.0 kg/cm2, 71 psi)
Relief valve operation pressure
2500 cc 588 kPa (6.0 kg/cm2, 85 psi)
Type Full-flow filter type
Filtration area 1,000 cm2 (155 sq in)
Oil filter By-pass valve opening pressure 156 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 (0.7 kg/cm2, 10 psi)
Type Immersed contact point type
Oil pressure Working voltage — wattage 12 V — 3.4 W or less
switch Warning light activation pressure 14.7 kPa (0.15 kg/cm2, 2.1 psi)
Proof pressure More than 981 kPa (10 kg/cm2, 142 psi)
Oil capacity (at replacement) 4.0 (4.2 US qt, 3.5 Imp qt)
2
COMPONENT PARTS [C100] 2-4
1. Lubrication System
1. Lubrication System
B2M2235A
3
2-4 [W1A0] SERVICE PROCEDURE
1. Oil Pump
S2M0016
B2M1252A
G2M0417
G2M0286
H2M2513A
4
SERVICE PROCEDURE [W1A0] 2-4
1. Oil Pump
11) Remove rear side V-belt tensioner. 15) Remove timing belt guide. (MT vehicles only)
S2M0113 S2M0115
12) Remove crankshaft pulley by using ST. 16) Remove crankshaft sprocket.
ST 49997700 CRANKSHAFT PULLEY
WRENCH
S2M0116
S2M0114
17) Remove bolts which install oil pump onto cyl-
inder block.
13) Remove timing belt.
<Ref. to 2-3 [W2A0].>
S2M0117
S2M0017
18) Remove oil pump by using flat bladed screw-
driver.
14) Remove water pump. <Ref. to 2-5 [W2A0].> CAUTION:
Be careful not to scratch mating surfaces of
cylinder block and oil pump.
H2M2516
S2M0722A
5
2-4 [W1B0] SERVICE PROCEDURE
1. Oil Pump
B: DISASSEMBLY C: INSPECTION
Remove screws which secure oil pump cover and 1. TIP CLEARANCE
disassemble oil pump.
Measure the tip clearance of rotors. If the clear-
Inscribe alignment marks on inner and outer rotors
ance exceeds the limit, replace rotors as a
so that they can be replaced in their original posi-
matched set.
tions during reassembly.
Tip clearance:
CAUTION:
Standard
Before removing relief valve, loosen plug when
0.04 — 0.14 mm (0.0016 — 0.0055 in)
removing oil pump from cylinder block.
Limit
0.18 mm (0.0071 in)
S2M0736A
2. CASE CLEARANCE
Measure the clearance between the outer rotor
and the cylinder block rotor housing. If the clear-
ance exceeds the limit, replace the rotor.
Case clearance:
Standard
S2M0735A
0.10 — 0.175 mm (0.0039 — 0.0069 in)
Limit
(A) Oil seal 0.20 mm (0.0079 in)
(B) Pump case
(C) Inner rotor
(D) Outer rotor
(E) Pump cover
(F) Relief valve
(G) Relief spring
(H) Plug
(I) Washer
S2M0737A
6
SERVICE PROCEDURE [W1D0] 2-4
1. Oil Pump
S2M0235A
S2M0735B
7
2-4 [W1E0] SERVICE PROCEDURE
2. Oil Pan and Oil Strainer
G6M0095
H2M2929
S2M0740A
8
SERVICE PROCEDURE [W2A0] 2-4
2. Oil Pan and Oil Strainer
B2M1979 B2M0014
G2M0295
H2M2928
G2M0297
9
2-4 [W2A0] SERVICE PROCEDURE
2. Oil Pan and Oil Strainer
13) Remove front and center exhaust pipe assem- 14) Remove nuts which install front cushion rub-
bly. ber onto front crossmember.
(1) Separate front and center exhaust assem-
bly pipe from rear exhaust pipe.
CAUTION:
Be careful, exhaust pipe is hot.
G2M0293
B2M2687
B2M0313
S2M0238
10
SERVICE PROCEDURE [W2C0] 2-4
2. Oil Pan and Oil Strainer
18) Remove baffle plate. 3) Apply fluid packing to mating surfaces and
install oil pan.
Fluid packing:
THREE BOND 1215 or equivalent
S2M0309
B: INSPECTION
G2M0084
By visual check make sure oil pan, oil strainer and
baffle plate are not damaged. 4) Tighten bolts which install oil pan onto engine
block.
C: INSTALLATION Tightening torque:
CAUTION: 5 N·m (0.5 kg-m, 3.6 ft-lb)
Before installing oil pan, clean sealant from oil
pan and engine block.
1) Install baffle plate.
Tightening torque:
6.4 N·m (0.65 kg-m, 4.7 ft-lb)
B2M2687
G2M0293
S2M0238
11
2-4 [W2C0] SERVICE PROCEDURE
2. Oil Pan and Oil Strainer
7) Install front and center exhaust pipe assembly. 8) Connect connector to rear oxygen sensor.
CAUTION:
Always use the new gaskets.
(1) Place front and center exhaust pipe assem-
bly on bracket.
(2) Tighten nuts which install front and center
exhaust pipe assembly on engine.
Tightening torque:
30±5 N·m (3.1±0.5 kg-m, 22.4±3.6 ft-lb)
B2M0312
B2M0054
B2M0055
B2M0313
B2M1979
12
SERVICE PROCEDURE [W2C0] 2-4
2. Oil Pan and Oil Strainer
13) Install pitching stopper. 16) Install air intake duct and air cleaner upper
Tightening torque: cover. (Except 2200 cc California spec. vehicles)
<Ref. to 2-7 [W1A2].>
T1: 49±5 N·m (5.0±0.5 kg-m, 36.2±3.6 ft-lb)
T2: 57±10 N·m (5.8±1.0 kg-m, 42±7 ft-lb)
B2M2020
H2M2928
H2M2929
13
2-4 [W3A0] SERVICE PROCEDURE
3. Oil Pressure Switch
A: REMOVAL
1) Remove alternator from bracket.
(1) Disconnect connector and terminal from
generator.
G2M0091
H6M0402
S2M0119
B: INSTALLATION
1) Apply fluid packing to oil pressure switch
B2M0017
threads before installation.
Fluid packing:
(3) Loosen lock bolt and slider bolt, and remove THREE BOND 1215 or equivalent
front side V-belt.
(4) Remove bolts which install generator on
bracket.
S2M0124A
H2M1499
14
SERVICE PROCEDURE [W3B0] 2-4
3. Oil Pressure Switch
2) Install oil pressure switch onto engine block. 5) Install front side V-belt and adjust it. <Ref. to
Tightening torque: 1-5 [G200].>
25±3 N·m (2.5±0.3 kg-m, 18.1±2.2 ft-lb) 6) Install V-belt cover.
S2M0119 B2M0017
3) Connect terminal of oil pressure switch. 7) Connect connector and terminal to generator.
G2M0091 H6M0402
H2M1499
15
2-4 [K100] DIAGNOSTICS
1. Engine Lubrication System Trouble in General
16
ENGINE COOLING SYSTEM 2-5
Page
S SPECIFICATIONS AND SERVICE DATA..........................................................2
1. Specifications ..............................................................................................2
2. Service Data................................................................................................2
C COMPONENT PARTS .......................................................................................3
1. Water Pump ................................................................................................3
2. Radiator and Radiator Fan..........................................................................4
3. Water Pipe...................................................................................................5
W SERVICE PROCEDURE ...................................................................................6
1. On-car Services...........................................................................................6
2. Water Pump ................................................................................................7
3. Thermostat ................................................................................................10
4. Radiator .....................................................................................................11
5. Radiator Cap .............................................................................................14
6. Radiator Main Fan and Fan Motor............................................................15
7. Radiator Sub Fan and Fan Motor .............................................................17
8. Water Pipe.................................................................................................19
9. Reservoir Tank ..........................................................................................22
K DIAGNOSTICS.................................................................................................23
1. Engine Cooling System Trouble in General..............................................23
2-5 [S100] SPECIFICATIONS AND SERVICE DATA
1. Specifications
1. Specifications
Electric fan + Forced engine coolant circula-
Cooling system
tion system
Total engine coolant capacity (US qt, Imp qt) 6.2 (6.6, 5.5)
Type Centrifugal impeller type
Discharge 20 (5.3 US gal, 4.4 Imp gal)/min.
Pump speed—total engine
Discharge performance I 760 rpm — 0.3 mAq (1.0 ftAq)
coolant head
Engine coolant temperature 85°C (185°F)
Discharge 100 (26.4 US gal, 22.0 Imp gal)/min.
Pump speed—total engine
Discharge performance II 3,000 rpm — 5.0 mAq (16.4 ftAq)
coolant head
Water pump
Engine coolant temperature 85°C (185°F)
Discharge 200 (52.8 US gal, 44.0 Imp gal)/min.
Pump speed—total engine
Discharge performance III 6,000 rpm — 23.0 mAq (75.5 ftAq)
coolant head
Engine coolant temperature 85°C (185°F)
Impeller diameter 76 mm (2.99 in)
Number of impeller vanes 8
Pump pulley diameter 60 mm (2.36 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)
70 W (main fan)
Motor
70 W (sub fan)
Radiator fan
320 mm (12.60 in) × 5 (main fan)
Fan diameter × Blade
320 mm (12.60 in) × 7 (sub fan)
Type Down flow, pressure type
Core dimensions 691 × 340 × 16 mm (27.20 × 13.39 × 0.63 in)
Above: 108±15 kPa (1.1±0.15 kg/cm2,
Radiator 15.6±2.1 psi)
Pressure range in which cap valve is open
Below: −9.8 to −4.9 kPa (−0.1 to −0.05
kg/cm2, −1.4 to −0.7 psi)
Fins Corrugated fin type
Reservoir tank Capacity 0.45 (0.5 US qt, 0.4 Imp qt)
2. Service Data
0.5 — 0.7 mm (0.020 — 0.028
Standard
Clearance between impeller and case in)
Water pump
Limit 1.0 mm (0.039 in)
“Thrust” runout of impeller end 0.5 mm (0.020 in)
2
COMPONENT PARTS [C100] 2-5
1. Water Pump
1. Water Pump
H2M2354A
(1) Water pump ASSY (6) Thermostat case Tightening torque: N·m (kg-m, ft-lb)
(2) Gasket
T1: First 10+4/−0 (1.0+0.4/−0,
(3) Heater hose 7.2+2.9/−0)
(4) Thermostat Second 10+4/−0 (1.0+0.4/−0,
(5) Gasket 7.2+2.9/−0)
T2: 6.4±0.5 (0.65±0.05, 4.7±0.4)
3
2-5 [C200] COMPONENT PARTS
2. Radiator and Radiator Fan
S2M0890A
(1) Radiator lower cushion (13) Radiator main fan shroud (21) ATF inlet hose B (AT vehicles
(2) Radiator (14) Radiator main fan only)
(3) Radiator upper cushion (15) Radiator main fan motor (22) Radiator outlet hose
(4) Radiator upper bracket (16) ATF hose clamp (AT vehicles (23) Radiator drain plug
(5) Clamp only)
(6) Radiator inlet hose (17) ATF inlet hose A (AT vehicles Tightening torque: N·m (kg-m, ft-lb)
(7) Engine coolant reservoir tank only) T1: 4.4±0.5 (0.45±0.05, 3.3±0.4)
cap (18) ATF outlet hose A (AT vehicles T2: 12±3 (1.2±0.3, 8.7±2.2)
(8) Over flow hose only) T3: 18±5 (1.8±0.5, 13.0±3.6)
(9) Engine coolant reservoir tank (19) ATF pipe (AT vehicles only) T4: 3.4±0.5 (0.35±0.05, 2.5±0.4)
(10) Radiator sub fan shroud (20) ATF outlet hose B (AT vehicles T5: 4.9±1.5 (0.50±0.15, 3.6±1.1)
(11) Radiator sub fan only)
(12) Radiator sub fan motor
4
COMPONENT PARTS [C300] 2-5
3. Water Pipe
3. Water Pipe
H2M2355A
(1) Engine coolant temperature sen- (3) Water pipe Tightening torque: N·m (kg-m, ft-lb)
sor (4) O-ring
T: 6.4±0.5 (0.65±0.05, 4.7±0.4)
(2) Engine coolant temperature (5) By-pass hose
gauge
5
2-5 [W1A0] SERVICE PROCEDURE
1. On-car Services
H2M1603A
C: CHECKING OF COOLING
SYSTEM
H2M2927A 1) Remove radiator cap, top off radiator, and
attach tester to radiator in place of cap.
4) Loosen drain cock to drain engine coolant into 2) Apply a pressure of 157 kPa (1.6 kg/cm2, 23
container. psi) to radiator to check if:
NOTE: (1) Engine coolant leaks at/around radiator.
Remove radiator cap so that engine coolant will (2) Engine coolant leaks at/around hoses or
drain faster. connections.
S2M0948
B2M0015A
CAUTION:
B: FILLING OF ENGINE COOLANT I Engine should be off.
I Wipe engine coolant from check points in
1) Fill engine coolant into radiator up to filler neck advance.
position. I Be careful to prevent engine coolant from
spurting out when removing tester.
I Be careful also not to deform filler neck of
radiator when installing or removing tester.
6
SERVICE PROCEDURE [W2A0] 2-5
2. Water Pump
H2M2515A
S2M0893
S2M1174
S2M0930
7
2-5 [W2A0] SERVICE PROCEDURE
2. Water Pump
S2M0931 H2M2518
11) Remove radiator main fan and sub fan motor 16) Remove camshaft position sensor.
assembly. <Ref. to 2-7 [W10A0].>
<Ref. to 2-5 [W6A0].> and <Ref. to 2-5 [W7A0].>
B2M2038
S2M0929
17) Remove left-hand camshaft sprocket by using
12) Remove V-belts. ST.
<Ref. to 1-5 [G200].> ST 499207100 CAMSHAFT SPROCKET
WRENCH
G2M0286
B2M2039A
13) Remove timing belt.
<Ref. to 2-3 [W2A0].> 18) Remove left-hand belt cover No. 2.
14) Remove automatic belt tension adjuster.
B2M2040
H2M2375
8
SERVICE PROCEDURE [W2B0] 2-5
2. Water Pump
H2M2380
G2M0211
20) Remove tensioner bracket.
21) Disconnect heater hose from water pump. 4) Check clearance between impeller and pump
22) Remove water 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)
G2M0210
two stages in alphabetical sequence as shown 5) After water pump installation, check pulley shaft
in figure. for engine coolant leaks. If leaks are noted, replace
Tightening torque: water pump assembly.
10+4/−0 N·m (1.0+0.4/−0 kg-m, 7.2+2.9/−0 ft-lb)
S2M0760A
B: INSPECTION
1) Check water pump bearing for smooth rotation.
2) Check water pump pulley for abnormalities.
3) Using a dial gauge, measure impeller runout in
thrust direction while rotating the pulley.
9
2-5 [W3A0] SERVICE PROCEDURE
3. Thermostat
B2M0014
S2M0026A
B: 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
water. Raise water temperature gradually, and
S2M0550A
measure the temperature and valve lift when the
valve begins to open and when the valve is fully
4) Remove thermostat cover and gasket, and pull opened. During the test, agitate the water for even
out the thermostat. temperature distribution. The measurement should
be to the specification.
Starts to open:
76.0 — 80.0°C (169 — 176°F)
Fully opens:
91°C (196°F)
S2M0582
H2M2357A
(A) Thermometer
(B) Thermostat
10
SERVICE PROCEDURE [W4A0] 2-5
4. Radiator
S2M0893
S2M0895
H2M2515A
S2M0930
11
2-5 [W4B0] SERVICE PROCEDURE
4. Radiator
10) Remove reservoir tank. 14) While slightly lifting radiator, slide it to left.
15) Lift radiator up and away from vehicle.
S2M0931
S2M0033
11) Remove V-belt covers.
B: INSTALLATION
1) Attach radiator mounting cushions to pins on
the lower side of radiator.
S2M0896
S2M0944
S2M0897
S2M0033
H2M2928
12
SERVICE PROCEDURE [W4B0] 2-5
4. Radiator
3) Install radiator brackets and tighten bolts. 8) Connect connectors to radiator main fan motor
Tightening torque: and sub fan motor.
18±5 N·m (1.8±0.5 kg-m, 13.0±3.6 ft-lb)
S2M0893
S2M0897 H2M2515A
B2M0014
S2M0896
S2M0895
13
2-5 [W5A0] SERVICE PROCEDURE
5. Radiator Cap
G6M0095
G2M0223
14
SERVICE PROCEDURE [W6A0] 2-5
6. Radiator Main Fan and Fan Motor
6. Radiator Main Fan and Fan 5) Detach ATF cooler hose attached to 2 clips
under the radiator main fan shroud.
Motor
A: REMOVAL AND INSTALLATION
1) Disconnect battery ground cable.
S2M1174
S2M0896
B2M0014
S2M0930
S2M0591
S2M0931
15
2-5 [W6B0] SERVICE PROCEDURE
6. Radiator Main Fan and Fan Motor
10) Remove radiator main fan motor assembly. B: DISASSEMBLY AND ASSEMBLY
1) Remove clip which holds motor connector onto
shroud.
S2M0929
S2M0936
Tightening torque:
4.9±1.5 N·m (0.50±0.15 kg-m, 3.6±1.1 ft-lb)
S2M0938
S2M0934
16
SERVICE PROCEDURE [W7A0] 2-5
7. Radiator Sub Fan and Fan Motor
4) Installation is in the reverse order of removal. 7. Radiator Sub Fan and Fan
Tightening torque: Motor
4.4±0.5 N·m (0.45±0.05 kg-m, 3.3±0.4 ft-lb)
A: REMOVAL AND INSTALLATION
1) Disconnect battery ground cable.
S2M0938
Tightening torque:
3.4±0.5 N·m (0.35±0.05 kg-m, 2.5±0.4 ft-lb) G6M0095
S2M0936
B2M0014
S2M0597
17
2-5 [W7B0] SERVICE PROCEDURE
7. Radiator Sub Fan and Fan Motor
S2M0896
S2M0935
S2M0939
9) Installation is in the reverse order of removal.
3) Remove bolts which install fan motor onto
Tightening torque: shroud.
4.9±1.5 N·m (0.50±0.15 kg-m, 3.6±1.1 ft-lb)
S2M0938
S2M0935
18
SERVICE PROCEDURE [W8A0] 2-5
8. Water Pipe
S2M0938
Tightening torque:
3.4±0.5 N·m (0.35±0.05 kg-m, 2.5±0.4 ft-lb) H2M2535
S2M0939
G6M0095
B2M0014
19
2-5 [W8B0] SERVICE PROCEDURE
8. Water Pipe
6) Drain engine coolant completely. 11) Remove bolts which install water pipe on cyl-
<Ref. to 2-5 [W1A0].> inder block.
S2M0550A B2M0141
B2M0160
B2M0141
B2M0138
B2M0139
B2M0139
20
SERVICE PROCEDURE [W8B0] 2-5
8. Water Pipe
B2M0138
B2M0014
4) Install intake manifold.
<Ref. to 2-7 [W4D0].> 9) Lower the vehicle.
10) Fill coolant.
<Ref. to 2-5 [W1B0].>
B2M0160
S2M0093A
G6M0095
21
2-5 [W9A0] SERVICE PROCEDURE
9. Reservoir Tank
S2M0931
S2M0934
S2M0934
22
ENGINE COOLING SYSTEM 2-5
Page
T DIAGNOSTICS ...................................................................................................2
1. Wiring Diagram............................................................................................2
2. Radiator Main Fan.......................................................................................3
3. Radiator Sub Fan (With A/C model only) ...................................................7
2-5 [T100] ENGINE COOLING SYSTEM
1. Wiring Diagram
1. Wiring Diagram
H2M2938
2
ENGINE COOLING SYSTEM [T2A3] 2-5
2. Radiator Main Fan
CAUTION:
Be careful not to overheat engine during repair.
1) Turn ignition switch to OFF. H2M1715B
2) Disconnect connector from main fan motor.
3) Start the engine, and warm it up until engine : Is the resistance less than 5 Ω?
coolant temperature increases over 95°C (203°F).
: Go to step 2A3.
4) Stop the engine and turn ignition switch to ON.
5) Measure voltage between main fan motor con- : Repair open circuit in harness between
nector and chassis ground. main fan motor connector and chassis
ground.
Connector & terminal
(F17) No. 2 (+) — Chassis ground (−):
2A3 : CHECK POOR CONTACT.
3
2-5 [T2A4] ENGINE COOLING SYSTEM
2. Radiator Main Fan
2A4 : CHECK MAIN FAN MOTOR. 2A6 : CHECK POWER SUPPLY TO MAIN
FAN RELAY.
Connect battery positive (+) terminal to terminal
No. 2, and negative (−) terminal to terminal No. 1 1) Turn ignition switch to ON.
of main fan motor connector. 2) Measure voltage between main fan relay termi-
nal and chassis ground.
Connector & terminal
(F66) No. 28 (+) — Chassis ground (−):
S2M1003B
S2M0439A
4
ENGINE COOLING SYSTEM [T2A12] 2-5
2. Radiator Main Fan
1) Disconnect connector from main fuse box. Measure resistance of harness between 20 A fuse
2) Disconnect connectors (F25) and (F26) from and main fan relay terminal.
generator, and (F34) from SBF holder. Connector & terminal
3) Measure resistance of harness connector (F27) No. 2 — (F66) No. 26:
between main fuse box connector and A/C relay
holder 20 A fuse terminals.
Connector & terminal
(F35) No. 1 — (F27) No. 1:
(F35) No. 2 — (F27) No. 1:
S2M0441A
5
2-5 [T2A13] ENGINE COOLING SYSTEM
2. Radiator Main Fan
S2M0468A
6
ENGINE COOLING SYSTEM [T3A1] 2-5
3. Radiator Sub Fan (With A/C model only)
7
2-5 [T3A2] ENGINE COOLING SYSTEM
3. Radiator Sub Fan (With A/C model only)
3A2 : CHECK GROUND CIRCUIT OF SUB 3A4 : CHECK SUB FAN MOTOR.
FAN MOTOR.
Connect battery positive (+) terminal to terminal
1) Turn ignition switch to OFF. No. 2, and negative (−) terminal to terminal No. 1
2) Measure resistance between sub fan motor of sub fan motor connector.
connector and chassis ground.
Connector & terminal
(F16) No. 1 — Chassis ground:
S2M1003B
H2M2520A
8
ENGINE COOLING SYSTEM [T3A10] 2-5
3. Radiator Sub Fan (With A/C model only)
H2M2521A
9
2-5 [T3A11] ENGINE COOLING SYSTEM
3. Radiator Sub Fan (With A/C model only)
Measure resistance of harness between 20 A fuse 1) Disconnect connector from ignition switch.
and sub fan relay terminal. 2) Separate connectors (F44) and (B61).
Connector & terminal 3) Disconnect connector (B159) from joint box.
(F27) No. 4 — (F28) No. 18: 4) Measure resistance of harness between igni-
tion switch connector and joint box.
Connector & terminal
(B72) No. 4 — (B159) No. 8:
H2M2522A
10
ENGINE COOLING SYSTEM [T3A20] 2-5
3. Radiator Sub Fan (With A/C model only)
H2M2523A
11
2-5 ENGINE COOLING SYSTEM
MEMO:
12
DIAGNOSTICS [K100] 2-5
1. Engine Cooling System Trouble in General
23
2-5 DIAGNOSTICS
MEMO:
24
FUEL INJECTION SYSTEM 2-7
Page
C COMPONENT PARTS .......................................................................................2
1. Intake Manifold ............................................................................................2
2. Air Intake System ........................................................................................6
3. Air Cleaner ..................................................................................................8
4. Crankshaft Position, Camshaft Position and Knock Sensors...................10
W SERVICE PROCEDURE .................................................................................11
1. Air Cleaner and Air Intake Duct ................................................................11
2. Mass Air Flow Sensor (Except 2200 cc California Spec. Vehicles) .........13
3. Throttle Body .............................................................................................14
4. Intake Manifold ..........................................................................................17
5. Engine Coolant Temperature Sensor........................................................41
6. Crankshaft Position Sensor.......................................................................42
7. Front Oxygen (A/F) Sensor.......................................................................43
8. Rear Oxygen Sensor.................................................................................44
9. Throttle Position Sensor............................................................................46
10. Camshaft Position Sensor.........................................................................50
11. Pressure Sensor........................................................................................51
12. Idle Air Control Solenoid Valve .................................................................51
13. Pressure Sources Switching Solenoid Valve ............................................53
14. Fuel Injector...............................................................................................53
15. Engine Control Module (ECM) ..................................................................58
16. Main Relay ................................................................................................59
17. Fuel Pump Relay.......................................................................................60
18. Air Intake Chamber (Except 2200 cc California Spec. Vehicles) .............60
19. Knock Sensor ............................................................................................61
20. Intake Manifold Pressure Sensor (2200 cc California Spec. Vehicles
only)...........................................................................................................62
21. Intake Air Temperature Sensor (2200 cc California Spec. Vehicles only).63
2-7 [C1A0] COMPONENT PARTS
1. Intake Manifold
1. Intake Manifold
A: 2200 cc CALIFORNIA SPEC. VEHICLES
H2M2933A
(1) Intake manifold gasket RH (9) Nipple (AT vehicles) Tightening torque: N·m (kg-m, ft-lb)
(2) Fuel injector cap (10) Plug
T1: 16±1.5 (1.6±0.15, 11.6±1.1)
(3) Insulator A (11) PCV valve
T2: 23±3 (2.3±0.3, 16.6±2.2)
(4) Insulator B (12) Purge control solenoid valve
T3: 25±2 (2.5±0.2, 18.1±1.4)
(5) Fuel injector (13) Nipple
(6) O-ring B (14) Intake manifold T4: 3.4±0.5 (0.35±0.05, 2.5±0.4)
(7) O-ring A (15) Intake manifold gasket LH
(8) Fuel pipe (16) Fuel pipe protector
2
COMPONENT PARTS [C1A0] 2-7
1. Intake Manifold
MEMO:
3
2-7 [C1B0] COMPONENT PARTS
1. Intake Manifold
S2M1011A
4
COMPONENT PARTS [C1B0] 2-7
1. Intake Manifold
(1) Intake manifold gasket LH (12) Purge control solenoid valve (20) Bracket (For Canada spec.
(2) Intake manifold gasket RH (13) Nipple vehicles)
(3) Fuel injector pipe (14) Pressure sensor (21) Intake manifold
(4) O-ring A (15) Pressure sources switching sole- (22) Fuel pipe protector LH
(5) O-ring B noid valve
(6) Fuel injector (16) Vacuum hose A Tightening torque: N·m (kg-m, ft-lb)
(7) Insulator (17) Vacuum hose B T1: 4.9±0.5 (0.5±0.05, 3.6±0.4)
(8) Fuel injector cap (18) Vacuum hose C T2: 23±3 (2.3±0.3, 16.6±2.2)
(9) Nipple (AT vehicles) (19) Bracket (Except Canada spec. T3: 25±2 (2.5±0.2, 18.1±1.4)
(10) Plug vehicles) T4: 3.4±0.5 (0.35±0.05, 2.5±0.4)
(11) PCV valve T5: 15.7±1.5 (1.6±0.15, 11.6±1.1)
5
2-7 [C2A0] COMPONENT PARTS
2. Air Intake System
B2M2278A
(1) Gasket (5) Intake manifold pressure sensor Tightening torque: N·m (kg-m, ft-lb)
(2) Throttle position sensor (6) Throttle body
T1: 2.0±0.4 (0.20±0.04, 1.4±0.3)
(3) Gasket
T2: 3.3±0.4 (0.34±0.045, 2.5±0.3)
(4) Idle air control solenoid valve
T3: 22±2 (2.2±0.2, 15.9±1.4)
6
COMPONENT PARTS [C2B0] 2-7
2. Air Intake System
S2M1117A
(1) Gasket (8) Stay LH (MT vehicles) Tightening torque: N·m (kg-m, ft-lb)
(2) Throttle position sensor (9) Stay LH (AT vehicles)
T1: 2.0±0.4 (0.20±0.04, 1.4±0.3)
(3) Throttle body (10) Stay RH
T2: 6.4±0.5 (0.65±0.05, 4.7±0.4)
(4) Idle air control solenoid valve (11) Spacer
T3: 22±2 (2.2±0.2, 15.9±1.4)
(5) Clamp (12) Bush
(6) Air intake duct T4: 6.0±0.8 (0.61±0.08, 4.4±0.6)
(7) Air intake chamber T5: 16±5 (1.6±0.5, 11.6±3.6)
7
2-7 [C3A0] COMPONENT PARTS
3. Air Cleaner
3. Air Cleaner
A: 2200 cc CALIFORNIA SPEC. VEHICLES
H2M2940A
8
COMPONENT PARTS [C3B0] 2-7
3. Air Cleaner
H2M2941A
(1) Mass air flow sensor bracket (7) Clip Tightening torque: N·m (kg-m, ft-lb)
(2) Mass air flow sensor ASSY (8) Air cleaner case
T1: 7.4±2.0 (0.75±0.2, 5.4±1.4)
(3) Air cleaner upper cover (9) Cushion rubber
T2: 33±10 (3.4±1.0, 25±7)
(4) Air cleaner element (10) Air intake duct
(5) Spacer (11) Resonator chamber ASSY
(6) Bush (12) Clip
9
2-7 [C400] COMPONENT PARTS
4. Crankshaft Position, Camshaft Position and Knock Sensors
B2M2282A
10
SERVICE PROCEDURE [W1A1] 2-7
1. Air Cleaner and Air Intake Duct
1. Air Cleaner and Air Intake 4) Remove air intake duct (A) and (B) as a unit.
Duct
A: REMOVAL AND INSTALLATION
1. 2200 cc CALIFORNIA SPEC. VEHICLES
1) Disconnect battery ground cable.
B2M2012
G6M0095
B2M2285
H2M2930A
B2M2286
B2M2284A
B2M2287
11
2-7 [W1A2] SERVICE PROCEDURE
1. Air Cleaner and Air Intake Duct
2. EXCEPT 2200 cc CALIFORNIA SPEC. 5) Remove air intake duct and air cleaner upper
VEHICLES cover as a unit.
1) Disconnect battery ground cable.
B2M2020
S2M0179
B2M2018
8) Installation is in the reverse order of removal.
CAUTION:
3) Loosen clamp which connects air intake duct to Before installing air cleaner upper cover, align
air intake chamber. holes with protruding portions of air cleaner
lower case, then secure upper cover to lower
case.
H2M3226
B2M2289
12
SERVICE PROCEDURE [W2A0] 2-7
2. Mass Air Flow Sensor (Except 2200 cc California Spec. Vehicles)
2. Mass Air Flow Sensor 4) Remove two clips of air cleaner upper cover.
(Except 2200 cc California
Spec. Vehicles)
A: REMOVAL AND INSTALLATION
1) Disconnect battery ground cable.
B2M2289
G6M0095
B2M2020
B2M2018
B2M2291
H2M3226
B2M2294
13
2-7 [W3A1] SERVICE PROCEDURE
3. Throttle Body
G6M0095
B2M2320
B2M2295A
14
SERVICE PROCEDURE [W3A2] 2-7
3. Throttle Body
5) Disconnect connectors from idle air control 8) Disconnect engine coolant hoses from throttle
solenoid valve (A) and intake manifold pressure body.
sensor (B).
B2M2299
B2M2296A
9) Remove bolts which install throttle body to
(A) Idle air control solenoid valve intake manifold.
(B) Intake manifold pressure sensor
B2M2300
B2M2298
G6M0095
15
2-7 [W3A2] SERVICE PROCEDURE
3. Throttle Body
2) Loosen clamps which connect air intake duct to 7) Disconnect connector from throttle position
air intake chamber and mass air flow sensor. sensor.
H2M3226 B2M2303
3) Loosen clamp which connects air intake cham- 8) Disconnect connector from idle air control sole-
ber to throttle body. noid valve.
S2M1001 B2M2756
4) Disconnect blow-by hose and air hoses, and 9) Disconnect engine coolant hoses from throttle
remove air intake chamber. body.
B2M2301 B2M2304
5) Disconnect accelerator cable (A). 10) Remove bolts which install throttle body to
6) Disconnect cruise control cable (B). (With intake manifold.
cruise control model)
B2M2305
B2M2302A
11) Installation is in the reverse order of removal.
16
SERVICE PROCEDURE [W4A1] 2-7
4. Intake Manifold
H2M2535
G6M0095
B2M2285
17
2-7 [W4A1] SERVICE PROCEDURE
4. Intake Manifold
5) Remove bolt which installs air intake duct (A) 9) Disconnect blow-by hose from air cleaner case.
on the front of body. 10) Remove air intake duct (A), (B) and air cleaner
assembly as a unit.
H2M2930A
H2M2931
6) Remove bolt which installs air intake duct (B)
on body. 11) Disconnect accelerator cable (A).
12) Disconnect cruise control cable (B). (With
cruise control model)
B2M2284A
B2M2349
B2M2286
S2M0896
18
SERVICE PROCEDURE [W4A1] 2-7
4. Intake Manifold
(3) Loosen lock bolt and slider bolt, and remove (6) Place power steering pump on the right side
power steering pump drive V-belt. wheel apron.
G2M0286 S2M0087
(4) Remove bolts which secure power steering 14) Remove fuel pipe protector.
pipe brackets to intake manifold.
NOTE:
Do not disconnect power steering hose.
B2M2754
B2M2312
B2M2313
19
2-7 [W4A1] SERVICE PROCEDURE
4. Intake Manifold
17) Disconnect engine coolant hoses from throttle 22) Disconnect knock sensor connector.
body.
H2M3227A
B2M2299
23) Disconnect connector from camshaft position
18) Disconnect brake booster hose. sensor.
B2M2314 B2M2317B
19) Remove air cleaner case stay RH and engine 24) Disconnect connector from crankshaft position
harness bracket, and disconnect engine harness sensor.
connectors from bulkhead harness connectors.
20) Pull out engine harness connector from
bracket.
B2M1252A
B2M1253A
S2M1658
20
SERVICE PROCEDURE [W4A2] 2-7
4. Intake Manifold
26) Disconnect fuel hoses from fuel pipes. 2. EXCEPT 2200 cc CALIFORNIA SPEC.
WARNING: VEHICLES
Catch fuel from hoses in a container. 1) Release fuel pressure. <Ref. to 2-8 [W1B0].>
2) Open fuel flap lid, and remove fuel filler cap.
S2M0500
H2M2535
27) Remove eight bolts which hold intake manifold
onto cylinder heads. 3) Disconnect battery ground cable.
B2M2318 G6M0095
28) Remove intake manifold. 4) Disconnect connector from mass air flow sen-
sor.
B2M0160
B2M2018
B2M2769
21
2-7 [W4A2] SERVICE PROCEDURE
4. Intake Manifold
6) Remove two clips of air cleaner upper cover. 11) Disconnect accelerator cable (A).
12) Disconnect cruise control cable (B). (With
cruise control model)
B2M2289
S2M1000
S2M0940
G2M0286
22
SERVICE PROCEDURE [W4A2] 2-7
4. Intake Manifold
(3) Remove bolts which secure power steering 16) Disconnect spark plug cords from ignition coil
pipe brackets to intake manifold. and ignitor assembly.
NOTE:
Do not disconnect power steering hose.
B2M2312
S2M0089A
S2M0086
(5) Place power steering pump on the right side 19) Disconnect engine coolant hose from throttle
wheel apron. body.
B2M2304
S2M0087
15) Remove fuel pipe protector. 20) Disconnect brake booster hose.
B2M2754 B2M2314
23
2-7 [W4A2] SERVICE PROCEDURE
4. Intake Manifold
21) Remove air intake chamber stay RH, engine 25) Disconnect connector from crankshaft position
harness bracket from transmission housing, and sensor.
disconnect engine harness connectors from bulk-
head harness connectors.
B2M1252A
B2M2315
26) Disconnect connector from oil pressure
switch.
22) Disconnect connectors from engine coolant
temperature sensor.
B2M1253A
S2M1658
27) Disconnect fuel hoses from fuel pipes.
WARNING:
23) Disconnect knock sensor connector. Catch fuel from hoses in a container.
H2M3227A
S2M0500
24) Disconnect connector from camshaft position 28) Remove bolts which hold intake manifold onto
sensor. cylinder heads.
B2M2317B B2M2318
24
SERVICE PROCEDURE [W4B1] 2-7
4. Intake Manifold
B2M0160
B: DISASSEMBLY
1. 2200 cc CALIFORNIA SPEC. VEHICLES B2M2346A
B2M2300
B2M2779
7) Disconnect connectors from fuel injectors, and
2) Disconnect connector from ignition coil and purge control solenoid valve.
ignitor assembly. 8) Remove harness bands which hold engine har-
3) Remove ignition coil and ignitor assembly. ness onto intake manifold.
9) Remove engine harness from intake manifold.
B2M2345
B2M2780A
25
2-7 [W4B1] SERVICE PROCEDURE
4. Intake Manifold
10) Remove purge control solenoid valve. 14) Remove bolts which hold fuel pipes on the left
side of intake manifold.
B2M2782A
B2M2786
11) Remove bolts which install injector pipe on
intake manifold. 15) Remove two bolts which install fuel pipes on
intake manifold.
B2M2783
B2M2787
12) Remove fuel injectors.
CAUTION: 16) Remove fuel injector pipe.
Replace o-rings and insulators with new ones.
B2M2781
B2M2788A
26
SERVICE PROCEDURE [W4B2] 2-7
4. Intake Manifold
B2M2305
B2M2348A
B2M2357A
B2M2350A
27
2-7 [W4B2] SERVICE PROCEDURE
4. Intake Manifold
10) Remove bolts which install injector pipe on 14) Remove two bolts which install fuel pipes on
intake manifold. intake manifold.
B2M2783 B2M2355
B2M2789
B2M2356A
B2M2786
28
SERVICE PROCEDURE [W4C1] 2-7
4. Intake Manifold
B2M2786
B2M2785
B2M2362A
(A) O-ring A
B2M2787
(B) Insulator A
(C) Fuel injector
(D) Insulator B
(E) O-ring B
29
2-7 [W4C1] SERVICE PROCEDURE
4. Intake Manifold
7) Tighten bolts which install injector pipe on 12) Assemble throttle body to intake manifold.
intake manifold. CAUTION:
Tightening torque: Replace gasket with a new one.
3.4±0.5 N·m (0.35±0.05 kg-m, 2.5±0.4 ft-lb) Tightening torque:
22±2 N·m (2.2±0.2 kg-m, 15.9±1.4 ft-lb)
B2M2783
B2M2782A
B2M2780A
30
SERVICE PROCEDURE [W4C2] 2-7
4. Intake Manifold
17) Install engine ground terminal to intake mani- 3) Tighten two bolts which install fuel pipes on
fold. intake manifold.
Tightening torque:
18.6±1.5 N·m (1.9±0.15 kg-m, 13.7±1.1
ft-lb)
B2M2355
B2M2786
B2M2356A
B2M2353
B2M2789
31
2-7 [W4C2] SERVICE PROCEDURE
4. Intake Manifold
B2M2795A
B2M2348A
(A) O-ring A
(B) Fuel injector (A) Fuel injector
(C) Insulator (B) Purge control solenoid valve
(D) O-ring B (C) Harness band
7) Tighten bolts which install injector pipe on 12) Assemble throttle body to intake manifold.
intake manifold. CAUTION:
Tightening torque: Replace gasket with a new one.
3.4±0.5 N·m (0.35±0.05 kg-m, 2.5±0.4 ft-lb) Tightening torque:
22±2 N·m (2.2±0.2 kg-m, 15.9±1.4 ft-lb)
B2M2783
B2M2305
8) Install purge control solenoid valve.
13) Connect connectors to throttle position sensor
(A) and idle air control solenoid valve (B).
B2M2350A
B2M2357A
32
SERVICE PROCEDURE [W4D1] 2-7
4. Intake Manifold
14) Install ignition coil and ignitor assembly. 2) Connect fuel hoses.
15) Connect connector to ignition coil and ignitor
assembly.
S2M0500
B2M2345
3) Connect connector to oil pressure switch.
B2M1253A
B2M2779
D: INSTALLATION
1. 2200 cc CALIFORNIA SPEC. VEHICLES
1) Install intake manifold onto cylinder heads.
CAUTION: B2M1252A
Always use new gaskets.
Tightening torque: 5) Connect connector to camshaft position sensor.
25±2 N·m (2.5±0.2 kg-m, 18.1±1.4 ft-lb)
B2M2317B
B2M2318
33
2-7 [W4D1] SERVICE PROCEDURE
4. Intake Manifold
6) Connect knock sensor connector. 11) Connect engine coolant hose to throttle body.
H2M3227A B2M2299
7) Connect connectors to engine coolant tempera- 12) Connect PCV hose and pressure regulator
ture sensor. vacuum hose to intake manifold.
S2M1658 B2M2313
8) Hold engine harness connector onto bracket. 13) Connect spark plug cords to ignition coil and
9) Install air cleaner case stay RH and engine har- ignitor assembly.
ness bracket, and connect engine harness con-
nectors to bulkhead connectors.
B2M2312
B2M2315
14) Install fuel protector.
B2M2754
B2M2314
34
SERVICE PROCEDURE [W4D1] 2-7
4. Intake Manifold
15) Install power steering pump on bracket. (4) Adjust V-belt. <Ref. to 1-5 [G200].>
(1) Tighten bolts which install power steering (5) Install V-belt covers.
pump on bracket.
Tightening torque:
20.1±2.5 N·m (2.05±0.25 kg-m, 14.8±1.8
ft-lb
S2M0896
B2M2306
B2M2295A
G2M0286
35
2-7 [W4D1] SERVICE PROCEDURE
4. Intake Manifold
18) Install air cleaner case and air intake duct as 21) Tighten bolts which install air cleaner case to
a unit. stays.
Tightening torque:
4.9±0.5 N·m (0.5±0.05 kg-m, 3.6±0.4 ft-lb)
H2M2931
H2M2930A B2M2285
20) Tighten bolt which installs air intake duct (B) 23) Connect connector to fuel pump relay.
on body.
Tightening torque:
7.4±2.0 N·m (0.75±0.2 kg-m, 5.4±1.4 ft-lb)
S2M0093A
H2M2535
36
SERVICE PROCEDURE [W4D2] 2-7
4. Intake Manifold
25) Connect battery ground cable. 3) Connect connector to oil pressure switch.
G6M0095 B2M1253A
B2M1252A
B2M2318
B2M2317B
S2M0500
H2M3227A
37
2-7 [W4D2] SERVICE PROCEDURE
4. Intake Manifold
7) Connect connectors to engine coolant tempera- 11) Connect PCV hose (A) and vacuum hose (B)
ture sensor. to intake manifold.
S2M1658 H2M2440A
8) Install air intake chamber stay RH and engine 12) Connect spark plug cords to ignition coil and
harness bracket, and connect engine harness con- ignitor assembly.
nectors to bulkhead connectors.
B2M2312
B2M2315
13) Install fuel pipe protector.
9) Connect brake booster hose.
B2M2754
B2M2314
B2M2304
38
SERVICE PROCEDURE [W4D2] 2-7
4. Intake Manifold
14) Install power steering pump on bracket. (4) Adjust V-belt. <Ref. to 1-5 [G200].>
(1) Install power steering pump on bracket, and (5) Install V-belt covers.
tighten bolts.
Tightening torque:
20.1±2.5 N·m (2.05±0.25 kg-m, 14.8±1.8
ft-lb)
S2M0896
S2M0086
B2M2295A
S2M0940
G2M0286
39
2-7 [W4D2] SERVICE PROCEDURE
4. Intake Manifold
S2M0093A
S2M0180
H2M2535
S2M1000
G6M0095
B2M2018
40
SERVICE PROCEDURE [W5A1] 2-7
5. Engine Coolant Temperature Sensor
5. Engine Coolant Temperature 4) Remove air intake duct (A) and (B) as a unit.
Sensor
A: REMOVAL AND INSTALLATION
1. 2200 cc CALIFORNIA SPEC. VEHICLES
1) Disconnect battery ground cable.
B2M2012
G6M0095
S2M1658
H2M3228
B2M2284A
41
2-7 [W5A2] SERVICE PROCEDURE
6. Crankshaft Position Sensor
G6M0095
G6M0095
2) Disconnect connector from mass air flow sen-
sor. 2) Remove bolt which install crankshaft position
sensor to cylinder block.
B2M2018
G2M0408
3) Loosen clamp which connects air intake duct to
air intake chamber. 3) Remove crankshaft position sensor, and dis-
connect connector from it.
H2M3226
G2M0409
4) Remove two clips of air cleaner upper cover.
B2M2289
42
SERVICE PROCEDURE [W7A0] 2-7
7. Front Oxygen (A/F) Sensor
G2M0408
G6M0095
B2M1979
G2M0411
43
2-7 [W7B0] SERVICE PROCEDURE
8. Rear Oxygen Sensor
G6M0095
G2M0412
B2M0335
G6M0095 B2M0351
44
SERVICE PROCEDURE [W8B0] 2-7
8. Rear Oxygen Sensor
G6M0095
B2M0352A
B2M0351
B2M0335
45
2-7 [W9A1] SERVICE PROCEDURE
9. Throttle Position Sensor
G6M0095
B2M2757
2) Disconnect connector from throttle position
sensor.
2. EXCEPT 2200 cc CALIFORNIA SPEC.
VEHICLES
1) Disconnect battery ground cable.
B2M2297
B2M2757
B2M2303
46
SERVICE PROCEDURE [W9B1] 2-7
9. Throttle Position Sensor
B2M2758
B2M2758
B: ADJUSTMENT
1. 2200 cc CALIFORNIA SPEC. VEHICLES
1) Turn ignition switch to OFF. B2M2759
2) Loosen throttle position sensor holding screws.
4) When using Subaru Select Monitor;
NOTE:
For detailed operation procedures, refer to the
Subaru Select Monitor Operation Manual.
(1) Insert the cartridge to Subaru Select Moni-
tor. <Ref. to 1-6 [G1100].>
B2M2759
S2M0286A
47
2-7 [W9B2] SERVICE PROCEDURE
9. Throttle Position Sensor
(2) Connect Subaru Select Monitor to the data 2. EXCEPT 2200 cc CALIFORNIA SPEC.
link connector. VEHICLES
(3) Turn ignition switch to ON, and Subaru
Select Monitor switch to ON. 1) Turn ignition switch to OFF.
(4) Select {2. Each System Check} in Main 2) Loosen throttle position sensor holding screws.
Menu.
(5) Select {Engine Control System} in Selection
Menu.
(6) Select {1. Current Data Display & Save} in
Engine Control System Diagnosis.
(7) Select {1.12 Data Display} in Data Display
Menu.
(8) Adjust throttle position sensor to the proper
position to match with the following specifica-
tions.
B2M2761
Condition: Throttle fully closed
Throttle opening angle 0.00% 3) When using voltage meter;
Throttle sensor voltage 0.50 V (1) Take out ECM.
(2) Turn ignition switch to ON.
(3) Adjust throttle position sensor to the proper
position to allow the voltage signal to ECM to be
in specification.
Connector & terminal / Specified voltage
(B136) No. 15 — (B136) No. 17 / 0.45 —
0.55 V
[Fully closed.]
S2M0098
B2M2760
B2M2759
B2M2761
48
SERVICE PROCEDURE [W9B2] 2-7
9. Throttle Position Sensor
4) When using Subaru Select Monitor; (9) Tighten throttle position sensor holding
NOTE: screws.
For detailed operation procedures, refer to the Tightening torque:
Subaru Select Monitor Operation Manual. 2.0±0.4 N·m (0.20±0.04 kg-m, 1.4±0.3 ft-lb)
(1) Insert the cartridge to Subaru Select Moni-
tor. <Ref. to 1-6 [G1100].>
B2M2761
S2M0286A
S2M0098
49
2-7 [W10A0] SERVICE PROCEDURE
10. Camshaft Position Sensor
10. Camshaft Position Sensor 4) Remove bolt which installs camshaft position
sensor support to camshaft cap LH.
A: REMOVAL AND INSTALLATION
1) Disconnect battery ground cable.
B2M2321
B2M2322
B2M2317C
7) Installation is in the reverse order of removal.
Tightening torque:
3) Remove bolt which installs camshaft position Camshaft position sensor support;
sensor to camshaft position sensor support. 6.4±0.5 N·m (0.65±0.05 kg-m, 4.7±0.4 ft-lb)
Camshaft position sensor;
6.4±0.5 N·m (0.65±0.05 kg-m, 4.7±0.4 ft-lb)
B2M2375
50
SERVICE PROCEDURE [W12A1] 2-7
12. Idle Air Control Solenoid Valve
G6M0095
H2M1453
H2M1454
51
2-7 [W12A2] SERVICE PROCEDURE
12. Idle Air Control Solenoid Valve
4) Remove idle air control solenoid valve from 2) Disconnect connector from idle air control sole-
throttle body. noid valve.
B2M2364 B2M2377
5) Installation is in the reverse order of removal. 3) Remove idle air control solenoid valve from
throttle body.
CAUTION:
Replace gasket with a new one.
Tightening torque:
3.3±0.4 N·m (0.34±0.045 kg-m, 2.5±0.3
ft-lb)
B2M2378
B2M2378
G6M0095
52
SERVICE PROCEDURE [W14A1] 2-7
14. Fuel Injector
G6M0095
G6M0095
H2M1463
4) Remove pressure sources switching solenoid 4) Remove component parts of air intake system
valve from bracket. on California spec. vehicles.
(1) Remove air intake duct (A) and (B) as a
unit.
H2M1464
53
2-7 [W14A1] SERVICE PROCEDURE
14. Fuel Injector
(2) Remove resonator chamber. 7) Remove power steering pump from bracket.
(1) Remove V-belt covers.
B2M2306
S2M0896
5) Remove component parts of air intake system.
(Except California spec. vehicles) (2) Loosen lock bolt and slider bolt, and remove
(1) Disconnect connector from mass air flow power steering pump drive V-belt.
sensor.
G2M0286
B2M2018
(3) Remove bolts which secure power steering
(2) Remove air intake duct and air cleaner
pipe brackets to intake manifold.
upper cover as a unit, and remove air cleaner
element. <Ref. to 2-7 [W1A0].>
B2M2309
B2M2020
(4) Remove bolts which install power steering
6) Remove spark plug cords from spark plugs (#1 pump to bracket.
and #3 cylinders).
S2M0086
B2M2014
54
SERVICE PROCEDURE [W14A2] 2-7
14. Fuel Injector
(5) Place power steering pump on the right side 11) Pull up injector pipe, and remove fuel injector
wheel apron. from intake manifold.
S2M0087 B2M2367
8) Remove band which holds engine harness to 12) Installation is in the reverse order of removal.
fuel injector pipe. CAUTION:
Replace O-rings with new ones.
Tightening torque:
3.4±0.5 N·m (0.35±0.05 kg-m, 2.5±0.4 ft-lb)
B2M2762
B2M2366
2. LH SIDE
1) Release fuel pressure. <Ref. to 2-8 [W1B0].>
2) Open fuel flap lid, and remove fuel filler cap.
B2M2365
H2M2535
B2M2366
55
2-7 [W14A2] SERVICE PROCEDURE
14. Fuel Injector
3) Disconnect battery ground cable. 8) Move washer tank, and secure it away from
working area.
G6M0095
B2M2023
4) Disconnect connector from front window
washer motor. 9) Remove spark plug cords from spark plugs (#1
5) Disconnect connector from rear gate glass and #3 cylinders).
washer motor. (Wagon only)
B2M2024
S2M0546
10) Remove fuel pipe protector.
6) Disconnect rear window glass washer hose
from washer motor, then plug connection with a
suitable cap.
7) Remove two bolts which install washer tank on
body.
B2M2754
B2M2764
B2M2765
56
SERVICE PROCEDURE [W14A2] 2-7
14. Fuel Injector
12) Disconnect connector from fuel injector. 15) Installation is in the reverse order of removal.
CAUTION:
Replace O-rings with new ones.
Tightening torque:
3.4±0.5 N·m (0.35±0.05 kg-m, 2.5±0.4 ft-lb)
B2M2766
B2M2767
B2M2767
B2M2768
57
2-7 [W15A0] SERVICE PROCEDURE
15. Engine Control Module (ECM)
15. Engine Control Module 5) Remove nuts which hold ECM to bracket.
(ECM)
A: REMOVAL AND INSTALLATION
1) Disconnect battery ground cable.
B2M2368
G6M0095
B2M2369A
B2M0672A
B2M2370
B2M0673A
B2M2371A
58
SERVICE PROCEDURE [W16A0] 2-7
16. Main Relay
S2M0137A
G6M0095
S2M0107
S2M0108A
59
2-7 [W17A0] SERVICE PROCEDURE
17. Fuel Pump Relay
G6M0095
S2M1001
S2M0093A
S2M1000
S2M0138
60
SERVICE PROCEDURE [W19B0] 2-7
19. Knock Sensor
H2M3227A
B2M2316
B: INSTALLATION
B2M2320
1) Install knock sensor to cylinder block.
Tightening torque:
3) Remove air intake chamber. 23.5±2.9 N·m (2.4±0.3 kg-m, 17.4±2.2 ft-lb)
(Except 2200 cc California spec. vehicles)
<Ref. to 2-7 [W18A0].> NOTE:
The knock sensor cord which is extracted from the
sensor must be positioned at a 45° angle against
the rear side of the engine.
B2M2301
B2M2316
61
2-7 [W20A0] SERVICE PROCEDURE
20. Intake Manifold Pressure Sensor (2200 cc California Spec. Vehicles only)
2) Connect knock sensor connector and hold 20. Intake Manifold Pressure
knock sensor harness with band.
3) Install air intake chamber. (Except California Sensor (2200 cc California
spec. vehicles) <Ref. to 2-7 [W18A0].> Spec. Vehicles only)
A: REMOVAL AND INSTALLATION
1) Disconnect battery ground cable.
B2M2301
B2M2320
G6M0095
B2M2372
62
SERVICE PROCEDURE [W21A0] 2-7
21. Intake Air Temperature Sensor (2200 cc California Spec. Vehicles only)
4) Remove intake manifold pressure sensor from 21. Intake Air Temperature
throttle body.
Sensor (2200 cc California
Spec. Vehicles only)
A: REMOVAL AND INSTALLATION
1) Disconnect battery ground cable.
B2M2373
B2M2285
B2M2374
63
2-7 SERVICE PROCEDURE
MEMO:
64
ON-BOARD DIAGNOSTICS II
SYSTEM 2-7
Page
T DIAGNOSTICS ...................................................................................2
1. General........................................................................................................2
2. Electrical Components Location..................................................................3
3. Diagnosis System......................................................................................31
4. Cautions ....................................................................................................47
5. Specified Data ...........................................................................................50
6. Basic Diagnostic Procedure ......................................................................60
7. Diagnostics for CHECK ENGINE Malfunction Indicator Lamp (MIL) .......64
8. Diagnostics for Engine Starting Failure ....................................................77
9. General Diagnostic Table ........................................................................108
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec.
Vehicles ...................................................................................................110
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec.
Vehicles ...................................................................................................390
2-7 [T1A0] ON-BOARD DIAGNOSTICS II SYSTEM
1. General
2
ON-BOARD DIAGNOSTICS II SYSTEM [T2A1] 2-7
2. Electrical Components Location
H2M2431I
B2M2237D S2M0258J
S2M0259D H2M2446D
3
2-7 [T2A2] ON-BOARD DIAGNOSTICS II SYSTEM
2. Electrical Components Location
2. SENSOR
H2M2768C
(1) Engine coolant temperature sen- (3) Throttle position sensor (6) Camshaft position sensor
sor (4) Intake manifold pressure sensor (7) Crankshaft position sensor
(2) Intake air temperature sensor (5) Knock sensor
4
ON-BOARD DIAGNOSTICS II SYSTEM [T2A2] 2-7
2. Electrical Components Location
H2M3229A B2M2250A
B2M2251A B2M2252A
B2M2241A B2M2242A
B2M0213J
5
2-7 [T2A2] ON-BOARD DIAGNOSTICS II SYSTEM
2. Electrical Components Location
H2M3091A
B2M2253A OBD0019I
S2M1036B OBD0525G
6
ON-BOARD DIAGNOSTICS II SYSTEM [T2A2] 2-7
2. Electrical Components Location
H2M2431B
H2M3207A B2M1807A
S2M0270A
7
2-7 [T2A3] ON-BOARD DIAGNOSTICS II SYSTEM
2. Electrical Components Location
H2M2768D
(1) Purge control solenoid valve (2) Ignition coil & ignitor ASSY (3) Idle air control solenoid valve
8
ON-BOARD DIAGNOSTICS II SYSTEM [T2A3] 2-7
2. Electrical Components Location
B2M2254A B2M2255A
B2M2256A
9
2-7 [T2A3] ON-BOARD DIAGNOSTICS II SYSTEM
2. Electrical Components Location
H2M2431C
H2M2443A S2M0949B
H2M2444A
10
ON-BOARD DIAGNOSTICS II SYSTEM [T2A3] 2-7
2. Electrical Components Location
MEMO:
11
2-7 [T2A3] ON-BOARD DIAGNOSTICS II SYSTEM
2. Electrical Components Location
H2M2431D
(1) Inhibitor switch (AT vehicles (3) Main relay (6) Radiator sub fan relay
only) (4) Fuel pump relay (7) Starter
(2) Fuel pump (5) Radiator main fan relay
B2M2246A S2M0277A
S2M0278A S2M0279A
12
ON-BOARD DIAGNOSTICS II SYSTEM [T2A3] 2-7
2. Electrical Components Location
B2M2247B
13
2-7 [T2B1] ON-BOARD DIAGNOSTICS II SYSTEM
2. Electrical Components Location
H2M2431F
B2M2237D S2M0258J
S2M0259D H2M2446D
14
ON-BOARD DIAGNOSTICS II SYSTEM [T2B1] 2-7
2. Electrical Components Location
MEMO:
15
2-7 [T2B2] ON-BOARD DIAGNOSTICS II SYSTEM
2. Electrical Components Location
2. SENSOR
S2M0887A
16
ON-BOARD DIAGNOSTICS II SYSTEM [T2B2] 2-7
2. Electrical Components Location
B2M0776B
B2M2239A
H2M3229B B2M2240A
B2M2241A B2M2242A
B2M0213J
17
2-7 [T2B2] ON-BOARD DIAGNOSTICS II SYSTEM
2. Electrical Components Location
H2M3230A
H2M3136A
18
ON-BOARD DIAGNOSTICS II SYSTEM [T2B2] 2-7
2. Electrical Components Location
S2M0264A OBD0019I
S2M1036B OBD0525G
19
2-7 [T2B2] ON-BOARD DIAGNOSTICS II SYSTEM
2. Electrical Components Location
H2M2431B
H2M3207A B2M1807A
S2M0270A
20
ON-BOARD DIAGNOSTICS II SYSTEM [T2B2] 2-7
2. Electrical Components Location
MEMO:
21
2-7 [T2B3] ON-BOARD DIAGNOSTICS II SYSTEM
2. Electrical Components Location
S2M0887B
(1) Pressure sources switching sole- (2) Idle air control solenoid valve (4) Ignition coil & ignitor ASSY
noid valve (3) Purge control solenoid valve
22
ON-BOARD DIAGNOSTICS II SYSTEM [T2B3] 2-7
2. Electrical Components Location
B2M0777B
B2M2243A
B2M2254B B2M2245A
23
2-7 [T2B3] ON-BOARD DIAGNOSTICS II SYSTEM
2. Electrical Components Location
H2M2431C
H2M2443A S2M0949B
H2M2444A
24
ON-BOARD DIAGNOSTICS II SYSTEM [T2B3] 2-7
2. Electrical Components Location
MEMO:
25
2-7 [T2B3] ON-BOARD DIAGNOSTICS II SYSTEM
2. Electrical Components Location
H2M2431D
(1) Inhibitor switch (AT vehicles (3) Main relay (6) Radiator sub fan relay
only) (4) Fuel pump relay (7) Starter
(2) Fuel pump (5) Radiator main fan relay
B2M2246A S2M0277A
S2M0278A S2M0279A
26
ON-BOARD DIAGNOSTICS II SYSTEM [T2B3] 2-7
2. Electrical Components Location
B2M2247B
27
2-7 [T2C1] ON-BOARD DIAGNOSTICS II SYSTEM
2. Electrical Components Location
C: TRANSMISSION
1. MODULE
H2M2445E
B3M0443O H2M2446E
28
ON-BOARD DIAGNOSTICS II SYSTEM [T2C2] 2-7
2. Electrical Components Location
2. SENSOR
B2M2258A B2M2259A
B2M2260A B2M2261A
OBD0653B
29
2-7 [T2C3] ON-BOARD DIAGNOSTICS II SYSTEM
2. Electrical Components Location
B2M2262A B2M2246B
B2M2263A B2M2264A
B2M2265A
30
ON-BOARD DIAGNOSTICS II SYSTEM [T3B1] 2-7
3. Diagnosis System
S2M0258B
OBD0053A
OBD0054A
31
2-7 [T3B2] ON-BOARD DIAGNOSTICS II SYSTEM
3. Diagnosis System
H2M1280
32
ON-BOARD DIAGNOSTICS II SYSTEM [T3B4] 2-7
3. Diagnosis System
33
2-7 [T3B5] ON-BOARD DIAGNOSTICS II SYSTEM
3. Diagnosis System
S2M0286A
S2M0285
34
ON-BOARD DIAGNOSTICS II SYSTEM [T3C3] 2-7
3. Diagnosis System
4) Connect Subaru Select Monitor to data link 2. READ DIAGNOSTIC TROUBLE CODE
connector. (DTC) SHOWN ON DISPLAY FOR ENGINE.
(1) Open the cover data link connector located (NORMAL MODE)
in the lower portion of the instrument panel (on
the driver’s side), to the lower cover. 1) On the Main Menu display screen, select the
{1. All System Diagnosis} and press the [YES] key.
2) Make sure that a diagnostic trouble code (DTC)
is shown on the {Engine Control System} display
screen.
NOTE:
I For detailed operation procedure, refer to the
SUBARU SELECT MONITOR OPERATION
MANUAL.
I For detailed concerning diagnostic trouble
codes, refer to the DIAGNOSTIC TROUBLE
S2M0258B
CODE (DTC) LIST.
I 2200 cc California spec. vehicles: <Ref. to
(2) Connect diagnosis cable to data link con- 2-7 [T10A0].>
nector. I Except 2200 cc California spec. vehicles:
CAUTION: <Ref. to 2-7 [T11A0].>
Do not connect scan tools except for Subaru 3. READ DIAGNOSTIC TROUBLE CODE
Select Monitor and OBD-II general scan tool. (DTC) SHOWN ON DISPLAY FOR ENGINE.
5) Turn ignition switch to ON (engine OFF) and (OBD MODE)
Subaru Select Monitor switch to ON. 1) On the Main Menu display screen, select the
{2. Each System Check} and press the [YES] key.
2) On the System Selection Menu display
screen, select the {Engine Control System} and
press the [YES] key.
3) Press the [YES] key after displayed the infor-
mation of engine type.
4) On the Engine Control System Diagnosis
display screen, select the {7. OBD System} and
press the [YES] key.
5) On the OBD Menu display screen, select the
S2M0288A {3. Diagnosis Code(s) Display} and press the
[YES] key.
6) Using Subaru Select Monitor, call up diagnostic 6) Make sure that a diagnostic trouble code (DTC)
trouble code(s) and various data, then record is shown on the display screen.
them.
NOTE:
I For detailed operation procedure, refer to the
SUBARU SELECT MONITOR OPERATION
MANUAL.
I For detailed concerning diagnostic trouble
codes, refer to the DIAGNOSTIC TROUBLE
CODE (DTC) LIST.
I 2200 cc California spec. vehicles: <Ref. to
2-7 [T10A0].>
I Except 2200 cc California spec. vehicles:
<Ref. to 2-7 [T11A0].>
35
2-7 [T3C4] ON-BOARD DIAGNOSTICS II SYSTEM
3. Diagnosis System
36
ON-BOARD DIAGNOSTICS II SYSTEM [T3C4] 2-7
3. Diagnosis System
37
2-7 [T3C5] ON-BOARD DIAGNOSTICS II SYSTEM
3. Diagnosis System
38
ON-BOARD DIAGNOSTICS II SYSTEM [T3C7] 2-7
3. Diagnosis System
6. READ FREEZE FRAME DATA SHOWN ON DISPLAY FOR ENGINE. (OBD MODE)
1) On the Main Menu display screen, select the {2. Each System Check} and press the [YES] key.
2) On the System Selection Menu display screen, select the {Engine Control System} and press the
[YES] key.
3) Press the [YES] key after displayed the information of engine type.
4) On the Engine Control System Diagnosis display screen, select the {7. OBD System} and press the
[YES] key.
5) On the OBD Menu display screen, select the {2. Freeze Frame Data} and press the [YES] key.
I A list of the support data is shown in the following table.
Contents Display Unit of measure
Diagnostic trouble code (DTC) for freeze frame data Freeze frame data DTC
Air fuel ratio control system for bank 1 Fuel system for Bank1 ON or OFF
Engine load data Engine Load %
Engine coolant temperature signal Coolant Temp. °C or °F
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 %
mmHg or kPa or inHg or
Intake manifold absolute pressure signal Mani. Absolute Pressure
psi
Engine speed signal Engine Speed rpm
Vehicle speed signal Vehicle Speed km/h or MPH
NOTE:
For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL.
7. READ OXYGEN SENSOR MONITORING TEST RESULTS DATA SHOWN ON DISPLAY
FOR ENGINE. (OBD MODE)
1) On the Main Menu display screen, select the {2. Each System Check} and press the [YES] key.
2) On the System Selection Menu display screen, select the {Engine Control System} and press the
[YES] key.
3) Press the [YES] key after displayed the information of engine type.
4) On the Engine Control System Diagnosis display screen, select the {7. OBD System} and press the
[YES] key.
5) On the OBD Menu display screen, select the {5. O2 Sensor Monitor} and press the [YES] key.
6) On the O2 Sensor Select display screen, select the {Bank 1-Sensor1} or {Bank 1-Sensor2} and press
the [YES] key.
I Bank 1-Sensor1 indicates the front oxygen or A/F sensor, and Bank 1-Sensor2 indicates the rear oxy-
gen sensor.
I A list of the support data is shown in the following table.
Contents Display Unit of measure
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:
For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL.
39
2-7 [T3C8] ON-BOARD DIAGNOSTICS II SYSTEM
3. Diagnosis System
40
ON-BOARD DIAGNOSTICS II SYSTEM [T3C9] 2-7
3. Diagnosis System
41
2-7 [T3D1] ON-BOARD DIAGNOSTICS II SYSTEM
3. Diagnosis System
42
ON-BOARD DIAGNOSTICS II SYSTEM [T3E2] 2-7
3. Diagnosis System
S2M0286A
S2M0259B
OBD0072A
43
2-7 [T3E3] ON-BOARD DIAGNOSTICS II SYSTEM
3. Diagnosis System
S2M0259B
S2M0288A
2) Open the cover and connect the OBD-II general
7) On the Main Menu display screen, select the scan tool to its data link connector in the lower
{2. Each System Check} and press the [YES] key. portion of the instrument panel (on the driver’s
8) On the System Selection Menu display side), to the lower cover.
screen, select the {Engine Control System} and CAUTION:
press the [YES] key. Do not connect the scan tools except for
9) Press the [YES] key after displayed the infor- Subaru Select Monitor and OBD-II general scan
mation of engine type. tool.
10) On the Engine Control System Diagnosis
display screen, select the {6. Dealer Check Mode
Procedure} and press the [YES] key.
11) When the “Perform Inspection (Dealer Check)
Mode?” is shown on the display screen, press the
[YES] key.
12) Perform subsequent procedures as instructed
on the display screen.
I If trouble still remains in the memory, the corre-
sponding diagnostic trouble code (DTC) appears
on the display screen. S2M0258B
44
ON-BOARD DIAGNOSTICS II SYSTEM [T3F1] 2-7
3. Diagnosis System
S2M0259B
45
2-7 [T3F1] ON-BOARD DIAGNOSTICS II SYSTEM
3. Diagnosis System
5) Connect Subaru Select Monitor to data link 7) On the Main Menu display screen, select the
connector. {2. Each System Check} and press the [YES] key.
(1) Open the cover and connect Subaru Select 8) On the System Selection Menu display
Monitor to data link connector located in the screen, select the {Engine Control System} and
lower portion of the instrument panel (on the press the [YES] key.
driver’s side), to the lower cover. 9) Press the [YES] key after displayed the infor-
mation of engine type.
10) On the Engine Control System Diagnosis
display screen, select the {4. System Operation
Check Mode} and press the [YES] key.
11) On the System Operation Check Mode
display screen, select the {Actuator ON/OFF
Operation} and press the [YES] key.
12) Select the desired compulsory actuator on the
Actuator ON/OFF Operation display screen and
press the [YES] key.
S2M0258B 13) Pressing the [NO] key completes the compul-
(2) Connect diagnosis cable to data link con- sory operation check mode. The display will then
nector. return to the Actuator ON/OFF Operation
screen.
CAUTION:
Do not connect scan tools except for Subaru
Select Monitor and OBD-II general scan tool.
6) Turn ignition switch to ON (engine OFF) and
Subaru Select Monitor switch to ON.
S2M0288A
46
ON-BOARD DIAGNOSTICS II SYSTEM [T4B0] 2-7
4. Cautions
47
2-7 [T4C0] ON-BOARD DIAGNOSTICS II SYSTEM
4. Cautions
7) Use ECM mounting stud bolts at the body head I The antenna feeder must be placed as far
grounding point when measuring voltage and apart as possible from the ECM and MFI har-
resistance inside the passenger compartment. ness.
I Carefully adjust the antenna for correct
matching.
I When mounting a large power type radio,
pay special attention to the three items above
mentioned.
I Incorrect installation of the radio may affect
the operation of the ECM.
12) Before disconnecting the fuel hose, discon-
nect the fuel pump connector and crank the engine
for more than five seconds to release pressure in
H2M1154A
the fuel system. If engine starts during this
8) Use engine grounding terminal or engine operation, run it until it stops.
proper as the grounding point to the body when 13) Problems in the electronic-controlled auto-
measuring voltage and resistance in the engine matic transmission may be caused by failure of the
compartment. engine, the electronic control system, the transmis-
sion proper, or by a combination of these. These
three causes must be distinguished clearly when
performing diagnostics.
14) 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.
15) In AT vehicles, do not continue the stall for
B2M2266C
more than five seconds at a time (from closed
throttle, fully open throttle to stall engine speed).
9) Use TCM mounting stud bolts at the body head 16) On ABS vehicle, when performing driving test
grounding point when measuring voltage and in jacked-up or lifted-up position, sometimes the
resistance inside the passenger compartment. warning light may be lit, but this is not a malfunc-
tion of the system. The reason for this is the speed
difference between the front and rear wheels. After
diagnosis of engine control system, perform the
ABS memory clearance procedure of self-diagno-
sis system.
C: PRE-INSPECTION
Before performing diagnostics, check the following
items which might affect engine problems:
OBD0040B 1. POWER SUPPLY
10) Every MFI-related part is a precision part. Do 1) Measure battery voltage and specific gravity of
not drop them. electrolyte.
11) Observe the following cautions when installing Standard voltage: 12 V
a radio in MFI equipped models.
Specific gravity: Above 1.260
CAUTION:
I The antenna must be kept as far apart as 2) Check the condition of the main and other
possible from the control unit. fuses, and harnesses and connectors. Also check
(The ECM is located under the steering column, for proper grounding.
inside of the instrument panel lower trim
panel.)
48
ON-BOARD DIAGNOSTICS II SYSTEM [T4C2] 2-7
4. Cautions
2. ENGINE GROUNDING
Make sure the engine grounding terminal is prop-
erly connected to the engine.
B2M2266C
49
2-7 [T5A0] ON-BOARD DIAGNOSTICS II SYSTEM
5. Specified Data
5. Specified Data
A: ENGINE CONTROL MODULE (ECM) I/O SIGNAL FOR 2200 cc
CALIFORNIA SPEC. VEHICLES
B2M2267A
Signal (V)
Connec- Terminal
Content Ignition SW ON Note
tor No. No. Engine ON (Idling)
(Engine OFF)
Crankshaft Signal (+) B135 1 0 −7 — +7 Sensor output waveform
position Signal (−) B135 8 0 0 —
sensor Shield B135 10 0 0 —
Camshaft Signal (+) B135 2 0 −7 — +7 Sensor output waveform
position Signal (−) B135 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
Signal 1 B134 22 0.5 — 13 0.5 — 14 Waveform
Front oxy- Signal 2 B134 23 0.5 — 13 0.5 — 14 Waveform
gen sen- Power
sor heater supply B136 3 10 — 13 13 — 14 —
monitor
Rear oxy- Signal B134 21 0.5 — 13 0.5 — 14 Waveform
gen sen- Power
sor heater supply B136 3 10 — 13 13 — 14 —
monitor
50
ON-BOARD DIAGNOSTICS II SYSTEM [T5A0] 2-7
5. Specified Data
Signal (V)
Connec- Terminal
Content Ignition SW ON Note
tor No. No. Engine ON (Idling)
(Engine OFF)
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.
Starter switch B135 28 0 0 Cranking: 8 — 14
ON: 10 — 13 ON: 13 — 14
A/C switch B135 27 —
OFF: 0 OFF: 0
Ignition switch B135 7 10 — 13 13 — 14 —
On MT vehicle; switch is ON
Neutral position switch ON: 5.0±0.5
B135 26 when gear is in neutral posi-
(MT) OFF: 0
tion.
On AT vehicle; switch is ON
Neutral position switch ON: 0
B135 26 when shift is in “N” or “P”
(AT) OFF: 5.0±0.5
position.
Test mode connector B135 14 5 5 When connected: 0
Knock Signal B136 4 2.5 2.5 —
sensor Shield B136 25 0 0 —
Ignition switch “OFF”: 10 —
Back-up power supply B136 9 10 — 13 13 — 14
13
Control unit power B136 1 10 — 13 13 — 14 —
supply B136 2 10 — 13 13 — 14 —
Sensor power supply B136 15 5 5 —
Line end check 1 B135 20 0 0 —
Ignition #1, #2 B134 25 0 1 — 3.4 Waveform
control #3, #4 B134 26 0 1 — 3.4 Waveform
#1 B134 4 10 — 13 1 — 14 Waveform
Fuel injec- #2 B134 13 10 — 13 1 — 14 Waveform
tor #3 B134 14 10 — 13 1 — 14 Waveform
#4 B134 15 10 — 13 1 — 14 Waveform
Signal B134 5 — 1 — 13 Waveform
Idle air
Power
control B136 2 10 — 13 13 — 14 —
supply
solenoid
valve GND
B134 8 0 0 —
(power)
Fuel pump relay con- ON: 0.5, or less
B134 16 0.5, or less —
trol 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
Radiator fan relay 2 ON: 0.5, or less ON: 0.5, or less
B134 2 With A/C vehicles only
control OFF: 10 — 13 OFF: 13 — 14
Self-shutoff control B135 19 10 — 13 13 — 14 —
Malfunction indicator Light “ON”: 1, or less
B134 11 — —
lamp Light “OFF”: 10 — 14
Engine speed output B134 30 — 0 — 13, or more Waveform
Torque control 1 signal B135 16 5 5 —
Torque control 2 signal B135 17 5 5 —
Torque control cut sig-
B134 31 8 8 —
nal
51
2-7 [T5A0] ON-BOARD DIAGNOSTICS II SYSTEM
5. Specified Data
Signal (V)
Connec- Terminal
Content Ignition SW ON Note
tor No. No. Engine ON (Idling)
(Engine OFF)
Intake manifold pres-
B136 11 3.5 — 3.8 1.2 — 1.8 —
sure signal for AT
Purge control solenoid ON: 1, or less ON: 1, or less
B134 2 —
valve OFF: 10 — 13 OFF: 13 — 14
ON: 0 Switch is ON when turning
Power steering switch B135 13 10 — 13
OFF: 13 — 14 steering wheel.
Signal B136 5 3.5 — 3.8 1.2 — 1.8 —
Intake
Power
manifold B136 15 5 5 —
supply
pressure
sensor GND (sen-
B136 16 0 0 —
sor)
Fuel temperature sen- Ambient temperature: 25°C
B136 26 2.5 — 3.8 2.5 — 3.8
sor (75°F)
Fuel level sensor B136 27 0.12 — 4.75 0.12 — 4.75 —
The value obtained after the
Signal B136 12 2.3 — 2.7 2.3 — 2.7 fuel filler cap was removed
Fuel tank once and recapped.
pressure Power
B136 15 5 5 —
sensor supply
GND (sen-
B136 16 0 0 —
sor)
Fuel tank pressure ON: 1, or less ON: 1, or less
B134 1 —
control solenoid valve OFF: 10 — 13 OFF: 13 — 14
ON: 1, or less ON: 1, or less
Drain valve B134 10 —
OFF: 10 — 13 OFF: 13 — 14
AT diagnosis input sig- Less than 1 ←→ More Less than 1 ←→ More
B135 4 Waveform
nal than 4 than 4
Intake air temperature Intake air temperature: 25°C
B136 13 3.0 — 3.4 3.0 — 3.4
sensor (75°F)
Line end check 2 B135 21 5 5 —
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)
52
ON-BOARD DIAGNOSTICS II SYSTEM [T5B0] 2-7
5. Specified Data
B2M2267A
Signal (V)
Connec- Terminal
Content Ignition SW ON Note
tor No. No. Engine ON (Idling)
(Engine OFF)
Crankshaft Signal (+) B135 1 0 −7 — +7 Sensor output waveform
position Signal (−) B135 8 0 0 —
sensor Shield B135 10 0 0 —
Camshaft Signal (+) B135 2 0 −7 — +7 Sensor output waveform
position Signal (−) B135 9 0 0 —
sensor Shield B135 10 0 0 —
Signal B136 5 0 — 0.3 0.8 — 1.2 —
Mass air Power
B136 15 5 5 —
flow sen- supply
sor Shield B136 25 0 0 —
GND B136 8 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)
Front oxy- Signal (+) B136 7 0 0 — 0.9 —
gen sen- Signal (–) B136 20 0 —
sor Shield B136 23 0 0 —
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 22 0 — 1.0 0 — 1.0 —
gen sen-
sor heater Signal 2 B134 23 0 — 1.0 0 — 1.0 —
Rear oxygen sensor
B134 21 0 — 1.0 0 — 1.0 —
heater signal
53
2-7 [T5B0] ON-BOARD DIAGNOSTICS II SYSTEM
5. Specified Data
Signal (V)
Connec- Terminal
Content Ignition SW ON Note
tor No. No. Engine ON (Idling)
(Engine OFF)
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.
Starter switch B135 28 0 0 Cranking: 8 — 14
ON: 10 — 13 ON: 13 — 14
A/C switch B135 27 —
OFF: 0 OFF: 0
Ignition switch B135 7 10 — 13 13 — 14 —
On MT vehicle; switch is ON
Neutral position switch ON: 5.0±0.5
B135 26 when gear is in neutral posi-
(MT) OFF: 0
tion.
On AT vehicle; switch is ON
Neutral position switch ON: 0
B135 26 when shift is in “N” or “P”
(AT) OFF: 5.0±0.5
position.
Test mode connector B135 14 5 5 When connected: 0
Knock Signal B136 4 2.8 2.8 —
sensor Shield B136 25 0 0 —
When measuring voltage
AT: 5 AT: 5
AT/MT identification B135 25 between ECM and chassis
MT: 0 MT: 0
ground.
Ignition switch “OFF”: 10 —
Back-up power supply B136 9 10 — 13 13 — 14
13
Control unit power B136 1 10 — 13 13 — 14 —
supply 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
Fuel pump relay con- ON: 0.5, or less
B134 16 0.5, or less —
trol 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
Radiator fan relay 2 ON: 0.5, or less ON: 0.5, or less
B134 2 With A/C vehicles only
control OFF: 10 — 13 OFF: 13 — 14
Self-shutoff control B135 19 10 — 13 13 — 14 —
Malfunction indicator Light “ON”: 1, or less
B134 11 — —
lamp Light “OFF”: 10 — 14
Engine speed output B134 30 — 0 — 13, or more Waveform
54
ON-BOARD DIAGNOSTICS II SYSTEM [T5B0] 2-7
5. Specified Data
Signal (V)
Connec- Terminal
Content Ignition SW ON Note
tor No. No. Engine ON (Idling)
(Engine OFF)
Torque control 1 signal B135 16 5 5 —
Torque control 2 signal B135 17 5 5 —
Torque control cut sig-
B134 31 8 8 —
nal
Mass air flow signal for
B136 11 0 — 0.3 0.8 — 1.2 —
AT
Purge control solenoid ON: 1, or less ON: 1, or less
B134 2 —
valve OFF: 10 — 13 OFF: 13 — 14
ON: 0 Switch is ON when turning
Power steering switch B135 13 10 — 13
OFF: 13 — 14 steering wheel.
Signal B136 29 3.5 — 3.8 1.2 — 1.8
Atmo-
Power
spheric B136 15 5 5
supply —
pressure
sensor GND (sen-
B136 16 0 0
sor)
Pressure sources
ON: 1, or less ON: 1, or less
switching solenoid B134 9 —
OFF: 10 — 13 OFF: 13 — 14
valve
Fuel temperature sen- Ambient temperature: 25°C
B136 26 2.5 — 3.8 2.5 — 3.8
sor (75°F)
Fuel level sensor B136 27 0.12 — 4.75 0.12 — 4.75 —
The value obtained after the
Signal B136 12 2.3 — 2.7 2.3 — 2.7 fuel filler cap was removed
Fuel tank once and recapped.
pressure Power
B136 15 5 5 —
sensor supply
GND (sen-
B136 16 0 0 —
sor)
Fuel tank pressure ON: 1, or less ON: 1, or less
B134 1 —
control solenoid valve OFF: 10 — 13 OFF: 13 — 14
ON: 1, or less ON: 1, or less
Drain valve B134 10 —
OFF: 10 — 13 OFF: 13 — 14
AT diagnosis input sig- Less than 1 ←→ More Less than 1 ←→ More
B135 4 Waveform
nal than 4 than 4
Line end check 2 B135 21 5 5 —
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)
55
2-7 [T5C0] ON-BOARD DIAGNOSTICS II SYSTEM
5. Specified Data
Measuring condition:
I After warm-up the engine.
I Gear position is in “N” or “P” position.
I A/C is turned OFF.
I All accessory switches are turned OFF.
56
ON-BOARD DIAGNOSTICS II SYSTEM [T5D0] 2-7
5. Specified Data
B2M2269A
NOTE:
Check with ignition switch ON.
Connector Terminal
Content Measuring conditions Voltage (V)
No. No.
Back-up power supply B55 6 Ignition switch OFF 10 — 16
B54 23
Ignition power supply Ignition switch ON (with engine OFF) 10 — 16
B54 24
“P” range Selector lever in “P” range Less than 1
B55 23
switch Selector lever in any other than “P” range More than 8
“N” range Selector lever in “N” range Less than 1
B55 22
switch Selector lever in any other than “N” range More than 8
“R” range Selector lever in “R” range Less than 1
B55 17
switch Selector lever in any other than “R” range More than 9.5
“D” range Selector lever in “D” range Less than 1
Inhibitor switch B55 8
switch Selector lever in any other than “D” range More than 9.5
“3” range Selector lever in “3” range Less than 1
B55 18
switch Selector lever in any other than “3” range More than 9.5
“2” range Selector lever in “2” range Less than 1
B54 10
switch Selector lever in any other than “2” range More than 9.5
“1” range Selector lever in “1” range Less than 1
B54 1
switch Selector lever in any other than “1” range More than 9.5
Brake pedal depressed More than 10.5
Brake switch B55 24
Brake pedal released Less than 1
ABS switch ON Less than 1
ABS signal B54 19
ABS switch OFF More than 6.5
57
2-7 [T5D0] ON-BOARD DIAGNOSTICS II SYSTEM
5. Specified Data
Resistance to
Connector Terminal
Content Measuring conditions Voltage (V) body
No. No.
(ohms)
Throttle position Throttle fully closed. 0.3 — 0.7
B55 1 —
sensor Throttle fully open. 4.3 — 4.9
Throttle position
Ignition switch ON (with
sensor power B55 2 4.8 — 5.3 —
engine OFF)
supply
ATF temperature ATF temperature 20°C (68°F) 2.9 — 4.0 2.1 k — 2.9 k
B55 11
sensor ATF temperature 80°C (176°F) 1.0 — 1.4 275 — 375
Vehicle stopped. 0
Vehicle speed
B55 3 Vehicle speed at least 20 km/h 450 — 650
sensor 1 More than 1 (AC range)
(12 MPH)
Vehicle speed Vehicle speed at most 10
B55 5 Less than 1←→More than 4 —
sensor 2 km/h (6 MPH)
Torque converter Vehicle stopped. 0
turbine speed B55 12 Vehicle speed at least 20 km/h 450 — 650
More than 1 (AC range)
sensor (12 MPH)
Vehicle speed Vehicle speed at most 10
B55 13 Less than 1←→More than 4 —
output signal km/h (6 MPH)
Ignition switch ON (with
More than 10.5
Engine speed engine OFF).
B55 4 —
signal Ignition switch ON (with
8 — 11
engine ON).
When cruise control is set
Less than 1
(SET lamp ON).
Cruise set signal B54 11 —
When cruise control is not set
More than 6.5
(SET lamp OFF).
Torque control 1 Ignition switch ON
B54 13 More than 9 —
signal (with engine ON)
Torque control 2 Ignition switch ON
B54 21 More than 9 —
signal (with engine ON)
Torque control
B54 2 Ignition switch ON 8 —
cut signal
1.2 — 1.8*1
AT load signal B55 20 Engine idling after warm-up —
0.5 — 1.2*2
1st or 4th gear More than 9
Shift solenoid 1 B54 7 10 — 16
2nd or 3rd gear Less than 1
1st or 2nd gear More than 9
Shift solenoid 2 B54 6 10 — 16
3rd or 4th gear Less than 1
Throttle fully closed (with
1.5 — 4.0
engine OFF) after warm-up.
Duty solenoid A B54 9 2.0 — 4.5
Throttle fully open (with engine
Less than 0.5
OFF) after warm-up.
Throttle fully closed (with
More than 8.5
engine OFF) after warm-up.
Dropping resistor B54 18 9 — 15
Throttle fully open (with engine
Less than 0.5
OFF) after warm-up.
When lock up occurs. More than 8.5
Duty solenoid B B54 16 10 — 17
When lock up is released. Less than 0.5
Fuse on FWD switch More than 8.5
Duty solenoid C Fuse removed from FWD
(AWD models B54 15 switch (with throttle fully open 10 — 17
Less than 0.5
only) and with select lever in 1st
gear).
58
ON-BOARD DIAGNOSTICS II SYSTEM [T5D0] 2-7
5. Specified Data
Resistance to
Connector Terminal
Content Measuring conditions Voltage (V) body
No. No.
(ohms)
Throttle fully closed (with
1.5 — 4.0
engine OFF) after warm-up.
Duty solenoid D B54 8 2.0 — 4.5
Throttle fully open (with engine
Less than 0.5
OFF) after warm-up.
Throttle fully closed (with
More than 8.5
2-4 brake duty engine OFF) after warm-up.
B54 17 9 — 15
solenoid resistor Throttle fully open (with engine
Less than 0.5
OFF) after warm-up.
2-4 brake timing 3rd gear More than 9
B54 5 10 — 16
solenoid 1st gear Less than 1
Low clutch timing 2nd gear Less than 1
B54 14 10 — 16
solenoid 4th gear More than 9
Sensor ground
B55 10 — 0 Less than 1
line 1
Sensor ground
B55 21 — 0 Less than 1
line 2
System ground 9
B55 — 0 Less than 1
line 19
Fuse removed. 6 — 9.1
FWD switch B55 14 —
Fuse installed. Less than 1
Fuse on FWD switch Less than 1
FWD indicator
B54 12 Fuse removed from FWD —
lamp More than 9
switch.
Data link signal 7 — —
(Subaru Select B55 —
Monitor) 16 — —
AT diagnosis sig-
B54 4 Ignition switch ON Less than 1 ←→ More than 4 —
nal
59
2-7 [T6A1] ON-BOARD DIAGNOSTICS II SYSTEM
6. Basic Diagnostic Procedure
60
ON-BOARD DIAGNOSTICS II SYSTEM [T6C1] 2-7
6. Basic Diagnostic Procedure
61
2-7 [T6C2] ON-BOARD DIAGNOSTICS II SYSTEM
6. Basic Diagnostic Procedure
62
ON-BOARD DIAGNOSTICS II SYSTEM [T6C2] 2-7
6. Basic Diagnostic Procedure
MEMO:
63
2-7 [T7A0] ON-BOARD DIAGNOSTICS II SYSTEM
7. Diagnostics for CHECK ENGINE Malfunction Indicator Lamp (MIL)
H2M3000
64
ON-BOARD DIAGNOSTICS II SYSTEM [T7A5] 2-7
7. Diagnostics for CHECK ENGINE Malfunction Indicator Lamp (MIL)
7A1 : CHECK OUTPUT SIGNAL FROM 7A4 : CHECK HARNESS BETWEEN COM-
ECM. BINATION METER AND ECM CON-
NECTOR.
1) Turn ignition switch to ON.
2) Measure voltage between ECM connector and 1) Turn ignition switch to OFF.
chassis ground. 2) Remove combination meter. <Ref. to 6-2
[W8A0].>
Connector & terminal
3) Disconnect connector from ECM and combina-
(B134) No. 11 (+) — Chassis ground (−):
tion meter.
4) Measure resistance of harness between ECM
and combination meter connector.
Connector & terminal
(B134) No. 11 — (i12) No. 18:
B2M2271A
65
2-7 [T7A6] ON-BOARD DIAGNOSTICS II SYSTEM
7. Diagnostics for CHECK ENGINE Malfunction Indicator Lamp (MIL)
H2M3232A
66
ON-BOARD DIAGNOSTICS II SYSTEM [T7A7] 2-7
7. Diagnostics for CHECK ENGINE Malfunction Indicator Lamp (MIL)
MEMO:
67
2-7 [T7B0] ON-BOARD DIAGNOSTICS II SYSTEM
7. Diagnostics for CHECK ENGINE Malfunction Indicator Lamp (MIL)
H2M3000
68
ON-BOARD DIAGNOSTICS II SYSTEM [T7B1] 2-7
7. Diagnostics for CHECK ENGINE Malfunction Indicator Lamp (MIL)
H2M2446C
69
2-7 [T7C0] ON-BOARD DIAGNOSTICS II SYSTEM
7. Diagnostics for CHECK ENGINE Malfunction Indicator Lamp (MIL)
H2M3001
70
ON-BOARD DIAGNOSTICS II SYSTEM [T7C4] 2-7
7. Diagnostics for CHECK ENGINE Malfunction Indicator Lamp (MIL)
H2M2446C
B2M0512A
71
2-7 [T7C5] ON-BOARD DIAGNOSTICS II SYSTEM
7. Diagnostics for CHECK ENGINE Malfunction Indicator Lamp (MIL)
B2M0514A
72
ON-BOARD DIAGNOSTICS II SYSTEM [T7C5] 2-7
7. Diagnostics for CHECK ENGINE Malfunction Indicator Lamp (MIL)
MEMO:
73
2-7 [T7D0] ON-BOARD DIAGNOSTICS II SYSTEM
7. Diagnostics for CHECK ENGINE Malfunction Indicator Lamp (MIL)
H2M3001
74
ON-BOARD DIAGNOSTICS II SYSTEM [T7D1] 2-7
7. Diagnostics for CHECK ENGINE Malfunction Indicator Lamp (MIL)
B2M2275A
75
2-7 [T7D1] ON-BOARD DIAGNOSTICS II SYSTEM
7. Diagnostics for CHECK ENGINE Malfunction Indicator Lamp (MIL)
MEMO:
76
ON-BOARD DIAGNOSTICS II SYSTEM [T8A0] 2-7
8. Diagnostics for Engine Starting Failure
77
2-7 [T8B0] ON-BOARD DIAGNOSTICS II SYSTEM
8. Diagnostics for Engine Starting Failure
H2M3085
OBD0724
78
ON-BOARD DIAGNOSTICS II SYSTEM [T8B5] 2-7
8. Diagnostics for Engine Starting Failure
4) Measure power supply voltage between starter 8B3 : CHECK HARNESS BETWEEN BAT-
motor connector terminal and engine ground. TERY AND IGNITION SWITCH CON-
Connector & terminal NECTOR.
(B14) No. 1 (+) — Engine ground (−):
1) Turn ignition switch to OFF.
2) Remove SBF No. 4 from main fuse box.
3) Measure resistance of fuse.
: Is resistance less than 1 Ω?
: Replace SBF No. 4. <Ref. to 6-3
[D5A0].>
: Go to step 8B4.
OBD0103A
79
2-7 [T8B6] ON-BOARD DIAGNOSTICS II SYSTEM
8. Diagnostics for Engine Starting Failure
H2M3095A
H2M3094A
80
ON-BOARD DIAGNOSTICS II SYSTEM [T8B11] 2-7
8. Diagnostics for Engine Starting Failure
8B10 : CHECK STARTER INTERLOCK CIR- 8B11 : CHECK STARTER INTERLOCK CIR-
CUIT. CUIT.
B2M2412A B2M2413A
81
2-7 [T8C0] ON-BOARD DIAGNOSTICS II SYSTEM
8. Diagnostics for Engine Starting Failure
H2M3003
8C1 : CHECK MAIN RELAY. 4) Measure resistance between main relay termi-
nals.
H2M2268
82
ON-BOARD DIAGNOSTICS II SYSTEM [T8C5] 2-7
8. Diagnostics for Engine Starting Failure
Measure resistance between main relay terminals. Measure resistance of harness between ECM and
Terminals chassis ground.
No. 4 — No. 6: Connector & terminal
(B134) No. 8 — Chassis ground:
H2M2269
B2M2418A
: Is the resistance less than 10 Ω?
: Go to step 8C3. : Is the resistance less than 5 Ω?
: Replace main relay. <Ref. to 2-7 : Go to step 8C5.
[W16A0].> : Repair open circuit in harness between
ECM connector and engine grounding
8C3 : CHECK GROUND CIRCUIT OF ECM. terminal.
B2M2417A
B2M2419A
: Is the resistance less than 5 Ω?
: Go to step 8C4. : Is the resistance less than 5 Ω?
: Repair open circuit in harness between : Go to step 8C6.
ECM connector and engine grounding : Repair open circuit in harness between
terminal. ECM connector and engine grounding
terminal.
83
2-7 [T8C6] ON-BOARD DIAGNOSTICS II SYSTEM
8. Diagnostics for Engine Starting Failure
8C6 : CHECK GROUND CIRCUIT OF ECM. 8C8 : CHECK GROUND CIRCUIT OF ECM.
Measure resistance of harness between ECM and Measure resistance of harness between ECM and
chassis ground. chassis ground.
Connector & terminal Connector & terminal
(B134) No. 34 — Chassis ground: (B136) No. 21 — Chassis ground:
B2M2420A B2M2422A
8C7 : CHECK GROUND CIRCUIT OF ECM. 8C9 : CHECK GROUND CIRCUIT OF ECM.
Measure resistance of harness between ECM and Measure resistance of harness between ECM and
chassis ground. chassis ground.
Connector & terminal Connector & terminal
(B134) No. 35 — Chassis ground: (B136) No. 22 — Chassis ground:
B2M2421A B2M2423A
84
ON-BOARD DIAGNOSTICS II SYSTEM [T8C13] 2-7
8. Diagnostics for Engine Starting Failure
8C10 : CHECK INPUT VOLTAGE OF ECM. 8C12 : CHECK HARNESS BETWEEN ECM
AND MAIN RELAY CONNECTOR.
1) Disconnect connector from ECM.
2) Measure voltage between ECM connector and 1) Ignition switch to OFF.
chassis ground. 2) Measure resistance between ECM and chassis
ground.
Connector & terminal
(B136) No. 9 (+) — Chassis ground (–): Connector & terminal
(B135) No. 19 — Chassis ground:
H2M3208A
H2M3210A
: Is the voltage more than 10 V?
: Go to step 8C11. : Is the resistance more than 1 MΩ?
: Repair open or ground short circuit of : Go to step 8C13.
power supply circuit. : Repair ground short circuit in harness
between ECM connector and main relay
8C11 : CHECK INPUT VOLTAGE OF ECM. connector, then replace ECM.
H2M3209A
85
2-7 [T8C14] ON-BOARD DIAGNOSTICS II SYSTEM
8. Diagnostics for Engine Starting Failure
8C14 : CHECK INPUT VOLTAGE OF MAIN 8C16 : CHECK INPUT VOLTAGE OF MAIN
RELAY. RELAY.
Check voltage between main relay connector and Measure voltage between main relay connector
chassis ground. and chassis ground.
Connector & terminal Connector & terminal
(B47) No. 2 (+) — Chassis ground (–): (B47) No. 5 (+) — Chassis ground (–):
H2M3212A H2M3214A
H2M3215A
86
ON-BOARD DIAGNOSTICS II SYSTEM [T8C21] 2-7
8. Diagnostics for Engine Starting Failure
8C18 : CHECK INPUT VOLTAGE OF ECM. 8C20 : CHECK INPUT VOLTAGE OF ECM.
1) Connect main relay connector. Measure voltage between ECM connector and
2) Ignition switch to ON. chassis ground.
3) Measure voltage between ECM connector and Connector & terminal
chassis ground. (B136) No. 3 (+) — Chassis ground (–):
Connector & terminal
(B136) No. 1 (+) — Chassis ground (–):
H2M3218A
H2M3217A
87
2-7 [T8C22] ON-BOARD DIAGNOSTICS II SYSTEM
8. Diagnostics for Engine Starting Failure
B2M2424A
88
ON-BOARD DIAGNOSTICS II SYSTEM [T8C22] 2-7
8. Diagnostics for Engine Starting Failure
MEMO:
89
2-7 [T8D0] ON-BOARD DIAGNOSTICS II SYSTEM
8. Diagnostics for Engine Starting Failure
H2M3004
90
ON-BOARD DIAGNOSTICS II SYSTEM [T8D2] 2-7
8. Diagnostics for Engine Starting Failure
8D1 : CHECK IGNITION SYSTEM FOR 8D2 : CHECK POWER SUPPLY CIRCUIT
SPARKS. FOR IGNITION COIL & IGNITOR
ASSEMBLY.
1) Remove plug cord cap from each spark plug.
2) Install new spark plug on plug cord cap. 1) Turn ignition switch to OFF.
2) Disconnect connector from ignition coil & ignitor
CAUTION:
assembly.
Do not remove spark plug from engine.
3) Turn ignition switch to ON.
3) Contact spark plug’s thread portion on engine. 4) Measure power supply voltage between ignition
4) While opening throttle valve fully, crank engine coil & ignitor assembly connector and engine
to check that spark occurs at each cylinder. ground.
Connector & terminal
(E12) No. 2 (+) — Engine ground (−):
B2M2426
91
2-7 [T8D3] ON-BOARD DIAGNOSTICS II SYSTEM
8. Diagnostics for Engine Starting Failure
8D3 : CHECK HARNESS OF IGNITION COIL 8D4 : CHECK IGNITION COIL & IGNITOR
& IGNITOR ASSEMBLY GROUND ASSEMBLY.
CIRCUIT.
1) Remove spark plug cords.
1) Turn ignition switch to OFF. 2) Measure resistance between spark plug cord
2) Measure resistance between ignition coil & igni- contact portions to check secondary coil.
tor assembly connector and engine ground.
Terminals
Connector & terminal No. 1 — No. 2:
(E12) No. 3 — Engine ground:
B2M2428A
S2M0693A
: Is the resistance between 10 and 15
: Is the resistance between less than 5 kΩ?
Ω? : Go to step 8D5.
: Go to step 8D4. : Replace ignition coil & ignitor assembly.
: Repair harness and connector. <Ref. to 6-1 [W4A0].>
NOTE:
In this case, repair the following: 8D5 : CHECK IGNITION COIL & IGNITOR
I Open circuit in harness between ignition coil & ASSEMBLY.
ignitor assembly connector and engine grounding
terminal Measure resistance between spark plug cord con-
tact portions to check secondary coil.
Terminals
No. 3 — No. 4:
B2M2428A
92
ON-BOARD DIAGNOSTICS II SYSTEM [T8D8] 2-7
8. Diagnostics for Engine Starting Failure
8D6 : CHECK INPUT SIGNAL FOR IGNI- 8D8 : CHECK HARNESS BETWEEN ECM
TION COIL & IGNITOR ASSEMBLY. AND IGNITION COIL & IGNITOR
ASSEMBLY CONNECTOR.
1) Connect connector to ignition coil & ignitor
assembly. 1) Turn ignition switch to OFF.
2) Check if voltage varies synchronously with 2) Disconnect connector from ECM.
engine speed when cranking, while monitoring 3) Disconnect connector from ignition coil & ignitor
voltage between ignition coil & ignitor assembly assembly.
connector and engine ground. 4) Measure resistance of harness between ECM
and ignition coil & ignitor assembly connector.
Connector & terminal
(E12) No. 1 (+) — Engine ground (–): Connector & terminal
(B134) No. 25 — (E12) No. 1:
B2M2429A
B2M2431A
: Is the voltage more than 10 V?
: Go to step 8D7. : Is the resistance less than 1 Ω?
: Replace ignition coil & ignitor assembly. : Go to step 8D9.
<Ref. to 6-1 [W4A0].> : Repair harness and connector.
NOTE:
8D7 : CHECK INPUT SIGNAL FOR IGNI- In this case, repair the following:
TION COIL & IGNITOR ASSEMBLY. I Open circuit in harness between ECM and igni-
tion coil & ignitor assembly connector
Check if voltage varies synchronously with engine I Poor contact in coupling connector (B22)
speed when cranking, while monitoring voltage
between ignition coil & ignitor assembly connector
and engine ground.
Connector & terminal
(E12) No. 4 (+) — Engine ground (–):
B2M2430A
93
2-7 [T8D9] ON-BOARD DIAGNOSTICS II SYSTEM
8. Diagnostics for Engine Starting Failure
8D9 : CHECK HARNESS BETWEEN ECM 8D10 : CHECK HARNESS BETWEEN ECM
AND IGNITION COIL & IGNITOR AND IGNITION COIL & IGNITOR
ASSEMBLY CONNECTOR. ASSEMBLY CONNECTOR.
Measure resistance of harness between ECM and Measure resistance of harness between ECM and
ignition coil & ignitor assembly connector. engine ground.
Connector & terminal Connector & terminal:
(B134) No. 26 — (E12) No. 4: (B134) No. 25 — Engine ground:
B2M2432A B2M2433A
B2M2434A
94
ON-BOARD DIAGNOSTICS II SYSTEM [T8D12] 2-7
8. Diagnostics for Engine Starting Failure
95
2-7 [T8E0] ON-BOARD DIAGNOSTICS II SYSTEM
8. Diagnostics for Engine Starting Failure
H2M3005
Make sure that fuel pump is in operation for two 1) Turn ignition switch to OFF.
seconds when turning ignition switch to ON. 2) Remove fuel pump access hole lid located on
NOTE: the right rear of trunk compartment floor (Sedan) or
Fuel pump operation check can also be executed luggage compartment floor (Wagon).
using Subaru Select Monitor (Function mode:
FD01).
For the procedure, refer to “COMPULSORY
VALVE OPERATION CHECK MODE”. <Ref. to 2-7
[T3F0].>
: Does fuel pump produce operating
sound?
: Check fuel injector circuit. <Ref. to 2-7
[T8F0].>
: Go to step 8E2. S2M0392
96
ON-BOARD DIAGNOSTICS II SYSTEM [T8E4] 2-7
8. Diagnostics for Engine Starting Failure
OBD0132A
OBD0133A
97
2-7 [T8E5] ON-BOARD DIAGNOSTICS II SYSTEM
8. Diagnostics for Engine Starting Failure
8E5 : CHECK HARNESS BETWEEN FUEL 8E6 : CHECK FUEL PUMP RELAY.
PUMP AND FUEL PUMP RELAY CON-
NECTOR. 1) Disconnect connectors from fuel pump relay
and main relay.
Measure resistance of harness between fuel pump 2) Remove fuel pump relay and main relay with
and fuel pump relay connector. bracket.
Connector & terminal 3) Connect battery to fuel pump relay connector
(R58) No. 1 — Chassis ground: terminals No. 1 and No. 3.
4) Measure resistance between connector termi-
nals of fuel pump relay.
Terminals
No. 2 — No. 4:
H2M2304A
98
ON-BOARD DIAGNOSTICS II SYSTEM [T8E8] 2-7
8. Diagnostics for Engine Starting Failure
B2M2436A
99
2-7 [T8F0] ON-BOARD DIAGNOSTICS II SYSTEM
8. Diagnostics for Engine Starting Failure
H2M3006
100
ON-BOARD DIAGNOSTICS II SYSTEM [T8F2] 2-7
8. Diagnostics for Engine Starting Failure
8F1 : CHECK OUTPUT SIGNAL FROM 8F2 : CHECK HARNESS BETWEEN FUEL
ECM. INJECTOR AND ECM CONNECTOR.
OBD0713A
B2M2068A
: Is the resistance less than 10 Ω?
: Is the voltage more than 10 V? : Repair ground short circuit in harness
: Go to step 8F6. between fuel injector and ECM connec-
: Go to step 8F2. tor.
: Go to step 8F3.
101
2-7 [T8F3] ON-BOARD DIAGNOSTICS II SYSTEM
8. Diagnostics for Engine Starting Failure
S2M0405
102
ON-BOARD DIAGNOSTICS II SYSTEM [T8F6] 2-7
8. Diagnostics for Engine Starting Failure
8F5 : CHECK POWER SUPPLY LINE. 8F6 : CHECK HARNESS BETWEEN FUEL
INJECTOR AND ECM CONNECTOR.
1) Turn ignition switch to ON.
2) Measure voltage between fuel injector and 1) Turn ignition switch to OFF.
engine ground on faulty cylinders. 2) Disconnect connector from fuel injector on
faulty cylinder.
Connector & terminal
3) Turn ignition switch to ON.
#1 (E5) No. 2 (+) — Engine ground (−):
4) Measure voltage between ECM connector and
#2 (E16) No. 2 (+) — Engine ground (−):
chassis ground on faulty cylinders.
#3 (E6) No. 2 (+) — Engine ground (−):
#4 (E17) No. 2 (+) — Engine ground (−): Connector & terminal
#1 (B134) No. 4 (+) — Chassis ground (−):
#2 (B134) No. 13 (+) — Chassis ground
(−):
#3 (B134) No. 14 (+) — Chassis ground
(−):
#4 (B134) No. 15 (+) — Chassis ground
(−):
OBD0715A
103
2-7 [T8F7] ON-BOARD DIAGNOSTICS II SYSTEM
8. Diagnostics for Engine Starting Failure
1) Turn ignition switch to OFF. Check poor contact in ECM connector. <Ref. to
2) Measure resistance between fuel injector termi- FOREWORD [T3C1].>
nals on faulty cylinder.
: Is there poor contact in ECM connec-
Terminals tor?
No. 1 — No. 2: : Repair poor contact in ECM connector.
: Check crankshaft position sensor cir-
cuit. <Ref. to 2-7 [T8G0].>
S2M0405
104
ON-BOARD DIAGNOSTICS II SYSTEM [T8G0] 2-7
8. Diagnostics for Engine Starting Failure
B2M2069
105
2-7 [T8H0] ON-BOARD DIAGNOSTICS II SYSTEM
8. Diagnostics for Engine Starting Failure
B2M2438
106
ON-BOARD DIAGNOSTICS II SYSTEM [T8I0] 2-7
8. Diagnostics for Engine Starting Failure
H2M3017
107
2-7 [T9A0] ON-BOARD DIAGNOSTICS II SYSTEM
9. General Diagnostic Table
108
ON-BOARD DIAGNOSTICS II SYSTEM [T9B0] 2-7
9. General Diagnostic Table
109
2-7 [T10A0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
110
ON-BOARD DIAGNOSTICS II SYSTEM [T10A0] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
DTC
Item Index
No.
P0303 Cylinder 3 misfire detected <Ref. to 2-7
[T10AA0].>
P0304 Cylinder 4 misfire detected <Ref. to 2-7
[T10AB0].>
P0325 Knock sensor circuit malfunction <Ref. to 2-7
[T10AC0].>
P0335 Crankshaft position sensor circuit malfunction <Ref. to 2-7
[T10AD0].>
P0336 Crankshaft position sensor circuit range/performance problem <Ref. to 2-7
[T10AE0].>
P0340 Camshaft position sensor circuit malfunction <Ref. to 2-7
[T10AF0].>
P0341 Camshaft position sensor circuit range/performance problem <Ref. to 2-7
[T10AG0].>
P0420 Catalyst system efficiency below threshold <Ref. to 2-7
[T10AH0].>
P0440 Evaporative emission control system malfunction <Ref. to 2-7
[T10AI0].>
P0443 Evaporative emission control system purge control valve circuit low input <Ref. to 2-7
[T10AJ0].>
P0446 Evaporative emission control system vent control low input <Ref. to 2-7
[T10AK0].>
P0451 Evaporative emission control system pressure sensor range/performance problem <Ref. to 2-7
[T10AL0].>
P0452 Evaporative emission control system pressure sensor low input <Ref. to 2-7
[T10AM0].>
P0453 Evaporative emission control system pressure sensor high input <Ref. to 2-7
[T10AN0].>
P0461 Fuel level sensor circuit range/performance problem <Ref. to 2-7
[T10AO0].>
P0462 Fuel level sensor circuit low input <Ref. to 2-7
[T10AP0].>
P0463 Fuel level sensor circuit high input <Ref. to 2-7
[T10AQ0].>
P0480 Cooling fan relay 1 circuit low input <Ref. to 2-7
[T10AR0].>
P0483 Cooling fan function problem <Ref. to 2-7
[T10AS0].>
P0500 Vehicle speed sensor malfunction <Ref. to 2-7
[T10AT0].>
P0505 Idle control system circuit low input <Ref. to 2-7
[T10AU0].>
P0506 Idle control system RPM lower than expected <Ref. to 2-7
[T10AV0].>
P0507 Idle control system RPM higher than expected <Ref. to 2-7
[T10AW0].>
P0601 Internal control module memory check sum error <Ref. to 2-7
[T10AX0].>
P0703 Brake switch input malfunction <Ref. to 2-7
[T10AY0].>
P0705 Transmission range sensor circuit malfunction <Ref. to 2-7
[T10AZ0].>
P0710 Transmission fluid temperature sensor circuit malfunction <Ref. to 2-7
[T10BA0].>
111
2-7 [T10A0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
DTC
Item Index
No.
P0715 Torque converter turbine speed sensor circuit malfunction <Ref. to 2-7
[T10BB0].>
P0720 Output speed sensor (vehicle speed sensor 2) circuit malfunction <Ref. to 2-7
[T10BC0].>
P0725 Engine speed input circuit malfunction <Ref. to 2-7
[T10BD0].>
P0731 Gear 1 incorrect ratio <Ref. to 2-7
[T10BE0].>
P0732 Gear 2 incorrect ratio <Ref. to 2-7
[T10BF0].>
P0733 Gear 3 incorrect ratio <Ref. to 2-7
[T10BG0].>
P0734 Gear 4 incorrect ratio <Ref. to 2-7
[T10BH0].>
P0740 Torque converter clutch system malfunction <Ref. to 2-7
[T10BI0].>
P0743 Torque converter clutch system (Duty solenoid B) electrical <Ref. to 2-7
[T10BJ0].>
P0748 Pressure control solenoid (Duty solenoid A) electrical <Ref. to 2-7
[T10BK0].>
P0753 Shift solenoid A (shift solenoid 1) electrical <Ref. to 2-7
[T10BL0].>
P0758 Shift solenoid B (shift solenoid 2) electrical <Ref. to 2-7
[T10BM0].>
P1100 Starter switch circuit low input <Ref. to 2-7
[T10BN0].>
P1101 Neutral position switch circuit low input [MT vehicles] <Ref. to 2-7
[T10BO0].>
P1101 Neutral position switch circuit high input [AT vehicles] <Ref. to 2-7
[T10BP0].>
P1103 Engine torque control signal 1 circuit malfunction <Ref. to 2-7
[T10BQ0].>
P1106 Engine torque control signal 2 circuit malfunction <Ref. to 2-7
[T10BR0].>
P1110 Atmospheric pressure sensor circuit low input <Ref. to 2-7
[T10BS0].>
P1111 Atmospheric pressure sensor circuit high input <Ref. to 2-7
[T10BT0].>
P1112 Atmospheric pressure sensor circuit range/performance problem <Ref. to 2-7
[T10BU0].>
P1115 Engine torque control cut signal circuit high input <Ref. to 2-7
[T10BV0].>
P1116 Engine torque control cut signal circuit low input <Ref. to 2-7
[T10BW0].>
P1120 Starter switch circuit high input <Ref. to 2-7
[T10BX0].>
P1121 Neutral position switch circuit high input [MT vehicles] <Ref. to 2-7
[T10BY0].>
P1121 Neutral position switch circuit low input [AT vehicles] <Ref. to 2-7
[T10BZ0].>
P1130 Front oxygen (A/F) sensor circuit malfunction (open circuit) <Ref. to 2-7
[T10CA0].>
P1131 Front oxygen (A/F) sensor circuit malfunction (short circuit) <Ref. to 2-7
[T10CB0].>
112
ON-BOARD DIAGNOSTICS II SYSTEM [T10A0] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
DTC
Item Index
No.
P1132 Front oxygen (A/F) sensor heater circuit low input <Ref. to 2-7
[T10CC0].>
P1133 Front oxygen (A/F) sensor heater circuit high input <Ref. to 2-7
[T10CD0].>
P1134 Front oxygen (A/F) sensor micro-computer problem <Ref. to 2-7
[T10CE0].>
P1139 Front oxygen (A/F) sensor #1 heater circuit range/performance problem <Ref. to 2-7
[T10CF0].>
P1142 Throttle position sensor circuit range/performance problem (low input) <Ref. to 2-7
[T10CG0].>
P1151 Rear oxygen sensor heater circuit high input <Ref. to 2-7
[T10CH0].>
P1400 Fuel tank pressure control solenoid valve circuit low input <Ref. to 2-7
[T10CI0].>
P1420 Fuel tank pressure control solenoid valve circuit high input <Ref. to 2-7
[T10CJ0].>
P1422 Evaporative emission control system purge control valve circuit high input <Ref. to 2-7
[T10CK0].>
P1423 Evaporative emission control system vent control high input <Ref. to 2-7
[T10CL0].>
P1443 Evaporative emission control system vent control function problem <Ref. to 2-7
[T10CM0].>
P1505 Idle control system circuit high input <Ref. to 2-7
[T10CN0].>
P1507 Idle control system malfunction (fail-safe) <Ref. to 2-7
[T10CO0].>
P1520 Cooling fan relay 1 circuit high input <Ref. to 2-7
[T10CP0].>
P1560 Back-up voltage circuit malfunction <Ref. to 2-7
[T10CQ0].>
P1700 Throttle position sensor circuit malfunction for automatic transmission <Ref. to 2-7
[T10CR0].>
P1701 Cruise control set signal circuit malfunction for automatic transmission <Ref. to 2-7
[T10CS0].>
P1702 Automatic transmission diagnosis input signal circuit low input <Ref. to 2-7
[T10CT0].>
P1703 Low clutch timing control solenoid valve circuit malfunction <Ref. to 2-7
[T10CU0].>
P1704 2-4 brake timing control solenoid valve circuit malfunction <Ref. to 2-7
[T10CV0].>
P1705 2-4 brake pressure control solenoid valve (Duty solenoid D) circuit malfunction <Ref. to 2-7
[T10CW0].>
P1722 Automatic transmission diagnosis input signal circuit high input <Ref. to 2-7
[T10CX0].>
P1742 Automatic transmission diagnosis input signal circuit malfunction <Ref. to 2-7
[T10CY0].>
113
2-7 [T10B0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
CAUTION:
After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].>
and INSPECTION MODE <Ref. to 2-7 [T3E0].>.
I WIRING DIAGRAM:
H2M3007
114
ON-BOARD DIAGNOSTICS II SYSTEM [T10B4] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
115
2-7 [T10C0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
CAUTION:
After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].>
and INSPECTION MODE <Ref. to 2-7 [T3E0].>.
I WIRING DIAGRAM:
H2M3007
116
ON-BOARD DIAGNOSTICS II SYSTEM [T10C4] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
10C1 : CONNECT SUBARU SELECT MONI- 10C3 : CHECK INPUT SIGNAL FOR ECM.
TOR OR THE OBD-II GENERAL
SCAN TOOL, AND READ DATA. Measure voltage between ECM connector and
chassis ground.
1) Turn ignition switch to OFF.
Connector & terminal
2) Connect Subaru Select Monitor or the OBD-II
(B136) No. 15 (+) — Chassis ground (−):
general scan tool to data link connector.
B2M2443A
S2M0258B
3) Turn ignition switch to ON and Subaru Select : Is the voltage more than 4.5 V?
Monitor or the OBD-II general scan tool switch to : Go to step 10C5.
ON. : Go to step 10C4.
4) Start engine.
5) Read the data of intake manifold absolute pres-
sure signal using Subaru Select Monitor or OBD-II 10C4 : CHECK INPUT SIGNAL FOR ECM.
general scan tool.
NOTE: Measure voltage between ECM connector and
I Subaru Select Monitor chassis ground.
For detailed operation procedure, refer to the Connector & terminal
“READ CURRENT DATA SHOWN ON DISPLAY (B136) No. 15 (+) — Chassis ground (−):
FOR ENGINE”. <Ref. to 2-7 [T3C4].>
I OBD-II general scan tool
For detailed operation procedures, refer to the
OBD-II General Scan Tool Instruction Manual.
: Is the value less than 3.3 kPa (25
mmHg, 0.98 inHg)?
: Go to step 10C3.
: Go to step 10C2.
Check poor contact in ECM and pressure sensor : Does the voltage change more than
connector. <Ref. to FOREWORD [T3C1].> 4.5 V by shaking harness and con-
nector of ECM while monitoring the
: Is there poor contact in ECM or pres- value with voltage meter?
sure sensor connector? : Repair poor contact in ECM connector.
: Repair poor contact in ECM or pressure : Contact with SOA service.
sensor connector.
: Even if MIL lights up, the circuit has NOTE:
returned to a normal condition at this Inspection by DTM is required, because probable
time. cause is deterioration of multiple parts.
117
2-7 [T10C5] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
10C5 : CHECK INPUT SIGNAL FOR ECM. 10C7 : CHECK HARNESS BETWEEN ECM
AND INTAKE MANIFOLD PRES-
SURE SENSOR CONNECTOR.
Measure voltage between ECM and chassis
ground.
1) Turn ignition switch to OFF.
Connector & terminal
2) Disconnect connector from intake manifold
(B136) No. 5 (+) — Chassis ground (−):
pressure sensor.
3) Turn ignition switch to ON.
4) Measure voltage between intake manifold pres-
sure sensor connector and engine ground.
Connector & terminal
(E28) No. 3 (+) — Engine ground (−):
B2M2444A
118
ON-BOARD DIAGNOSTICS II SYSTEM [T10C10] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
10C8 : CHECK HARNESS BETWEEN ECM 10C9 : CHECK HARNESS BETWEEN ECM
AND INTAKE MANIFOLD PRES- AND INTAKE MANIFOLD PRES-
SURE SENSOR CONNECTOR. SURE SENSOR CONNECTOR.
B2M2447A
H2M3097A
: Is the resistance more than 500 kΩ?
: Is the resistance less than 1 Ω? : Go to step 10C10.
: Go to step 10C9. : Repair ground short circuit in harness
between ECM and intake manifold pres-
: Repair open circuit in harness between
sure sensor connector.
ECM and intake manifold pressure sen-
sor connector.
10C10 : CHECK POOR CONTACT.
119
2-7 [T10D0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
CAUTION:
After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].>
and INSPECTION MODE <Ref. to 2-7 [T3E0].>.
I WIRING DIAGRAM:
H2M3007
120
ON-BOARD DIAGNOSTICS II SYSTEM [T10D3] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
10D1 : CONNECT SUBARU SELECT MONI- 10D2 : CHECK INPUT SIGNAL FOR ECM.
TOR OR THE OBD-II GENERAL
SCAN TOOL, AND READ DATA. Measure voltage between ECM connector and
chassis ground.
1) Turn ignition switch to OFF.
Connector & terminal
2) Connect Subaru Select Monitor or the OBD-II
(B136) No. 15 (+) — Chassis ground (−):
general scan tool to data link connector.
B2M2443A
S2M0258B
3) Turn ignition switch to ON and Subaru Select : Is the voltage more than 4.5 V?
Monitor or the OBD-II general scan tool switch to : Go to step 10D4.
ON. : Go to step 10D3.
4) Start engine.
5) Read the data of intake manifold absolute pres-
sure signal using Subaru Select Monitor or OBD-II 10D3 : CHECK INPUT SIGNAL FOR ECM.
general scan tool.
NOTE: Measure voltage between ECM connector and
I Subaru Select Monitor chassis ground.
For detailed operation procedure, refer to the Connector & terminal
“READ CURRENT DATA SHOWN ON DISPLAY (B136) No. 15 (+) — Chassis ground (−):
FOR ENGINE”. <Ref. to 2-7 [T3C4].>
I OBD-II general scan tool
For detailed operation procedures, refer to the
OBD-II General Scan Tool Instruction Manual.
: Is the value more than 130 kPa (975
mmHg, 38.39 inHg)?
: Go to step 10D10.
: Go to step 10D2.
B2M2443A
121
2-7 [T10D4] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
10D4 : CHECK INPUT SIGNAL FOR ECM. 10D6 : CHECK HARNESS BETWEEN ECM
AND INTAKE MANIFOLD PRES-
SURE SENSOR CONNECTOR.
Measure voltage between ECM connector and
chassis ground.
1) Turn ignition switch to OFF.
Connector & terminal
2) Disconnect connector from intake manifold
(B136) No. 5 (+) — Chassis ground (−):
pressure sensor.
3) Turn ignition switch to ON.
4) Measure voltage between intake manifold pres-
sure sensor connector and engine ground.
Connector & terminal
(B28) No. 3 (+) — Engine ground (−):
B2M2444A
122
ON-BOARD DIAGNOSTICS II SYSTEM [T10D10] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
H2M3097A
123
2-7 [T10E0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
I TROUBLE SYMPTOM:
I Erroneous idling
I Poor driving performance
CAUTION:
After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].>
and INSPECTION MODE <Ref. to 2-7 [T3E0].>.
I WIRING DIAGRAM:
H2M3008
124
ON-BOARD DIAGNOSTICS II SYSTEM [T10E1] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
125
2-7 [T10F0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
I TROUBLE SYMPTOM:
I Erroneous idling
I Poor driving performance
CAUTION:
After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].>
and INSPECTION MODE <Ref. to 2-7 [T3E0].>.
I WIRING DIAGRAM:
H2M3008
126
ON-BOARD DIAGNOSTICS II SYSTEM [T10F2] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
127
2-7 [T10G0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
I TROUBLE SYMPTOM:
I Erroneous idling
I Poor driving performance
CAUTION:
After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].>
and INSPECTION MODE <Ref. to 2-7 [T3E0].>.
I WIRING DIAGRAM:
H2M3008
128
ON-BOARD DIAGNOSTICS II SYSTEM [T10G2] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
S2M0258B
129
2-7 [T10G3] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
1) Turn ignition switch to ON. Measure voltage between intake air temperature
2) Measure voltage between intake air tempera- sensor connector and engine ground.
ture sensor connector and engine ground. Connector & terminal
Connector & terminal (E20) No. 1 (+) — Engine ground (−):
(E20) No. 1 (+) — Engine ground (−):
B2M2688A
B2M2688A
: Is the voltage more than 3 V?
: Is the voltage more than 10 V? : Go to step 10G5.
: Repair battery short circuit in harness : Repair harness and connector.
between intake air temperature sensor
and ECM connector. NOTE:
In this case, repair the following:
: Go to step 10G4. I Open circuit in harness between intake air tem-
perature sensor and ECM connector
I Poor contact in intake air temperature sensor
I Poor contact in ECM
I Poor contact in coupling connector (B21)
130
ON-BOARD DIAGNOSTICS II SYSTEM [T10G5] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
B2M2689A
131
2-7 [T10H0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
I TROUBLE SYMPTOM:
I Hard to start
I Erroneous idling
I Poor driving performance
CAUTION:
After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].>
and INSPECTION MODE <Ref. to 2-7 [T3E0].>.
I WIRING DIAGRAM:
H2M3009
132
ON-BOARD DIAGNOSTICS II SYSTEM [T10H2] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
S2M0258B B2M2449
3) Turn ignition switch to ON and Subaru Select 3) Remove engine harness connector bracket
Monitor or OBD-II general scan tool switch to ON. from cylinder block.
4) Start engine.
5) Read data of engine coolant temperature sen-
sor signal using Subaru Select Monitor or OBD-II
general scan tool.
NOTE:
I Subaru Select Monitor
For detailed operation procedure, refer to the
“READ CURRENT DATA SHOWN ON DISPLAY
FOR ENGINE”. <Ref. to 2-7 [T3C4].>
I OBD-II general scan tool
For detailed operation procedures, refer to the B2M2451
OBD-II General Scan Tool Instruction Manual.
4) Remove blow-by hoses.
: Is the value greater than 120°C
(248°F)?
: Go to step 10H2.
: Repair poor contact.
NOTE:
In this case, repair the following:
I Poor contact in engine coolant temperature sen-
sor
I Poor contact in ECM
I Poor contact in coupling connector (B21) and
B2M2450
(B171)
133
2-7 [T10H2] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
134
ON-BOARD DIAGNOSTICS II SYSTEM [T10H2] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
MEMO:
135
2-7 [T10I0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
H2M3009
136
ON-BOARD DIAGNOSTICS II SYSTEM [T10I2] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
S2M0258B B2M2449
3) Turn ignition switch to ON and Subaru Select 3) Remove engine harness connector bracket
Monitor or OBD-II general scan tool switch to ON. from cylinder block.
4) Start engine.
5) Read data of engine coolant temperature sen-
sor signal using Subaru Select Monitor or OBD-II
general scan tool.
NOTE:
I Subaru Select Monitor
For detailed operation procedure, refer to the
“READ CURRENT DATA SHOWN ON DISPLAY
FOR ENGINE”. <Ref. to 2-7 [T3C4].>
I OBD-II general scan tool
For detailed operation procedures, refer to the B2M2451
OBD-II General Scan Tool Instruction Manual.
: Is the value less than −40°C (−40°F)? 4) Remove blow-by hoses.
: Go to step 10I2.
: Repair poor contact.
NOTE:
In this case, repair the following:
I Poor contact in engine coolant temperature sen-
sor
I Poor contact in ECM
I Poor contact in coupling connector (B21) and
(B171)
B2M2450
137
2-7 [T10I3] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
6) Measure voltage between engine coolant tem- 10I4 : CHECK HARNESS BETWEEN
perature sensor connector and engine ground. ENGINE COOLANT TEMPERATURE
Connector & terminal SENSOR AND ECM CONNECTOR.
(E8) No. 1 (+) — Engine ground (−):
Measure voltage between engine coolant tempera-
ture sensor connector and engine ground.
Connector & terminal
(E8) No. 1 (+) — Engine ground (−):
H2M3099A
H2M3099A
138
ON-BOARD DIAGNOSTICS II SYSTEM [T10I5] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
H2M3100A
139
2-7 [T10J0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
H2M3010
140
ON-BOARD DIAGNOSTICS II SYSTEM [T10J2] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
S2M0258B
141
2-7 [T10K0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
I TROUBLE SYMPTOM:
I Erroneous idling
I Engine stalls.
I Poor driving performance
CAUTION:
After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].>
and INSPECTION MODE <Ref. to 2-7 [T3E0].>.
I WIRING DIAGRAM:
H2M3010
142
ON-BOARD DIAGNOSTICS II SYSTEM [T10K3] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
10K1 : CONNECT SUBARU SELECT MONI- 10K2 : CHECK INPUT SIGNAL FOR ECM.
TOR OR THE OBD-II GENERAL
SCAN TOOL, AND READ DATA. Measure voltage between ECM connector and
chassis ground while throttle valve is fully closed.
1) Turn ignition switch to OFF.
Connector & terminal
2) Connect Subaru Select Monitor or the OBD-II
(B136) No. 15 (+) — Chassis ground (−):
general scan tool to data link connector.
B2M2443A
S2M0258B
3) Turn ignition switch to ON and Subaru Select : Is the voltage more than 4.5 V?
Monitor or OBD-II general scan tool switch to ON. : Go to step 10K4.
4) Start engine. : Go to step 10K3.
5) Read data of throttle position sensor signal
using Subaru Select Monitor or OBD-II general
scan tool. 10K3 : CHECK INPUT SIGNAL FOR ECM.
NOTE:
I Subaru Select Monitor Measure voltage between ECM connector and
For detailed operation procedure, refer to the chassis ground.
“READ CURRENT DATA SHOWN ON DISPLAY Connector & terminal
FOR ENGINE”. <Ref. to 2-7 [T3C4].> (B136) No. 15 (+) — Chassis ground (−):
I OBD-II general scan tool
For detailed operation procedures, refer to the
OBD-II General Scan Tool Instruction Manual.
: Is the value less than 0.1 V?
: Go to step 10K2.
: Even if MIL lights up, the circuit has
returned to a normal condition at this
time. A temporary poor contact of the
connector may be the cause.
NOTE: B2M2443A
143
2-7 [T10K4] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
10K4 : CHECK INPUT SIGNAL FOR ECM. 10K6 : CHECK HARNESS BETWEEN ECM
AND THROTTLE POSITION SEN-
SOR CONNECTOR.
Measure voltage between ECM connector and
chassis ground.
1) Turn ignition switch to OFF.
Connector & terminal
2) Disconnect connectors from throttle position
(B136) No. 17 (+) — Chassis ground (−):
sensor.
3) Turn ignition switch to ON.
4) Measure voltage between throttle position sen-
sor connector and engine ground.
Connector & terminal
(E13) No. 1 (+) — Engine ground (−):
B2M2452A
144
ON-BOARD DIAGNOSTICS II SYSTEM [T10K9] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
10K7 : CHECK HARNESS BETWEEN ECM 10K8 : CHECK HARNESS BETWEEN ECM
AND THROTTLE POSITION SEN- AND THROTTLE POSITION SEN-
SOR CONNECTOR. SOR CONNECTOR.
B2M2455A
B2M2454A
: Is the resistance less than 10 Ω?
: Is the resistance less than 1 Ω? : Repair ground short circuit in harness
: Go to step 10K8. between throttle position sensor and
: Repair harness and connector. ECM connector.
NOTE: : Go to step 10K9.
In this case, repair the following:
I Open circuit in harness between throttle position 10K9 : CHECK POOR CONTACT.
sensor and ECM connector
I Poor contact in ECM connector Check poor contact in throttle position sensor con-
I Poor contact in throttle position sensor connec- nector. <Ref. to FOREWORD [T3C1].>
tor
I Poor contact in coupling connector (B21) and : Is there poor contact in throttle posi-
(B171) tion sensor connector?
: Repair poor contact in throttle position
sensor connector.
: Replace throttle position sensor. <Ref.
to 2-7 [W9A1].>
145
2-7 [T10L0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
I TROUBLE SYMPTOM:
I Erroneous idling
I Engine stalls.
I Poor driving performance
CAUTION:
After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].>
and INSPECTION MODE <Ref. to 2-7 [T3E0].>.
I WIRING DIAGRAM:
H2M3010
146
ON-BOARD DIAGNOSTICS II SYSTEM [T10L2] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
S2M0258B
147
2-7 [T10L3] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
B2M2457A
148
ON-BOARD DIAGNOSTICS II SYSTEM [T10M1] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
H2M3009
149
2-7 [T10N0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
CAUTION:
After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].>
and INSPECTION MODE <Ref. to 2-7 [T3E0].>.
I WIRING DIAGRAM:
H2M3011
150
ON-BOARD DIAGNOSTICS II SYSTEM [T10O4] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
10O2 : CHECK FRONT (A/F) OXYGEN SEN- 10O3 : CHECK REAR OXYGEN SENSOR
SOR DATA. SIGNAL.
1) Turn ignition switch to OFF. 1) Race engine at speeds from idling to 5,000 rpm
2) Connect the Subaru Select Monitor or the for a total of 5 cycles.
OBD-II general scan tool to data link connector. 2) Operate the LED operation mode for engine.
NOTE:
I Subaru Select Monitor
For detailed operation procedure, refer to the “LED
OPERATION MODE FOR ENGINE”. <Ref. to 2-7
[T3C8].>
: Does the LED of {Rear O2 Rich Sig-
nal} blink?
: Repair poor contact in front oxygen
(A/F) sensor and rear oxygen sensor
S2M0258B
connector.
: Check rear oxygen sensor circuit. <Ref.
3) Start engine and Turn the Subaru Select Moni- to 2-7 [T10Q0].>
tor and the OBD-II general scan tool switch to ON.
4) Warm-up the engine until coolant temperature
is above 70°C (160°F). 10O4 : CHECK EXHAUST SYSTEM.
5) Read data of front oxygen (A/F) sensor signal
using Subaru Select Monitor or OBD-II general Check exhaust system parts.
scan tool.
NOTE:
NOTE: Check the following items.
I Subaru Select Monitor I Loose installation of portions
For detailed operation procedure, refer to the I Damage (crack, hole etc.) of parts
“READ CURRENT DATA SHOWN ON DISPLAY I Looseness of front oxygen (A/F) sensor
FOR ENGINE”. <Ref. to 2-7 [T3C4].> I Looseness and ill fitting of parts between front
I OBD-II general scan tool oxygen (A/F) sensor and rear oxygen sensor
For detailed operation procedures, refer to the
OBD-II General Scan Tool Instruction Manual. : Is there a fault in exhaust system?
: Repair or replace faulty parts.
: Is the value equal to or more than
0.85 and equal to less than 1.15? : Replace front oxygen (A/F) sensor.
<Ref. to 2-7 [W7A0].>
: Go to step 10O3.
: Go to step 10O4.
151
2-7 [T10P0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
H2M3011
10P1 : CHECK ANY OTHER DTC ON DIS- 10P2 : CHECK EXHAUST SYSTEM.
PLAY.
NOTE:
: Does the Subaru Select Monitor or Check the following items.
OBD-II general scan tool indicate I Loose installation of front portion of exhaust pipe
DTC P1130 or P1131? onto cylinder heads
: Inspect DTC P1130 or P1131 using “10. I Loose connection between front exhaust pipe
Diagnostics Chart with Trouble Code for and front catalytic converter
I Damage of exhaust pipe resulting in a hole
2200 cc California Spec. Vehicles”.
<Ref. to 2-7 [T10A0].> : Is there a fault in exhaust system?
NOTE: : Repair exhaust system.
In this case, it is not necessary to inspect DTC : Replace front oxygen (A/F) sensor.
P0133. <Ref. to 2-7 [W7A0].>
: Go to step 10P2.
152
ON-BOARD DIAGNOSTICS II SYSTEM [T10P2] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
MEMO:
153
2-7 [T10Q0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
H2M3012
10Q1 : CHECK ANY OTHER DTC ON DIS- 10Q2 : CHECK FAILURE CAUSE OF P1130
PLAY. OR P1131.
: Does the Subaru Select Monitor or Inspect DTC P1130 or P1131 using “10. Diagnos-
OBD-II general scan tool indicate tics Chart with Trouble Code for 2200 cc California
DTC P1130 or P1131? Spec. Vehicles”. <Ref. to 2-7 [T10A0].>
: Go to step 10Q2. : Is the failure cause of P1130 or P1131
: Go to step 10Q3. in the fuel system?
: Check fuel system.
NOTE:
In this case, it is not necessary to inspect DTC
P0136.
: Go to step 10Q3.
154
ON-BOARD DIAGNOSTICS II SYSTEM [T10Q5] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
10Q3 : CHECK REAR OXYGEN SENSOR 10Q5 : CHECK HARNESS BETWEEN ECM
DATA. AND REAR OXYGEN SENSOR CON-
NECTOR.
1) Turn ignition switch to OFF.
2) Connect Subaru Select Monitor or OBD-II gen- 1) Turn ignition switch to OFF.
eral scan tool to data link connector. 2) Disconnect connectors from ECM and rear oxy-
gen sensor.
3) Measure resistance of harness between ECM
and rear oxygen sensor connector.
Connector & terminal
(B136) No. 16 — (E25) No. 3:
S2M0258B
155
2-7 [T10Q6] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
H2M3106A
156
ON-BOARD DIAGNOSTICS II SYSTEM [T10R1] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
H2M3012
157
2-7 [T10S0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
H2M3013
158
ON-BOARD DIAGNOSTICS II SYSTEM [T10S3] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
10S2 : CHECK GROUND CIRCUIT OF ECM. 10S3 : CHECK GROUND CIRCUIT OF ECM.
B2M2467A
159
2-7 [T10S4] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
10S4 : CHECK HARNESS BETWEEN ECM 10S6 : CHECK POWER SUPPLY TO REAR
AND REAR OXYGEN SENSOR CON- OXYGEN SENSOR.
NECTOR.
1) Connect connector to ECM.
Measure resistance of harness between ECM con- 2) Turn ignition switch to ON.
nector and chassis ground. 3) Measure voltage between rear oxygen sensor
Connector & terminal connector and engine ground or chassis ground.
(B134) No. 21 — Chassis ground: Connector & terminal
(E25) No. 2 (+) — Engine ground (−):
B2M2479A
B2M2481A
: Is the resistance less than 10 Ω?
: Repair ground short circuit in harness : Is the voltage more than 10 V?
between ECM and rear oxygen sensor : Go to step 10S7.
connector. : Repair power supply line.
: Go to step 10S5.
NOTE:
In this case, repair the following:
10S5 : CHECK HARNESS BETWEEN ECM I Open circuit in harness between main relay and
AND REAR OXYGEN SENSOR CON- rear oxygen sensor connector
NECTOR. I Poor contact in rear oxygen sensor connector
I Poor contact in coupling connector (E1)
1) Disconnect connector from rear oxygen sensor.
2) Measure resistance of harness between ECM
and rear oxygen sensor connector.
Connector & terminal
(B134) No. 21 — (E25) No. 4:
B2M2480A
160
ON-BOARD DIAGNOSTICS II SYSTEM [T10S7] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
B2M2482
161
2-7 [T10T0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
10U1 : CHECK EXHAUST SYSTEM. (2) Disconnect connector from fuel tank.
B2M0047
S2M0392
162
ON-BOARD DIAGNOSTICS II SYSTEM [T10U4] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
3) Disconnect fuel delivery hose from fuel filter, 10U4 : CHECK FUEL PRESSURE.
and connect fuel pressure gauge.
163
2-7 [T10U5] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
10U5 : CHECK ENGINE COOLANT TEM- 10U6 : CHECK INTAKE MANIFOLD PRES-
PERATURE SENSOR. < REF. TO 2-7 SURE SENSOR.
[T10H0].> OR <REF. TO 2-7 [T10I0].>
1) Start the engine and warm-up engine until cool-
1) Turn ignition switch to OFF. ant temperature is greater than 60°C (140°F).
2) Connect the Subaru Select Monitor or the 2) Place the shift lever in neutral position (MT
OBD-II general scan tool to data link connector. vehicles) or the selector lever in “N” or “P” position
(AT vehicles).
3) Turn A/C switch to OFF.
4) Turn all accessory switches to OFF.
5) Read data of intake manifold pressure sensor
signal using Subaru Select Monitor or OBD-II gen-
eral scan tool.
NOTE:
I Subaru Select Monitor
For detailed operation procedure, refer to the
“READ CURRENT DATA SHOWN ON DISPLAY
S2M0258B
FOR ENGINE”. <Ref. to 2-7 [T3C4].>
3) Start the engine and warm-up completely. I OBD-II general scan tool
4) Read data of engine coolant temperature sen- For detailed operation procedure, refer to the
sor signal using Subaru Select Monitor or OBD-II OBD-II General Scan Tool Instruction Manual.
general scan tool. Specification:
NOTE: I Intake manifold absolute pressure
I Subaru Select Monitor Engine speed Specified value
For detailed operation procedure, refer to the
20.0 — 46.7 kPa
“READ CURRENT DATA SHOWN ON DISPLAY Idling
(150 — 350 mmHg, 5.91 — 13.78 inHg)
FOR ENGINE”. <Ref. to 2-7 [T3C4].> 20.0 — 46.7 kPa
I OBD-II general scan tool 2,500 rpm
(150 — 350 mmHg, 5.91 — 13.78 inHg)
For detailed operation procedures, refer to the
OBD-II General Scan Tool Instruction Manual. : Is the value within the specifica-
tions?
: Is temperature greater than 60°C
(140°F)? : Go to step 10U7.
: Go to step 10U6. : Replace intake manifold pressure sen-
sor. <Ref. to 2-7 [W20A0].>
: Replace engine coolant temperature
sensor. <Ref. to 2-7 [W5A1].>
164
ON-BOARD DIAGNOSTICS II SYSTEM [T10U7] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
165
2-7 [T10V0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
H2M3014
166
ON-BOARD DIAGNOSTICS II SYSTEM [T10V1] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
MEMO:
167
2-7 [T10W0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
H2M3014
168
ON-BOARD DIAGNOSTICS II SYSTEM [T10W2] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
10W1 : CONNECT SUBARU SELECT MONI- 10W2 : CHECK HARNESS BETWEEN FUEL
TOR OR THE OBD-II GENERAL TEMPERATURE SENSOR AND ECM
SCAN TOOL, AND READ DATA. CONNECTOR.
S2M0392
S2M0258B
3) Disconnect connector from fuel pump.
3) Turn ignition switch to ON and Subaru Select 4) Connect Subaru Select Monitor or the OBD-II
Monitor or OBD-II general scan tool switch to ON. general scan tool to data link connector.
4) Start engine.
5) Read data of fuel temperature sensor signal
using Subaru Select Monitor or OBD-II general
scan tool.
NOTE:
I Subaru Select Monitor
For detailed operation procedure, refer to the
“READ CURRENT DATA SHOWN ON DISPLAY
FOR ENGINE”. <Ref. to 2-7 [T3C4].>
I OBD-II general scan tool
S2M0258B
For detailed operation procedures, refer to the
OBD-II General Scan Tool Instruction Manual. 5) Turn ignition switch and Subaru Select Monitor
: Is the value greater than 150°C or OBD-II general scan tool switch to ON.
(300°F)? 6) Read data of fuel temperature sensor signal
: Go to step 10W2. using Subaru Select Monitor or the OBD-II general
scan tool.
: Even if MIL lights up, the circuit has
returned to a normal condition at this NOTE:
time. I Subaru Select Monitor
For detailed operation procedure, refer to the
“READ CURRENT DATA SHOWN ON DISPLAY
FOR ENGINE”. <Ref. to 2-7 [T3C4].>
I OBD-II general scan tool
For detailed operation procedures, refer to the
OBD-II General Scan Tool Instruction Manual.
: Is the value less than −40°C (−40°F)?
: Replace fuel temperature sensor. <Ref.
to 2-1 [W5A0].>
: Repair ground short circuit in harness
between fuel pump and ECM connector.
169
2-7 [T10X0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
CAUTION:
After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].>
and INSPECTION MODE <Ref. to 2-7 [T3E0].>.
I WIRING DIAGRAM:
H2M3014
170
ON-BOARD DIAGNOSTICS II SYSTEM [T10X2] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
10X1 : CONNECT SUBARU SELECT MONI- 10X2 : CHECK HARNESS BETWEEN FUEL
TOR OR THE OBD-II GENERAL TEMPERATURE SENSOR AND ECM
SCAN TOOL, AND READ DATA. CONNECTOR.
S2M0392
S2M0258B
3) Disconnect connector from fuel pump.
3) Turn ignition switch to ON and Subaru Select 4) Measure voltage between fuel pump connector
Monitor or OBD-II general scan tool switch to ON. and chassis ground.
4) Start engine. Connector & terminal
5) Read data of fuel temperature sensor signal (R58) No. 6 (+) — Chassis ground (−):
using Subaru Select Monitor or OBD-II general
scan tool.
NOTE:
I Subaru Select Monitor
For detailed operation procedure, refer to the
“READ CURRENT DATA SHOWN ON DISPLAY
FOR ENGINE”. <Ref. to 2-7 [T3C4].>
I OBD-II general scan tool
For detailed operation procedures, refer to the
OBD-II General Scan Tool Instruction Manual.
S2M0403A
: Is the value less than −40°C (−40°F)?
: Go to step 10X2.
: Is the voltage more than 10 V?
: Repair poor contact.
: Repair battery short circuit in harness
NOTE: between ECM and fuel pump connector.
In this case, repair the following: : Go to step 10X3.
I Poor contact in fuel pump connector
I Poor contact in ECM connector
I Poor contact in coupling connectors (B22),
(B98), (B97) and (R57)
171
2-7 [T10X3] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
10X3 : CHECK HARNESS BETWEEN FUEL 10X4 : CHECK HARNESS BETWEEN FUEL
TEMPERATURE SENSOR AND ECM TEMPERATURE SENSOR AND ECM
CONNECTOR. CONNECTOR.
1) Turn ignition switch to ON. Measure voltage between fuel pump connector
2) Measure voltage between fuel pump connector and chassis ground.
and chassis ground. Connector & terminal
Connector & terminal (R58) No. 6 (+) — Chassis ground (−):
(R58) No. 6 (+) — Chassis ground (−):
S2M0403A
S2M0403A
: Is the voltage more than 4 V?
: Is the voltage more than 10 V? : Go to step 10X5.
: Repair battery short circuit in harness : Repair harness and connector.
between ECM and fuel pump connector.
NOTE:
: Go to step 10X4. In this case, repair the following:
I Open circuit in harness between ECM and fuel
pump connector
I Poor contact in fuel pump connector
I Poor contact in ECM connector
I Poor contact in coupling connectors (B98) and
(R57)
172
ON-BOARD DIAGNOSTICS II SYSTEM [T10X5] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
S2M0404A
173
2-7 [T10Y0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
H2M3015
174
ON-BOARD DIAGNOSTICS II SYSTEM [T10AB3] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
10AB1 : CHECK ANY OTHER DTC ON DIS- 10AB3 : CHECK HARNESS BETWEEN
PLAY. FUEL INJECTOR AND ECM CON-
NECTOR.
: Does the Subaru Select Monitor or
OBD-II general scan tool indicate 1) Turn ignition switch to OFF.
DTC P0106, P0107, P0108, P0116, 2) Disconnect connector from fuel injector on
P0117 or P0125? faulty cylinders.
: Inspect DTC P0106, P0107, P0108, 3) Measure voltage between ECM connector and
P0116, P0117 or P0125 using “10. Diag- engine ground on faulty cylinders.
nostics Chart with Trouble Code for Connector & terminal
2200 cc California Spec. Vehicles”. #1 (E5) No. 1 — Engine ground:
<Ref. to 2-7 [T10A0].> #2 (E16) No. 1 — Engine ground:
NOTE: #3 (E6) No. 1 — Engine ground:
In this case, it is not necessary to inspect DTC #4 (E17) No. 1 — Engine ground:
P0301, P0302, P0303 and P0304.
: Go to step 10AB2.
B2M2068A
175
2-7 [T10AB4] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
S2M0405
176
ON-BOARD DIAGNOSTICS II SYSTEM [T10AB7] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
OBD0715A
177
2-7 [T10AB8] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
S2M0258B
S2M0405
H2M2446C
178
ON-BOARD DIAGNOSTICS II SYSTEM [T10AB15] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
cylinders
3) Turn ignition switch to ON, and turn Subaru
I Poor contact in ECM connector
Select Monitor or OBD-II general scan tool switch
I Poor contact in coupling connector (B22)
to ON.
4) Read diagnostic trouble code (DTC).
10AB12 : CHECK AIR INTAKE SYSTEM.
I Subaru Select Monitor
<Ref. to 2-7 [T3C2].>
: Is there a fault in air intake system? I OBD-II general scan tool
: Repair air intake system. For detailed operation procedures, refer to the
OBD-II General Scan Tool Operation Manual.
NOTE:
Check the following items: NOTE:
I Are there air leaks or air suction caused by loose Perform diagnosis according to the items listed
or dislocated nuts and bolts? below.
I Are there cracks or any disconnection of hoses? : Does the Subaru Select Monitor or
: Go to step 10AB13. OBD-II general scan tool indicate
only one DTC?
: Go to step 10AB18.
: Go to step 10AB14.
179
2-7 [T10AB16] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
: Does the Subaru Select Monitor or : Are there faults in #3 and #4 cylin-
OBD-II general scan tool indicate ders?
DTC P0301 and P0303? : Repair or replace faulty parts.
: Go to step 10AB21. NOTE:
: Go to step 10AB17. I Check the following items.
I Spark plugs
10AB17 : CHECK DIAGNOSTIC TROUBLE I Fuel injectors
CODE (DTC) ON DISPLAY. I Ignition coil
I If no abnormal is discovered, check for “9. D:
IGNITION CONTROL SYSTEM” of #3 and #4 cyl-
: Does the Subaru Select Monitor or
inders side. <Ref. to 2-7 [T8D0].>
OBD-II general scan tool indicate
DTC P0302 and P0304? : Go to DTC P0171 <Ref. to 2–7
[T10T0].> and P0172. <Ref. to 2-7
: Go to step 10AB22.
[T10U0].>
: Go to step 10AB23.
10AB21 : GROUP OF #1 AND #3 CYLIN-
10AB18 : ONLY ONE CYLINDER DERS
: Are there faults in #1 and #2 cylin- : Are there faults in #2 and #4 cylin-
ders? ders?
: Repair or replace faulty parts. : Repair or replace faulty parts.
NOTE: NOTE:
I Check the following items. Check the following items.
I Spark plugs I Spark plugs
I Fuel injectors I Fuel injectors
I Ignition coil I Compression ratio
I Compression ratio I Skipping timing belt teeth
I If no abnormal is discovered, check for “9. D: : Go to DTC P0171 <Ref. to 2-7
IGNITION CONTROL SYSTEM” of #1 and #2 cyl- [T10T0].> and P0172. <Ref. to 2-7
inders side. <Ref. to 2-7 [T8D0].> [T10U0].>
: Go to DTC P0171 <Ref. to 2-7
[T10T0].> and P0172. <Ref. to 2-7
[T10U0].>
180
ON-BOARD DIAGNOSTICS II SYSTEM [T10AB23] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
181
2-7 [T10AC0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
H2M3016
182
ON-BOARD DIAGNOSTICS II SYSTEM [T10AC4] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
B2M1090
Measure resistance of harness between ECM con- 10AC4 : CHECK CONDITION OF KNOCK
nector and chassis ground. SENSOR INSTALLATION.
Connector & terminal
(B136) No. 4 — Chassis ground: : Is the knock sensor installation bolt
tightened securely?
: Replace knock sensor. <Ref. to 2-7
[W19A0].>
: Tighten knock sensor installation bolt
securely.
B2M2487A
183
2-7 [T10AC5] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
10AC5 : CHECK KNOCK SENSOR. 10AC6 : CHECK INPUT SIGNAL FOR ECM.
1) Disconnect connector from knock sensor. 1) Connect connectors to ECM and knock sensor.
2) Measure resistance between knock sensor 2) Turn ignition switch to ON.
connector terminal and engine ground. 3) Measure voltage between ECM and chassis
ground.
Terminal
No. 2 — Engine ground: Connector & terminal
(B136) No. 4 (+) — Chassis ground (−):
B2M1090
B2M2488A
184
ON-BOARD DIAGNOSTICS II SYSTEM [T10AC6] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
MEMO:
185
2-7 [T10AD0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
B2M2069
186
ON-BOARD DIAGNOSTICS II SYSTEM [T10AD2] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
OBD0718A
187
2-7 [T10AD3] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
H2M1632A
OBD0719A
: Is the resistance between 1 and 4
: Is the resistance less than 5 Ω? kΩ?
: Go to step 10AD4. : Repair poor contact in crankshaft posi-
tion sensor connector.
: Repair harness and connector.
: Replace crankshaft position sensor.
NOTE: <Ref. to 2-7 [W6A0].>
In this case, repair the following:
I Open circuit in harness between crankshaft
position sensor and ECM connector
I Poor contact in ECM connector
I Poor contact in coupling connector (B21)
188
ON-BOARD DIAGNOSTICS II SYSTEM [T10AD5] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
MEMO:
189
2-7 [T10AE0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
B2M2069
10AE1 : CHECK ANY OTHER DTC ON DIS- 10AE2 : CHECK CONDITION OF CRANK-
PLAY. SHAFT POSITION SENSOR.
190
ON-BOARD DIAGNOSTICS II SYSTEM [T10AE4] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
Remove front belt cover. <Ref. to 2-3 [W2A1].> Turn crankshaft using ST, and align alignment
mark on crankshaft sprocket. Then, make sure left
: Are crankshaft sprocket teeth
and right camshaft sprockets are matched with
cracked or damaged? notches (alignment marks of belt cover and cylin-
: Replace crankshaft sprocket. <Ref. to der head).
2-3 [W2A0].> ST 499987500 CRANKSHAFT SOCKET
: Go to step 10AE4.
B2M2489A
B2M2589B
191
2-7 [T10AF0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
H2M3017
192
ON-BOARD DIAGNOSTICS II SYSTEM [T10AF2] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
OBD0720A
193
2-7 [T10AF3] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
OBD0721A H2M1632A
194
ON-BOARD DIAGNOSTICS II SYSTEM [T10AF5] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
MEMO:
195
2-7 [T10AG0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
H2M3017
196
ON-BOARD DIAGNOSTICS II SYSTEM [T10AG3] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
OBD0720A
197
2-7 [T10AG4] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
OBD0721A H2M1632A
198
ON-BOARD DIAGNOSTICS II SYSTEM [T10AG8] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
B2M2489A
B2M2589B
199
2-7 [T10AH0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
H2M3018
200
ON-BOARD DIAGNOSTICS II SYSTEM [T10AH4] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
10AH1 : CHECK ANY OTHER DTC ON DIS- 10AH3 : CHECK REAR CATALYTIC CON-
PLAY. VERTER.
: Does the Subaru Select Monitor or Separate rear catalytic converter from rear exhaust
OBD-II general scan tool indicate pipe.
DTC P0131, P0132, P0133, P0135,
P0136, P0139, P0141, P0301, P0302,
P0303, P0304, P1130, P1131, P1134,
P1139, P1150 and P1151?
: Inspect the relevant DTC using “10.
Diagnostics Chart with Trouble Code for
2200 cc California Spec. Vehicles”.
<Ref. to 2-7 [T10A0].>
NOTE:
In this case, it is not necessary to inspect DTC OBD0525B
P0420.
: Go to step 10AH2. : Is there damage at rear face of rear
catalyst?
10AH2 : CHECK EXHAUST SYSTEM. : Replace front catalytic converter <Ref.
to 2-1 [W1A0].> and rear catalytic con-
Check for gas leaks or air suction caused by loose verter <Ref. to 2-1 [W2A0].>.
or dislocated nuts and bolts, and open hole at : Go to step 10AH4.
exhaust pipes.
NOTE: 10AH4 : CHECK FRONT CATALYTIC CON-
Check the following positions. VERTER.
I Between cylinder head and front exhaust pipe
I Between front exhaust pipe and front catalytic Remove front catalytic converter.
converter
I Between front catalytic converter and rear cata-
lytic converter
: Is there a fault in exhaust system?
: Repair or replace exhaust system. <Ref.
to 2-9 [W1A0].>
: Go to step 10AH3.
S2M1059A
201
2-7 [T10AI0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
H2M3019
10AI1 : CHECK ANY OTHER DTC ON DIS- 10AI2 : CHECK FUEL FILLER CAP.
PLAY.
1) Turn ignition switch to OFF.
: Is there any other DTC on display? 2) Open the fuel flap.
: Inspect the relevant DTC using “10. : Is the fuel filler cap tightened
Diagnostics Chart with Trouble Code for securely?
2200 cc California Spec. Vehicles”.
: Go to step 10AI3.
<Ref. to 2-7 [T10A0].>
: Tighten fuel filler cap securely.
: Go to step 10AI2.
202
ON-BOARD DIAGNOSTICS II SYSTEM [T10AI6] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
10AI3 : CHECK FUEL FILLER PIPE PACK- 10AI5 : CHECK PURGE CONTROL SOLE-
ING. NOID VALVE.
B2M2254C
B2M1873E
: Go to step 10AI5.
: Does pressure control solenoid valve
: Replace drain valve. <Ref. to 2-1
produce operating sound?
[W13A0].>
: Go to step 10AI7.
: Replace pressure control solenoid
valve. <Ref. to 2-1 [W7A0].>
203
2-7 [T10AI7] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
204
ON-BOARD DIAGNOSTICS II SYSTEM [T10AI10] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
MEMO:
205
2-7 [T10AJ0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
H2M3020
206
ON-BOARD DIAGNOSTICS II SYSTEM [T10AJ2] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
B2M2493A
207
2-7 [T10AJ3] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
B2M2494A S2M0568
OBD0339A
208
ON-BOARD DIAGNOSTICS II SYSTEM [T10AJ6] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
209
2-7 [T10AK0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
H2M3021
210
ON-BOARD DIAGNOSTICS II SYSTEM [T10AK3] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
B2M2495A
211
2-7 [T10AK4] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
B2M2496A S2M0466A
Measure resistance between drain valve terminals. Check poor contact in drain valve connector. <Ref.
Terminals to FOREWORD [T3C1].>
No. 1 — No. 2: : Is there poor contact in drain valve
connector?
: Repair poor contact in drain valve con-
nector.
: Contact with SOA service.
NOTE:
Inspection by DTM is required, because probable
cause is deterioration of multiple parts.
S2M0465
212
ON-BOARD DIAGNOSTICS II SYSTEM [T10AK7] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
MEMO:
213
2-7 [T10AL0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
H2M3022
10AL1 : CHECK ANY OTHER DTC ON DIS- 10AL2 : CHECK FUEL FILLER CAP.
PLAY.
1) Turn ignition switch to OFF.
: Is there any DTC on display? 2) Open the fuel flap.
: Inspect the relevant DTC using “10. : Is the fuel filler cap tightened
Diagnostics Chart with Trouble Code for securely?
2200 cc California Spec. Vehicles”.
: Go to step 10AL3.
<Ref. to 2-7 [T10A0].>
: Tighten fuel filler cap securely.
: Go to step 10AL2.
214
ON-BOARD DIAGNOSTICS II SYSTEM [T10AL3] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
NOTE:
Check the following items.
I Disconnection, leakage and clogging of the
vacuum hoses and pipes between fuel tank pres-
sure sensor and fuel tank
I Disconnection, leakage and clogging of air ven-
tilation hoses and pipes between fuel filler pipe and
fuel tank
: Is there a fault in pressure/vacuum
line?
: Repair or replace hoses and pipes.
: Replace fuel tank pressure sensor.
<Ref. to 2-1 [W6A0].>
215
2-7 [T10AM0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
H2M3022
216
ON-BOARD DIAGNOSTICS II SYSTEM [T10AM3] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
B2M2497A
217
2-7 [T10AM4] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
10AM4 : CHECK INPUT SIGNAL FOR ECM. 10AM6 : CHECK HARNESS BETWEEN
ECM AND COUPLING CONNEC-
TOR IN REAR WIRING HARNESS.
Measure voltage between ECM and chassis
ground.
1) Turn ignition switch to OFF.
Connector & terminal
2) Remove rear seat cushion (Sedan) or move
(B136) No. 12 (+) — Chassis ground (−):
rear seat cushion (Wagon).
3) Separate rear wiring harness and fuel tank
cord.
4) Turn ignition switch to ON.
5) Measure voltage between rear wiring harness
connector and chassis ground.
Connector & terminal
(R15) No. 9 (+) — Chassis ground (−):
B2M2498A
218
ON-BOARD DIAGNOSTICS II SYSTEM [T10AM9] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
1) Turn ignition switch to OFF. Measure resistance of harness between rear wir-
2) Disconnect connector from ECM. ing harness connector and chassis ground.
3) Measure resistance of harness between ECM Connector & terminal
and rear wiring harness connector. (R15) No. 11 — Chassis ground:
Connector & terminal
(B136) No. 16 — (R15) No. 11:
H2M3110A
H2M3111A
219
2-7 [T10AM10] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
Measure resistance of fuel tank cord. Check poor contact in fuel tank pressure sensor
connector. <Ref. to FOREWORD [T3C1].>
Connector & terminal
(R57) No. 10 — (R47) No. 1: : Is there poor contact in fuel tank
pressure sensor connector?
: Repair poor contact in fuel tank pres-
sure sensor connector.
: Replace fuel tank pressure sensor.
<Ref. to 2-1 [W6A0].>
H2M3112A
B2M1882A
220
ON-BOARD DIAGNOSTICS II SYSTEM [T10AM12] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
MEMO:
221
2-7 [T10AN0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
H2M3022
222
ON-BOARD DIAGNOSTICS II SYSTEM [T10AN3] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
B2M2497A
B2M2497A
223
2-7 [T10AN4] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
10AN4 : CHECK INPUT SIGNAL FOR ECM. 10AN6 : CHECK HARNESS BETWEEN ECM
AND COUPLING CONNECTOR IN
REAR WIRING HARNESS.
Measure voltage between ECM and chassis
ground.
1) Turn ignition switch to OFF.
Connector & terminal
2) Remove rear seat cushion (Sedan) or move
(B136) No. 12 (+) — Chassis ground (−):
rear seat cushion (Wagon).
3) Separate rear wiring harness and fuel tank
cord.
4) Turn ignition switch to ON.
5) Measure voltage between rear wiring harness
connector and chassis ground.
Connector & terminal
(R15) No. 9 (+) — Chassis ground (−):
B2M2498A
224
ON-BOARD DIAGNOSTICS II SYSTEM [T10AN9] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
10AN7 : CHECK HARNESS BETWEEN ECM 10AN8 : CHECK HARNESS BETWEEN ECM
AND COUPLING CONNECTOR IN AND COUPLING CONNECTOR IN
REAR WIRING HARNESS. REAR WIRING HARNESS.
1) Turn ignition switch to OFF. Measure resistance of harness between rear wir-
2) Disconnect connector from ECM. ing harness connector and chassis ground.
3) Measure resistance of harness between ECM Connector & terminal
and rear wiring harness connector. (B136) No. 16 — (R15) No. 11:
Connector & terminal
(B136) No. 12 — (R15) No. 10:
H2M3114A
H2M3115A
225
2-7 [T10AN10] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
226
ON-BOARD DIAGNOSTICS II SYSTEM [T10AO1] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
H2M3023
227
2-7 [T10AP0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
H2M3023
228
ON-BOARD DIAGNOSTICS II SYSTEM [T10AP4] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
10AP2 : CHECK GROUND CIRCUIT OF 10AP3 : CHECK INPUT SIGNAL FOR ECM.
COMBINATION METER.
1) Turn ignition switch to ON. (Engine OFF)
1) Turn ignition switch to OFF. 2) Measure voltage between ECM connector and
2) Pull out combination meter from instrument chassis ground.
panel. <Ref. to 6-2 [W8A0].>
Connector & terminal
(B136) No. 27 (+) — Chassis ground (−):
H6M0522A
229
2-7 [T10AP5] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
S2M0428
B2M0940A
230
ON-BOARD DIAGNOSTICS II SYSTEM [T10AP10] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
10AP7 : CHECK REAR WIRING HARNESS. 10AP9 : CHECK REAR WIRING HARNESS.
1) Separate fuel tank cord connector (R57) and 1) Separate rear wiring harness connector (R3)
rear wiring harness connector (R15). and bulkhead wiring harness connector (B99).
2) Measure resistance of harness between fuel 2) Measure resistance of harness between rear
sub meter unit connector and chassis ground. wiring harness connector and chassis ground.
Connector & terminal Connector & terminal
(R59) No. 1 — Chassis ground: (R3) No. 5 — Chassis ground:
B2M0941A H2M3118A
H2M3117A
H2M3119A
231
2-7 [T10AP11] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
H6M0522A
: Is there flaw or burning on printed
circuit plate assembly?
3) Disconnect connector from combination meter. : Replace printed circuit plate assembly.
4) Measure resistance of harness between com- : Replace fuel meter assembly. <Ref. to
bination meter connector and chassis ground. 6-2 [W8A0].>
Connector & terminal
(i10) No. 8 — Chassis ground:
H2M3120A
232
ON-BOARD DIAGNOSTICS II SYSTEM [T10AP13] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
MEMO:
233
2-7 [T10AQ0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
H2M3023
234
ON-BOARD DIAGNOSTICS II SYSTEM [T10AQ3] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
10AQ2 : CHECK GROUND CIRCUIT OF 10AQ3 : CHECK INPUT SIGNAL FOR ECM.
COMBINATION METER.
1) Turn ignition switch to ON. (Engine OFF)
1) Turn ignition switch to OFF. 2) Measure voltage between ECM connector and
2) Pull out combination meter from instrument chassis ground.
panel. <Ref. to 6-2 [W8A0].>
Connector & terminal
(B136) No. 27 (+) — Chassis ground (−):
H6M0522A
235
2-7 [T10AQ4] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
10AQ4 : CHECK FUEL LEVEL SENSOR. 10AQ5 : CHECK FUEL SUB LEVEL SEN-
SOR.
1) Turn ignition switch to OFF.
2) Remove fuel pump access hole lid located on 1) Remove service hole cover located on the left
the right rear of trunk compartment floor (Sedan) or rear of trunk compartment floor (Sedan) or luggage
luggage compartment floor (Wagon). compartment floor (Wagon).
S2M0392 S2M0428
3) Disconnect connector from fuel pump. 2) Disconnect connector from fuel sub meter unit.
4) Measure resistance between connector termi- 3) Measure resistance between connector termi-
nals of fuel pump. nals of fuel sub meter unit.
Terminals Terminals
No. 3 — No. 5: No. 1 — No. 2:
B2M0935 B2M0936
: Is the resistance less than 100 Ω? : Is the resistance less than 100 Ω?
: Go to step 10AQ5. : Go to step 10AQ6.
: Replace fuel sending unit. <Ref. to 2-1 : Replace fuel sub meter unit. <Ref. to 2-1
[W8A0].> [W10A0].>
236
ON-BOARD DIAGNOSTICS II SYSTEM [T10AQ7] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
B2M0938A
B2M0937A
: Is the resistance less than 5 Ω?
: Is the resistance less than 1 Ω? : Go to step 10AQ8.
: Go to step 10AQ7. : Repair harness and connector.
: Repair open circuit in harness between
NOTE:
fuel pump and fuel sub meter unit con-
In this case, repair the following:
nector.
I Open circuit in harness between fuel pump con-
nector and chassis grounding terminal
I Poor contact in fuel pump connector
I Poor contact in coupling connectors (R57),
(B97) and (B22)
237
2-7 [T10AQ8] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
10AQ8 : CHECK HARNESS BETWEEN ECM 10AQ9 : CHECK HARNESS BETWEEN ECM
AND FUEL PUMP CONNECTOR. AND FUEL PUMP CONNECTOR.
1) Connect connector to fuel sub meter unit. 1) Turn ignition switch to OFF.
2) Turn ignition switch to ON. 2) Disconnect connector from ECM.
3) Measure voltage between fuel pump connector 3) Turn ignition switch to ON.
and chassis ground. 4) Measure voltage between ECM connector and
chassis ground.
Connector & terminal
(R58) No. 3 (+) — Chassis ground (−): Connector & terminal
(B136) No. 27 (+) — Chassis ground (−):
B2M0939A
B2M2653A
238
ON-BOARD DIAGNOSTICS II SYSTEM [T10AQ9] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
MEMO:
239
2-7 [T10AR0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
H2M3075
240
ON-BOARD DIAGNOSTICS II SYSTEM [T10AR3] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
10AR1 : CHECK OUTPUT SIGNAL FROM 10AR2 : CHECK GROUND SHORT CIRCUIT
ECM. IN RADIATOR FAN RELAY 1 CON-
TROL CIRCUIT.
1) Turn ignition switch to OFF.
2) Connect test mode connector at the lower por- 1) Turn ignition switch to OFF.
tion of instrument panel (on the driver’s side), to 2) Disconnect connectors from ECM.
the side of the center console box. 3) Measure resistance of harness between ECM
connector and chassis ground.
Connector & terminal
(B134) No. 3 — Chassis ground:
S2M0259B
B2M2654A
H2M3234A
241
2-7 [T10AR4] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
1) Turn ignition switch to OFF. Check poor contact in ECM or main fan relay 1
2) Measure resistance between main fan relay 1 connector. <Ref. to FOREWORD [T3C1].>
terminals. : Is there poor contact in ECM or main
Terminal fan relay 1 connector?
No. 27 — No. 28: : Repair poor contact in ECM or main fan
relay 1 connector.
: Contact with SOA service.
S2M0434
S2M1034A
242
ON-BOARD DIAGNOSTICS II SYSTEM [T10AR6] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
MEMO:
243
2-7 [T10AS0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
H2M3076
244
ON-BOARD DIAGNOSTICS II SYSTEM [T10AS1] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
245
2-7 [T10AT0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
H2M3077
246
ON-BOARD DIAGNOSTICS II SYSTEM [T10AT5] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
10AT4 : CHECK HARNESS BETWEEN ECM 10AT5 : CHECK HARNESS BETWEEN ECM
AND COMBINATION METER CON- AND COMBINATION METER CON-
NECTOR. NECTOR.
B2M2659A
B2M2658A
247
2-7 [T10AU0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
H2M3078
248
ON-BOARD DIAGNOSTICS II SYSTEM [T10AU2] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
10AU1 : CHECK OUTPUT SIGNAL FROM 10AU2 : CHECK POWER SUPPLY TO IDLE
ECM. AIR CONTROL SOLENOID VALVE.
B2M2660A
249
2-7 [T10AU3] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
10AU3 : CHECK HARNESS BETWEEN ECM 10AU4 : CHECK HARNESS BETWEEN ECM
AND IDLE AIR CONTROL SOLE- AND IDLE AIR CONTROL SOLE-
NOID VALVE CONNECTOR. NOID VALVE CONNECTOR.
1) Turn ignition switch to OFF. Measure resistance of harness between ECM and
2) Disconnect connector from ECM. chassis ground.
3) Measure resistance of harness between ECM Connector & terminal
and idle air control solenoid valve connector. (B134) No. 5 — Chassis ground:
Connector & terminal
(B134) No. 5 — (E7) No. 1:
B2M2663A
B2M2662A
: Is the resistance less than 10 Ω?
: Repair ground short circuit in harness
: Is the resistance less than 1 Ω? between ECM and idle air control sole-
noid valve connector.
: Go to step 10AU4.
: Go to step 10AU5.
: Repair harness and connector.
NOTE: 10AU5 : CHECK GROUND CIRCUIT OF
In this case, repair the following: IDLE AIR CONTROL SOLENOID
I Open circuit in harness between ECM and idle VALVE.
air control solenoid valve connector
I Poor contact in coupling connector (B21)
Measure resistance of harness between idle air
control solenoid valve connector and engine
ground.
Connector & terminal
(E7) No. 3 — Engine ground:
B2M2664A
250
ON-BOARD DIAGNOSTICS II SYSTEM [T10AU6] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
251
2-7 [T10AV0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
AV: DTC P0506 — IDLE CONTROL SYSTEM RPM LOWER THAN EXPECTED
—
I DTC DETECTING CONDITION:
I Two consecutive driving cycles with fault
I TROUBLE SYMPTOM:
I Engine is difficult to start.
I Engine does not start.
I Erroneous idling
I Engine stalls.
CAUTION:
After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].>
and INSPECTION MODE <Ref. to 2-7 [T3E0].>.
I WIRING DIAGRAM:
H2M3078
252
ON-BOARD DIAGNOSTICS II SYSTEM [T10AV3] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
10AV1 : CHECK ANY OTHER DTC ON DIS- 10AV3 : CHECK IDLE AIR CONTROL SOLE-
PLAY. NOID VALVE DUTY RATIO.
253
2-7 [T10AV4] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
254
ON-BOARD DIAGNOSTICS II SYSTEM [T10AW2] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
AW: DTC P0507 — IDLE CONTROL SYSTEM RPM HIGHER THAN EXPECTED
—
I DTC DETECTING CONDITION:
I Two consecutive driving cycles with fault
I TROUBLE SYMPTOM:
I Engine keeps running at higher revolution than specified idling revolution.
CAUTION:
After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].>
and INSPECTION MODE <Ref. to 2-7 [T3E0].>.
I WIRING DIAGRAM:
H2M3078
10AW1 : CHECK ANY OTHER DTC ON DIS- 10AW2 : CHECK AIR INTAKE SYSTEM.
PLAY.
1) Turn ignition switch to ON.
: Does the Subaru Select Monitor or 2) Start engine, and idle it.
OBD-II general scan tool indicate 3) Check the following items.
DTC P0505 or P1505? I Loose installation of intake manifold, idle air
: Inspect DTC P0505 or P1505 using “10. control solenoid valve and throttle body
Diagnostics Chart with Trouble Code for I Cracks of intake manifold gasket, idle air control
2200 cc California Spec. Vehicles”. solenoid valve gasket and throttle body gasket
<Ref. to 2-7 [T10A0].> I Disconnections of vacuum hoses
NOTE: : Is there a fault in air intake system?
In this case, it is not necessary to inspect DTC : Repair air suction and leaks.
P0507. : Replace idle air control solenoid valve.
: Go to step 10AW2. <Ref. to 2-7 [W12A1].>
255
2-7 [T10AX0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
H2M3079
256
ON-BOARD DIAGNOSTICS II SYSTEM [T10AX1] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
MEMO:
257
2-7 [T10AY0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
H2M3080
258
ON-BOARD DIAGNOSTICS II SYSTEM [T10AY4] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
10AY2 : CHECK HARNESS BETWEEN TCM 10AY3 : CHECK HARNESS BETWEEN TCM
AND BRAKE LIGHT SWITCH CON- AND BRAKE LIGHT SWITCH CON-
NECTOR. NECTOR.
1) Disconnect connectors from TCM and brake Measure resistance of harness between TCM and
light switch. chassis ground.
2) Measure resistance of harness between TCM Connector & terminal
and brake light switch connector. (B55) No. 24 — Chassis ground:
Connector & terminal
(B55) No. 24 — (B64) No. 2:
(B55) No. 24 — (B65) No. 3 (With cruise
control):
B2M2548A
B2M2549A
259
2-7 [T10AY5] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
B2M2549A
260
ON-BOARD DIAGNOSTICS II SYSTEM [T10AY6] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
MEMO:
261
2-7 [T10AZ0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
B2M2218
262
ON-BOARD DIAGNOSTICS II SYSTEM [T10AZ2] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
10AZ1 : CHECK HARNESS BETWEEN TCM 10AZ2 : CHECK HARNESS BETWEEN TCM
AND INHIBITOR SWITCH CON- AND INHIBITOR SWITCH CON-
NECTOR. NECTOR.
1) Turn ignition switch to OFF. Measure resistance of harness between TCM and
2) Disconnect connectors from TCM and trans- transmission harness connector.
mission. Connector & terminal
3) Measure resistance of harness between TCM (B55) No. 17 — (T7) No. 9:
and transmission harness connector.
Connector & terminal
(B55) No. 23 — (T7) No. 8:
B2M2552A
263
2-7 [T10AZ3] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
10AZ3 : CHECK HARNESS BETWEEN TCM 10AZ4 : CHECK HARNESS BETWEEN TCM
AND INHIBITOR SWITCH CON- AND INHIBITOR SWITCH CON-
NECTOR. NECTOR.
Measure resistance of harness between TCM and Measure resistance of harness between TCM and
transmission harness connector. transmission harness connector.
Connector & terminal Connector & terminal
(B55) No. 22 — (T7) No. 5: (B55) No. 8 — (T7) No. 6:
B2M2553A B2M2554A
264
ON-BOARD DIAGNOSTICS II SYSTEM [T10AZ6] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
10AZ5 : CHECK HARNESS BETWEEN TCM 10AZ6 : CHECK HARNESS BETWEEN TCM
AND INHIBITOR SWITCH CON- AND INHIBITOR SWITCH CON-
NECTOR. NECTOR.
Measure resistance of harness between TCM and Measure resistance of harness between TCM and
transmission harness connector. transmission harness connector.
Connector & terminal Connector & terminal
(B55) No. 18 — (T7) No. 4: (B54) No. 10 — (T7) No. 11:
B2M2555A B2M2556A
265
2-7 [T10AZ7] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
10AZ7 : CHECK HARNESS BETWEEN TCM 10AZ8 : CHECK HARNESS BETWEEN TCM
AND INHIBITOR SWITCH CON- AND INHIBITOR SWITCH CON-
NECTOR. NECTOR.
Measure resistance of harness between TCM and Measure resistance of harness between TCM and
transmission harness connector. chassis ground.
Connector & terminal Connector & terminal
(B54) No. 1 — (T7) No. 3: (B55) No. 23 — Chassis ground:
B2M2063A B2M2558A
B2M2559A
266
ON-BOARD DIAGNOSTICS II SYSTEM [T10AZ13] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
Measure resistance of harness between TCM and Measure resistance of harness between TCM and
chassis ground. chassis ground.
Connector & terminal Connector & terminal
(B55) No. 22 — Chassis ground: (B55) No. 18 — Chassis ground:
B2M2560A B2M2562A
: Is the resistance more than 1 MΩ? : Is the resistance more than 1 MΩ?
: Go to step 10AZ11. : Go to step 10AZ13.
: Repair ground short circuit in harness : Repair ground short circuit in harness
between TCM and transmission harness between TCM and transmission harness
connector. connector.
Measure resistance of harness between TCM and Measure resistance of harness between TCM and
chassis ground. chassis ground.
Connector & terminal Connector & terminal
(B55) No. 8 — Chassis ground: (B54) No. 10 — Chassis ground:
B2M2561A B2M2563A
: Is the resistance more than 1 MΩ? : Is the resistance more than 1 MΩ?
: Go to step 10AZ12. : Go to step 10AZ14.
: Repair ground short circuit in harness : Repair ground short circuit in harness
between TCM and transmission harness between TCM and transmission harness
connector. connector.
267
2-7 [T10AZ14] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
H2M1673
B2M2090A
H2M1674
268
ON-BOARD DIAGNOSTICS II SYSTEM [T10AZ21] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
Measure resistance between inhibitor switch con- Measure resistance between inhibitor switch con-
nector receptacle’s terminals in selector lever nector receptacle’s terminals in selector lever
except for “R” position. except for “N” position.
Terminals Terminals
No. 9 — No. 10: No. 5 — No. 10:
H2M1674 B2M2798
: Is the resistance more than 1 MΩ? : Is the resistance more than 1 MΩ?
: Go to step 10AZ19. : Go to step 10AZ21.
: Go to step 10AZ29. : Go to step 10AZ29.
Measure resistance between inhibitor switch con- Measure resistance between inhibitor switch con-
nector receptacle’s terminals in selector lever for nector receptacle’s terminals in selector lever
“N” position. except for “D” position.
Terminals Terminals
No. 5 — No. 10: No. 6 — No. 10:
B2M2798 H2M1676
269
2-7 [T10AZ22] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
Measure resistance between inhibitor switch con- Measure resistance between inhibitor switch con-
nector receptacle’s terminals in selector lever nector receptacle’s terminals in selector lever
except for “D” position. except for “3” position.
Terminals Terminals
No. 6 — No. 10: No. 4 — No. 10:
H2M1676 H2M1677
: Is the resistance more than 1 MΩ? : Is the resistance more than 1 MΩ?
: Go to step 10AZ23. : Go to step 10AZ25.
: Go to step 10AZ29. : Go to step 10AZ29.
Measure resistance between inhibitor switch con- Measure resistance between inhibitor switch con-
nector receptacle’s terminals in selector lever for nector receptacle’s terminals in selector lever
“3” position. except for “2” position.
Terminals Terminals
No. 4 — No. 10: No. 11 — No. 10:
H2M1677 H2M1678
270
ON-BOARD DIAGNOSTICS II SYSTEM [T10AZ29] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
Measure resistance between inhibitor switch con- Measure resistance between inhibitor switch con-
nector receptacle’s terminals in selector lever nector receptacle’s terminals in selector lever
except for “R” position. except for “1” position.
Terminals Terminals
No. 11 — No. 10: No. 3 — No. 10:
H2M1678 H2M1679
: Is the resistance more than 1 MΩ? : Is the resistance more than 1 MΩ?
: Go to step 10AZ27. : Go to step 10AZ30.
: Go to step 10AZ29. : Go to step 10AZ29.
Measure resistance between inhibitor switch con- : Is there faulty connection in the
nector receptacle’s terminals in selector lever selector cable?
except for “1” position. : Repair connection of selector cable.
Terminals : Replace inhibitor switch. <Ref. to 3-2
No. 3 — No. 10: [W2C0].>
H2M1679
271
2-7 [T10AZ30] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
10AZ30 : CHECK INPUT SIGNAL FOR TCM. 10AZ32 : CHECK INPUT SIGNAL FOR TCM.
1) Turn ignition switch to OFF. Measure voltage between TCM chassis ground in
2) Connect connector to TCM and transmission. selector lever “R” position.
3) Turn ignition switch to ON. Connector & terminal
4) Measure voltage between TCM and chassis (B55) No. 17 (+) — Chassis ground (−):
ground.
Connector & terminal
(B55) No. 23 (+) — Chassis ground (−):
B2M2566A
B2M2566A
272
ON-BOARD DIAGNOSTICS II SYSTEM [T10AZ37] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
10AZ34 : CHECK INPUT SIGNAL FOR TCM. 10AZ36 : CHECK INPUT SIGNAL FOR TCM.
Measure voltage between TCM chassis ground in Measure voltage between TCM and chassis
selector lever “P” and “N” positions. ground in selector lever “D” position.
Connector & terminal Connector & terminal
(B55) No. 22 (+) — Chassis ground (−): (B55) No. 8 (+) — Chassis ground (−):
B2M2567A B2M2568A
10AZ35 : CHECK INPUT SIGNAL FOR TCM. 10AZ37 : CHECK INPUT SIGNAL FOR TCM.
Measure voltage between TCM chassis ground in Measure voltage between TCM chassis ground in
selector lever except for “N” and “P” positions. selector lever except for “N” and “P” positions.
Connector & terminal Connector & terminal
(B55) No. 22 (+) — Chassis ground (−): (B55) No. 8 (+) — Chassis ground (−):
B2M2567A B2M2568A
273
2-7 [T10AZ38] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
10AZ38 : CHECK INPUT SIGNAL FOR TCM. 10AZ40 : CHECK INPUT SIGNAL FOR TCM.
Measure voltage between TCM chassis ground in Measure voltage between TCM chassis ground in
selector lever “3” position. selector lever “2” position.
Connector & terminal Connector & terminal
(B55) No. 18 (+) — Chassis ground (−): (B54) No. 10 (+) — Chassis ground (−):
B2M2569A B2M2570A
10AZ39 : CHECK INPUT SIGNAL FOR TCM. 10AZ41 : CHECK INPUT SIGNAL FOR TCM.
Measure voltage between TCM and chassis Measure voltage between TCM and chassis
ground in selector lever except for “3” position. ground in selector lever except for “2” position.
Connector & terminal Connector & terminal
(B55) No. 18 (+) — Chassis ground (−): (B54) No. 10 (+) — Chassis ground (−):
B2M2569A B2M2570A
274
ON-BOARD DIAGNOSTICS II SYSTEM [T10AZ44] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
10AZ42 : CHECK INPUT SIGNAL FOR TCM. 10AZ44 : CHECK POOR CONTACT.
Measure voltage between TCM chassis ground in Check poor contact in TCM connector. <Ref. to
selector lever “1” position. FOREWORD [T3C1].>
Connector & terminal : Is there poor contact in TCM connec-
(B54) No. 1 (+) — Chassis ground (−): tor?
: Repair poor contact in TCM connector.
: Replace TCM. <Ref. to 3-2 [W22A0].>
B2M2581A
B2M2581A
275
2-7 [T10BA0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
B2M2219
276
ON-BOARD DIAGNOSTICS II SYSTEM [T10BB1] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
H2M3081
277
2-7 [T10BC0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
H2M3082
278
ON-BOARD DIAGNOSTICS II SYSTEM [T10BD1] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
B2M2095
279
2-7 [T10BE0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
280
ON-BOARD DIAGNOSTICS II SYSTEM [T10BH2] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
I WIRING DIAGRAM:
H2M3083
10BH1 : CHECK ANY OTHER DTC ON DIS- 10BH2 : CHECK THROTTLE POSITION
PLAY. SENSOR CIRCUIT.
: Is there any other DTC on display? Check throttle position sensor circuit. <Ref. to 3-2
: Inspect relevant DTC using “10. Diag- [T8F0].>
nostics Chart with Trouble Code for : Is there any trouble in throttle posi-
2200 cc California Spec. Vehicles”. tion sensor circuit?
<Ref. to 2-7 [T10A0].> : Repair or replace throttle position sen-
: Go to step 10BH2. sor circuit.
: Go to step 10BH3.
281
2-7 [T10BH3] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
282
ON-BOARD DIAGNOSTICS II SYSTEM [T10BH6] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
MEMO:
283
2-7 [T10BI0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
H2M3084
284
ON-BOARD DIAGNOSTICS II SYSTEM [T10BI8] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
10BI1 : CHECK ANY OTHER DTC ON DIS- 10BI5 : CHECK INHIBITOR SWITCH CIR-
PLAY. CUIT.
: Is there any other DTC on display? Check inhibitor switch circuit. <Ref. to 2-7
: Inspect the relevant DTC using “10. [T10AZ0].>
Diagnostics Chart with Trouble Code for : Is there any trouble in inhibitor
2200 cc California Spec. Vehicles”. switch circuit?
<Ref. to 2-7 [T10A0].> : Repair or replace inhibitor switch circuit.
: Go to step 10BI2. : Go to step 10BI6.
10BI2 : CHECK DUTY SOLENOID B CIR- 10BI6 : CHECK BRAKE LIGHT SWITCH
CUIT. CIRCUIT.
Check duty solenoid B circuit. <Ref. to 3-2 Check brake light switch circuit. <Ref. to 2-7
[T8Q0].> [T10AY0].>
: Is there any trouble in duty solenoid : Is there any trouble in brake light
B circuit? switch circuit?
: Repair or replace duty solenoid B circuit. : Repair or replace brake light switch cir-
: Go to step 10BI3. cuit.
: Go to step 10BI7.
10BI3 : CHECK THROTTLE POSITION SEN-
SOR CIRCUIT. 10BI7 : CHECK ATF TEMPERATURE SEN-
SOR CIRCUIT.
Check throttle position sensor circuit. <Ref. to 3-2
[T8F0].> Check ATF temperature sensor circuit. <Ref. to 3-2
: Is there any trouble in throttle posi- [T8E0].>
tion sensor circuit? : Is there any trouble in ATF tempera-
: Repair or replace throttle position sen- ture sensor circuit?
sor circuit. : Repair or replace ATF temperature sen-
: Go to step 10BI4. sor circuit.
: Go to step 10BI8.
10BI4 : CHECK TORQUE CONVERTER
TURBINE SPEED SENSOR CIR- 10BI8 : CHECK POOR CONTACT.
CUIT.
285
2-7 [T10BI9] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
286
ON-BOARD DIAGNOSTICS II SYSTEM [T10BJ1] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
B2M2224
287
2-7 [T10BK0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
B2M2100
288
ON-BOARD DIAGNOSTICS II SYSTEM [T10BL1] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
B2M2226
289
2-7 [T10BM0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
B2M2098
290
ON-BOARD DIAGNOSTICS II SYSTEM [T10BN1] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
H2M3085
NOTE:
I On AT vehicles, place the inhibitor switch in the
“P” or “N” position.
I On MT vehicles, depress the clutch pedal.
: Does starter motor operate when
ignition switch to “ST”?
: Repair harness and connector.
NOTE:
In this case, repair the following:
I Open or ground short circuit in harness between
ECM and starter motor connector.
I Poor contact in ECM connector.
: Check starter motor circuit. <Ref. to 2-7
[T8B0].>
291
2-7 [T10BO0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
BO: DTC P1101 — NEUTRAL POSITION SWITCH CIRCUIT LOW INPUT [MT
VEHICLES] —
I DTC DETECTING CONDITION:
I Two consecutive driving cycles with fault
I TROUBLE SYMPTOM:
I Erroneous idling
CAUTION:
After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].>
and INSPECTION MODE <Ref. to 2-7 [T3E0].>.
I WIRING DIAGRAM:
B2M2105
292
ON-BOARD DIAGNOSTICS II SYSTEM [T10BO4] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
10BO1 : CHECK INPUT SIGNAL FOR ECM. 10BO3 : CHECK POOR CONTACT.
1) Turn ignition switch to ON. Check poor contact in ECM connector. <Ref. to
2) Measure voltage between ECM and chassis FOREWORD [T3C1].>
ground. : Is there poor contact in ECM connec-
Connector & terminal tor?
(B135) No. 26 (+) — Chassis ground (−): : Repair poor contact in ECM connector.
: Contact with SOA service.
NOTE:
Inspection by DTM is required, because probable
cause is deterioration of multiple parts.
OBD0469A
293
2-7 [T10BO5] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
B2M2092A
294
ON-BOARD DIAGNOSTICS II SYSTEM [T10BO6] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
MEMO:
295
2-7 [T10BP0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
BP: DTC P1101 — NEUTRAL POSITION SWITCH CIRCUIT HIGH INPUT [AT
VEHICLES] —
I DTC DETECTING CONDITION:
I Two consecutive driving cycles with fault
I TROUBLE SYMPTOM:
I Erroneous idling
CAUTION:
After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].>
and INSPECTION MODE <Ref. to 2-7 [T3E0].>.
I WIRING DIAGRAM:
H2M3086
296
ON-BOARD DIAGNOSTICS II SYSTEM [T10BP5] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
10BP2 : CHECK INPUT SIGNAL FOR ECM. 10BP4 : CHECK POOR CONTACT.
1) Turn ignition switch to ON. Check poor contact in ECM connector. <Ref. to
2) Measure voltage between ECM and chassis FOREWORD [T3C1].>
ground in selector lever “N” and “P” positions. : Is there poor contact in ECM connec-
Connector & terminal tor?
(B135) No. 26 (+) — Chassis ground (−): : Repair poor contact in ECM connector.
: Contact with SOA service.
NOTE:
Inspection by DTM is required, because probable
cause is deterioration of multiple parts.
B2M2091A
297
2-7 [T10BP6] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
B2M1118A
B2M1119
298
ON-BOARD DIAGNOSTICS II SYSTEM [T10BP9] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
299
2-7 [T10BQ0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
B2M2107
10BQ1 : CHECK INPUT SIGNAL FOR ECM. 10BQ2 : CHECK INPUT SIGNAL FOR ECM.
1) Turn ignition switch to ON. Measure voltage between ECM and chassis
2) Measure voltage between ECM and chassis ground.
ground. Connector & terminal
Connector & terminal (B135) No. 16 (+) — Chassis ground (−):
(B135) No. 16 (+) — Chassis ground (−):
B2M2094A
B2M2094A
: Is the voltage more than 10 V?
: Is the voltage more than 4.5 V? : Repair battery short circuit in harness
: Go to step 10BQ2. between ECM and TCM connector.
: Go to step 10BQ4. : Go to step 10BQ3.
300
ON-BOARD DIAGNOSTICS II SYSTEM [T10BQ6] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
301
2-7 [T10BR0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
B2M2404
10BR1 : CHECK INPUT SIGNAL FOR ECM. 10BR2 : CHECK INPUT SIGNAL FOR ECM.
1) Turn ignition switch to ON. Measure voltage between ECM and chassis
2) Measure voltage between ECM and chassis ground.
ground. Connector & terminal
Connector & terminal (B135) No. 17 (+) — Chassis ground (−):
(B135) No. 17 (+) — Chassis ground (−):
B2M2501A
B2M2501A
: Is the voltage more than 10 V?
: Is the voltage more than 4.5 V? : Repair battery short circuit in harness
: Go to step 10BR2. between ECM and TCM connector.
: Go to step 10BR4. : Go to step 10BR3.
302
ON-BOARD DIAGNOSTICS II SYSTEM [T10BR6] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
303
2-7 [T10BS0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
H2M3007
304
ON-BOARD DIAGNOSTICS II SYSTEM [T10BT1] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
H2M3007
305
2-7 [T10BU0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
H2M3007
306
ON-BOARD DIAGNOSTICS II SYSTEM [T10BU1] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
MEMO:
307
2-7 [T10BV0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
BV: DTC P1115 — ENGINE TORQUE CONTROL CUT SIGNAL CIRCUIT HIGH
INPUT —
I DTC DETECTING CONDITION:
I Two consecutive driving cycles with fault
CAUTION:
After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].>
and INSPECTION MODE <Ref. to 2-7 [T3E0].>.
I WIRING DIAGRAM:
B2M2667
308
ON-BOARD DIAGNOSTICS II SYSTEM [T10BV2] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
10BV1 : CHECK OUTPUT SIGNAL FROM 10BV2 : CHECK HARNESS BETWEEN ECM
ECM. AND TCM CONNECTOR.
1) Start engine, and warm-up the engine. 1) Turn ignition switch to OFF.
2) Turn ignition swtich to OFF. 2) Measure voltage between ECM and chassis
3) Disconnect connector from TCM. ground.
4) Turn ignition switch to ON. Connector & terminal
5) Measure voltage between ECM and chassis (B134) No. 31 (+) — Chassis ground (−):
ground.
Connector & terminal
(B134) No. 31 (+) — Chassis ground (−):
B2M2668A
309
2-7 [T10BW0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
BW: DTC P1116 — ENGINE TORQUE CONTROL CUT SIGNAL CIRCUIT LOW
INPUT —
I DTC DETECTING CONDITION:
I Two consecutive driving cycles with fault
CAUTION:
After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].>
and INSPECTION MODE <Ref. to 2-7 [T3E0].>.
I WIRING DIAGRAM:
B2M2667
1) Start engine, and warm-up the engine. 1) Turn ignition switch to OFF.
2) Turn ignition switch to OFF. 2) Disconnect connectors from ECM and TCM.
3) Turn ignition switch to ON. 3) Measure resistance of harness between ECM
4) Measure voltage between ECM and chassis and chassis ground.
ground. Connector & terminal
Connector & terminal (B134) No. 31 — Chassis ground:
(B134) No. 31 (+) — Chassis ground (−):
B2M2670A
B2M2668A
: Is the resistance less than 10 Ω?
: Is the voltage more than 3 V? : Repair ground short circuit in harness
: Repair poor contact in ECM connector. between ECM and TCM connector.
: Go to step 10BW2. : Go to step 10BW3.
310
ON-BOARD DIAGNOSTICS II SYSTEM [T10BW3] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
B2M2714A
311
2-7 [T10BX0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
H2M3085
NOTE:
I On AT vehicles, place the inhibitor switch in each
position.
I On MT vehicles, depress or release the clutch
pedal.
: Does starter motor operate when
ignition switch to “ON”?
: Repair battery short circuit in starter
motor circuit. After repair, replace ECM.
<Ref. to 2-7 [W15A0].>
: Check starter motor circuit. <Ref. to 2-7
[T8B0].>
312
ON-BOARD DIAGNOSTICS II SYSTEM [T10BX1] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
MEMO:
313
2-7 [T10BY0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
BY: DTC P1121 — NEUTRAL POSITION SWITCH CIRCUIT HIGH INPUT [MT
VEHICLES] —
I DTC DETECTING CONDITION:
I Two consecutive driving cycles with fault
I TROUBLE SYMPTOM:
I Erroneous idling
CAUTION:
After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].>
and INSPECTION MODE <Ref. to 2-7 [T3E0].>.
I WIRING DIAGRAM:
B2M2105
314
ON-BOARD DIAGNOSTICS II SYSTEM [T10BY4] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
10BY1 : CHECK INPUT SIGNAL FOR ECM. 10BY3 : CHECK POOR CONTACT.
1) Turn ignition switch to ON. Check poor contact in ECM connector. <Ref. to
2) Measure voltage between ECM and chassis FOREWORD [T3C1].>
ground. : Is there poor contact in ECM connec-
Connector & terminal tor?
(B135) No. 26 (+) — Chassis ground (−): : Repair poor contact in ECM connector.
: Contact with SOA service.
NOTE:
Inspection by DTM is required, because probable
cause is deterioration of multiple parts.
B2M2091A
315
2-7 [T10BY5] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
10BY5 : CHECK HARNESS BETWEEN ECM 10BY7 : CHECK HARNESS BETWEEN ECM
AND TCM CONNECTOR. AND NEUTRAL POSITION SWITCH
CONNECTOR.
1) Turn ignition switch to ON.
2) Measure voltage between ECM and chassis 1) Disconnect connector from ECM.
ground. 2) Measure resistance of harness between ECM
and transmission harness connector.
Connector & terminal
(B135) No. 26 (+) — Chassis ground (−): Connector & terminal
(B135) No. 26 — (B25) No. 1:
B2M2091A
B2M2671A
: Is the voltage more than 10 V?
: Repair battery short circuit in harness : Is the resistance less than 1 Ω?
between ECM and transmission har- : Go to step 10BY8.
ness connector. : Repair open circuit in harness between
: Go to step 10BY6. ECM and transmission harness connec-
tor.
10BY6 : CHECK NEUTRAL POSITION
SWITCH.
OBD0469A
316
ON-BOARD DIAGNOSTICS II SYSTEM [T10BY9] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
OBD0472A
317
2-7 [T10BZ0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
BZ: DTC P1121 — NEUTRAL POSITION SWITCH CIRCUIT LOW INPUT [AT
VEHICLES] —
I DTC DETECTING CONDITION:
I Two consecutive driving cycles with fault
I TROUBLE SYMPTOM:
I Erroneous idling
CAUTION:
After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].>
and INSPECTION MODE <Ref. to 2-7 [T3E0].>.
I WIRING DIAGRAM:
H2M3086
318
ON-BOARD DIAGNOSTICS II SYSTEM [T10BZ3] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
10BZ2 : CHECK INPUT SIGNAL FOR ECM. 10BZ3 : CHECK HARNESS BETWEEN ECM
AND TRANSMISSION HARNESS
1) Turn ignition switch to ON. CONNECTOR.
2) Measure voltage between ECM and chassis
ground. 1) Turn ignition switch to OFF.
2) Disconnect connectors from ECM and trans-
Connector & terminal
mission harness connector.
(B135) No. 26 (+) — Chassis ground (−):
3) Measure resistance of harness between ECM
connector and chassis ground.
Connector & terminal
(B135) No. 26 — Chassis ground:
B2M2091A
319
2-7 [T10BZ4] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
1) Disconnect connector from inhibitor switch. : Is there any fault in selector cable
2) Measure resistance of harness between trans- connection to inhibitor switch?
mission harness connector and engine ground. : Repair selector cable connection. <Ref.
Connector & terminal to 3-2 [W2A0].>
(T3) No. 12 — Engine ground: : Contact with SOA service.
NOTE:
Inspection by DTM is required, because probable
cause is deterioration of multiple parts.
S2M0458A
B2M1119
320
ON-BOARD DIAGNOSTICS II SYSTEM [T10BZ6] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
MEMO:
321
2-7 [T10CA0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
CAUTION:
After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].>
and INSPECTION MODE <Ref. to 2-7 [T3E0].>.
I WIRING DIAGRAM:
H2M3011
322
ON-BOARD DIAGNOSTICS II SYSTEM [T10CA3] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
10CA1 : CHECK HARNESS BETWEEN ECM 10CA2 : CHECK HARNESS BETWEEN ECM
AND FRONT OXYGEN (A/F) SEN- AND FRONT OXYGEN (A/F) SEN-
SOR CONNECTOR. SOR CONNECTOR.
1) Turn ignition switch to OFF. Measure resistance of harness between ECM and
2) Disconnect connectors from ECM and front front oxygen (A/F) sensor connector.
oxygen (A/F) sensor connector. Connector & terminal
3) Measure resistance of harness between ECM (B136) No. 20 — (E24) No. 3:
and front oxygen (A/F) sensor connector.
Connector & terminal
(B136) No. 7 — (E24) No. 4:
H2M3127A
323
2-7 [T10CB0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
CAUTION:
After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].>
and INSPECTION MODE <Ref. to 2-7 [T3E0].>.
I WIRING DIAGRAM:
H2M3011
324
ON-BOARD DIAGNOSTICS II SYSTEM [T10CB4] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
10CB1 : CHECK HARNESS BETWEEN ECM 10CB3 : CHECK OUTPUT SIGNAL FOR
AND FRONT OXYGEN (A/F) SEN- ECM.
SOR CONNECTOR.
1) Connect connector to ECM.
1) Turn ignition switch to OFF. 2) Turn ignition switch to ON.
2) Disconnect connector from ECM. 3) Measure voltage between ECM connector and
3) Measure resistance of harness between ECM chassis ground.
connector and chassis ground.
Connector & terminal
Connector & terminal (B136) No. 7 (+) — Chassis ground (−):
(B136) No. 7 — Chassis ground:
B2M2464A
B2M2462A
: Is the voltage more than 4.5 V?
: Is the resistance more than 10 Ω? : Go to step 10CB4.
: Go to step 10CB2. : Go to step 10CB5.
: Repair ground short circuit in harness
between ECM and front oxygen (A/F) 10CB4 : CHECK OUTPUT SIGNAL FOR
sensor connector. ECM.
10CB2 : CHECK HARNESS BETWEEN ECM Measure voltage between ECM connector and
AND FRONT OXYGEN (A/F) SEN- chassis ground.
SOR CONNECTOR.
Connector & terminal
(B136) No. 7 (+) — Chassis ground (−):
Measure resistance of harness between ECM con-
nector and chassis ground.
Connector & terminal
(B136) No. 20 — Chassis ground:
B2M2464A
325
2-7 [T10CB5] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
B2M2466A
B2M2466A
326
ON-BOARD DIAGNOSTICS II SYSTEM [T10CB6] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
MEMO:
327
2-7 [T10CC0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
CC: DTC P1132 — FRONT OXYGEN (A/F) SENSOR HEATER CIRCUIT LOW
INPUT —
I DTC DETECTING CONDITION:
I Two consecutive driving cycles with fault
CAUTION:
After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].>
and INSPECTION MODE <Ref. to 2-7 [T3E0].>.
I WIRING DIAGRAM:
H2M3087
328
ON-BOARD DIAGNOSTICS II SYSTEM [T10CC4] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
1) Disconnect connectors from ECM. Measure resistance of harness between ECM con-
2) Turn ignition switch to ON. nector and chassis ground.
3) Measure power supply voltage between ECM Connector & terminal
connector terminals. (B134) No. 35 — Chassis ground:
Connector & terminal
(B136) No. 3 (+) — (B134) No. 34 (−):
B2M2467A
B2M2797A
329
2-7 [T10CC5] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
S2M0258B
330
ON-BOARD DIAGNOSTICS II SYSTEM [T10CC10] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
10CC7 : CHECK OUTPUT SIGNAL FROM 10CC9 : CHECK OUTPUT SIGNAL FROM
ECM. ECM.
1) Start and idle the engine. Measure voltage between ECM connector and
2) Measure voltage between ECM connector and chassis ground.
chassis ground. Connector & terminal
Connector & terminal (B134) No. 23 (+) — Chassis ground (−):
(B134) No. 22 (+) — Chassis ground (−):
B2M2469A
B2M2468A
: Is the voltage less than 1.0 V?
: Is the voltage less than 1.0 V? : Go to step 10CC11.
: Go to step 10CC9. : Go to step 10CC10.
: Go to step 10CC8.
10CC10 : CHECK OUTPUT SIGNAL FROM
10CC8 : CHECK OUTPUT SIGNAL FROM ECM.
ECM.
Measure voltage between ECM connector and
Measure voltage between ECM connector and chassis ground.
chassis ground. Connector & terminal
Connector & terminal (B134) No. 23 (+) — Chassis ground (−):
(B134) No. 22 (+) — Chassis ground (−):
B2M2469A
B2M2468A
: Does the voltage change less than
: Does the voltage change less than 1.0 V by shaking harness and con-
1.0 V by shaking harness and con- nector of ECM while monitoring the
nector of ECM while monitoring the value with voltage meter?
value with voltage meter? : Repair poor contact in ECM connector.
: Repair poor contact in ECM connector. : Go to step 10CC11.
: Go to step 10CC9.
331
2-7 [T10CC11] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
B2M2471
332
ON-BOARD DIAGNOSTICS II SYSTEM [T10CC12] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
MEMO:
333
2-7 [T10CD0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
CD: DTC P1133 — FRONT OXYGEN (A/F) SENSOR HEATER CIRCUIT HIGH
INPUT —
I DTC DETECTING CONDITION:
I Two consecutive driving cycles with fault
CAUTION:
After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].>
and INSPECTION MODE <Ref. to 2-7 [T3E0].>.
I WIRING DIAGRAM:
H2M3087
334
ON-BOARD DIAGNOSTICS II SYSTEM [T10CD3] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
10CD1 : CHECK OUTPUT SIGNAL FROM 10CD3 : CHECK FRONT OXYGEN (A/F)
ECM. SENSOR HEATER CURRENT.
S2M0258B
B2M2715A
B2M2468A
335
2-7 [T10CD4] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
10CD4 : CHECK OUTPUT SIGNAL FROM 10CD5 : CHECK OUTPUT SIGNAL FROM
ECM. ECM.
Measure voltage between ECM connector and Measure voltage between ECM connector and
chassis ground. chassis ground.
Connector & terminal Connector & terminal
(B134) No. 23 (+) — Chassis ground (−): (B134) No. 22 (+) — Chassis ground (−):
B2M2715A B2M2468A
: Does the voltage change more than 8 : Does the voltage change more than 8
V by shaking harness and connector V by shaking harness and connector
of ECM while monitoring the value of ECM while monitoring the value
with voltage meter?
with voltage meter?
: Repair battery short circuit in harness
: Repair battery short circuit in harness
between ECM and front oxygen (A/F)
between ECM and front oxygen (A/F) sensor connector.
sensor connector.
: END
: Go to step 10CD5.
336
ON-BOARD DIAGNOSTICS II SYSTEM [T10CE1] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
CAUTION:
After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].>
and INSPECTION MODE <Ref. to 2-7 [T3E0].>.
I WIRING DIAGRAM:
H2M3087
337
2-7 [T10CF0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
CAUTION:
After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].>
and INSPECTION MODE <Ref. to 2-7 [T3E0].>.
I WIRING DIAGRAM:
H2M3087
338
ON-BOARD DIAGNOSTICS II SYSTEM [T10CF3] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
10CF1 : CHECK HARNESS BETWEEN ECM 10CF2 : CHECK HARNESS BETWEEN ECM
AND FRONT OXYGEN (A/F) SEN- AND FRONT OXYGEN (A/F) SEN-
SOR CONNECTOR. SOR CONNECTOR.
1) Start engine, and warm-up the engine. Measure resistance of harness between ECM and
2) Turn ignition switch to OFF. front oxygen (A/F) sensor connector.
3) Disconnect connectors from ECM and front Connector & terminal
oxygen (A/F) sensor. (B136) No. 7 — (E24) No. 4:
4) Measure resistance of harness between ECM
and front oxygen (A/F) sensor connector.
Connector & terminal
(B134) No. 22 — (E24) No. 1:
H2M3131A
H2M3132A
339
2-7 [T10CF4] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
H2M3133A
B2M2471
340
ON-BOARD DIAGNOSTICS II SYSTEM [T10CF6] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
MEMO:
341
2-7 [T10CG0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
H2M3088
342
ON-BOARD DIAGNOSTICS II SYSTEM [T10CG2] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
10CG1 : CHECK ANY OTHER DTC ON DIS- 10CG2 : CONNECT SUBARU SELECT
PLAY. MONITOR OR THE OBD-II GEN-
ERAL SCAN TOOL, AND READ
: Does the Subaru Select Monitor or DATA.
OBD-II general scan tool indicate
DTC P0106, P0107, P0108, P0122 or 1) Turn ignition switch to OFF.
P0123? 2) Connect Subaru Select Monitor or the OBD-II
: Inspect DTC P0106, P0107, P0108, general scan tool to data link connector.
P0122 or P0123 using “12. Diagnostics
Chart with Trouble Code for 2200 cc
California Spec. Vehicles”. <Ref. to 2-7
[T10A0].>
NOTE:
In this case, it is not necessary to inspect DTC
P1142.
: Go to step 10CG2.
S2M0258B
343
2-7 [T10CH0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
CH: DTC P1151 — REAR OXYGEN SENSOR HEATER CIRCUIT HIGH INPUT
—
I DTC DETECTING CONDITION:
I Two consecutive driving cycles with fault
CAUTION:
After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].>
and INSPECTION MODE <Ref. to 2-7 [T3E0].>.
I WIRING DIAGRAM:
H2M3013
344
ON-BOARD DIAGNOSTICS II SYSTEM [T10CH4] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
10CH1 : CHECK INPUT SIGNAL FOR ECM. 10CH3 : CHECK INPUT SIGNAL FOR ECM.
Measure voltage between ECM connector and Measure voltage between ECM connector and
chassis ground. chassis ground.
Connector & terminal Connector & terminal
(B134) No. 21 (+) — Chassis ground (−): (B134) No. 21 (+) — Chassis ground (−):
B2M2483A B2M2483A
: Is the voltage more than 8 V? : Does the voltage change more than 8
: Go to step 10CH2. V by shaking harness and connector
of ECM while monitoring the value
: Go to step 10CH3.
with voltage meter?
: Repair poor contact in ECM connector.
10CH2 : CHECK DTC P1151 ON DISPLAY.
: Go to step 10CH4.
1) Turn ignition switch to OFF.
2) Repair battery short circuit in harness between 10CH4 : CHECK INPUT SIGNAL FOR ECM.
ECM and rear oxygen sensor connector.
3) Operate the INSPECTION MODE. <Ref. to 2-7 Measure voltage between ECM connector and
[T3E1].> chassis ground.
: Does the Subaru Select Monitor or Connector & terminal
OBD-II general scan tool indicate (B134) No. 21 (+) — Chassis ground (−):
DTC P1151?
: Replace ECM. <Ref. to 2-7 [W15A0].>
: END
B2M2483A
345
2-7 [T10CH5] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
B2M2483A
346
ON-BOARD DIAGNOSTICS II SYSTEM [T10CH5] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
MEMO:
347
2-7 [T10CI0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
H2M3089
348
ON-BOARD DIAGNOSTICS II SYSTEM [T10CI3] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
10CI1 : CHECK OUTPUT SIGNAL FROM 10CI3 : CHECK HARNESS BETWEEN FUEL
ECM. TANK PRESSURE CONTROL
SOLENOID VALVE AND ECM CON-
NECTOR.
1) Turn ignition switch to ON.
2) Measure voltage between ECM and chassis
ground. 1) Turn ignition switch to OFF.
2) Disconnect connectors from fuel tank pressure
Connector & terminal
control solenoid valve and ECM.
(B134) No. 1 (+) — Chassis ground (−):
3) Measure resistance of harness between fuel
tank pressure control solenoid valve connector and
chassis ground.
Connector & terminal
(R68) No. 2 — Chassis ground:
B2M2673A
349
2-7 [T10CI4] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
10CI4 : CHECK HARNESS BETWEEN FUEL 10CI5 : CHECK FUEL TANK PRESSURE
TANK PRESSURE CONTROL CONTROL SOLENOID VALVE.
SOLENOID VALVE AND ECM CON-
NECTOR. Measure resistance between fuel tank pressure
control solenoid valve terminals.
Measure resistance of harness between ECM and
Terminals
fuel tank pressure control solenoid valve connec-
No. 1 — No. 2:
tor.
Connector & terminal
(B134) No. 1 — (R68) No. 2:
B2M2676
350
ON-BOARD DIAGNOSTICS II SYSTEM [T10CI7] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
B2M2677A
351
2-7 [T10CJ0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
H2M3089
352
ON-BOARD DIAGNOSTICS II SYSTEM [T10CJ3] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
10CJ1 : CHECK OUTPUT SIGNAL FROM 10CJ2 : CHECK OUTPUT SIGNAL FROM
ECM. ECM.
S2M0259B
B2M2673A
353
2-7 [T10CJ4] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
B2M2676
354
ON-BOARD DIAGNOSTICS II SYSTEM [T10CJ6] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
MEMO:
355
2-7 [T10CK0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
H2M3020
356
ON-BOARD DIAGNOSTICS II SYSTEM [T10CK3] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
10CK1 : CHECK OUTPUT SIGNAL FROM 10CK2 : CHECK OUTPUT SIGNAL FROM
ECM. ECM.
S2M0259B
B2M2493A
357
2-7 [T10CK4] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
S2M0424
358
ON-BOARD DIAGNOSTICS II SYSTEM [T10CK6] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
MEMO:
359
2-7 [T10CL0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
H2M3021
360
ON-BOARD DIAGNOSTICS II SYSTEM [T10CL3] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
10CL1 : CHECK OUTPUT SIGNAL FROM 10CL2 : CHECK OUTPUT SIGNAL FROM
ECM. ECM.
S2M0259B
B2M2495A
361
2-7 [T10CL4] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
S2M0465
362
ON-BOARD DIAGNOSTICS II SYSTEM [T10CL6] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
MEMO:
363
2-7 [T10CM0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
H2M3021
364
ON-BOARD DIAGNOSTICS II SYSTEM [T10CM3] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
10CM2 : CHECK VENT LINE HOSES. 10CM3 : CHECK DRAIN VALVE OPERA-
TION.
Check the following items.
I Clogging of vent hoses between canister and 1) Turn ignition switch to OFF.
drain valve 2) Connect test mode connector at the lower por-
I Clogging of vent hose between drain valve and tion of instrument panel (on the driver’s side), to
air filter the side of the center console box.
I Clogging of vent hose between air filter and
junction pipe
I Clogging of junction pipe
I Clogging of air filter
S2M0259B
365
2-7 [T10CN0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
H2M3078
366
ON-BOARD DIAGNOSTICS II SYSTEM [T10CN2] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
10CN1 : CHECK OUTPUT SIGNAL FROM 10CN2 : CHECK OUTPUT SIGNAL FROM
ECM. ECM.
B2M2660A
367
2-7 [T10CN3] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
B2M2660A
368
ON-BOARD DIAGNOSTICS II SYSTEM [T10CO2] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
H2M3078
10CO1 : CHECK ANY OTHER DTC ON DIS- 10CO2 : CHECK AIR INTAKE SYSTEM.
PLAY.
1) Turn ignition switch to ON.
: Does the Subaru Select Monitor or 2) Start engine, and idle it.
OBD-II general scan tool indicate 3) Check the following items.
DTC P0116 or P0117 or P0505 or I Loose installation of intake manifold, idle air
P1505? control solenoid valve and throttle body
: Inspect DTC P0116 or P0117 or P0505 I Cracks of intake manifold gasket, idle air control
solenoid valve gasket and throttle body gasket
or P1505 using “10. Diagnostics Chart
I Disconnections of vacuum hoses
with Trouble Code for 2200 cc California
Spec. Vehicles”. <Ref. to 2-7 [T10A0].> : Is there a fault in air intake system?
NOTE: : Repair air suction and leaks.
In this case, it is not necessary to inspect DTC : Replace idle air control solenoid valve.
P1507. <Ref. to 2-7 [W12A1].>
: Go to step 10CO2.
369
2-7 [T10CP0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
H2M3075
370
ON-BOARD DIAGNOSTICS II SYSTEM [T10CP3] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
S2M0259B
B2M2654A
371
2-7 [T10CP4] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
1) Turn ignition switch to OFF. Check poor contact in ECM connector. <Ref. to
2) Remove main fan relay 1. FOREWORD [T3C1].>
3) Measure resistance between main fan relay 1 : Is there poor contact in ECM connec-
terminals. tor?
Terminal : Repair poor contact in ECM connector.
No. 1 — No. 3: : Replace ECM. <Ref. to 2-7 [W15A0].>
OBD0535
OBD0536
372
ON-BOARD DIAGNOSTICS II SYSTEM [T10CP6] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
MEMO:
373
2-7 [T10CQ0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
H2M3079
374
ON-BOARD DIAGNOSTICS II SYSTEM [T10CQ4] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
10CQ1 : CHECK INPUT SIGNAL FOR ECM. 10CQ3 : CHECK FUSE SBF-2.
B2M2679A
375
2-7 [T10CR0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
H2M3088
376
ON-BOARD DIAGNOSTICS II SYSTEM [T10CR1] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
MEMO:
377
2-7 [T10CS0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
H2M3090
10CS1 : CHECK HARNESS BETWEEN TCM 10CS2 : CHECK HARNESS BETWEEN TCM
AND CCM CONNECTOR. AND CCM CONNECTOR.
1) Turn ignition switch to OFF. Measure resistance of harness between TCM and
2) Disconnect connectors from TCM and CCM. chassis ground.
3) Measure resistance of harness between TCM Connector & terminal
and CCM connector. (B54) No. 11 — Chassis ground:
Connector & terminal
(B54) No. 11 — (B94) No. 12:
B2M2682A
378
ON-BOARD DIAGNOSTICS II SYSTEM [T10CS4] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
10CS3 : CHECK INPUT SIGNAL FOR TCM. 10CS4 : CHECK POOR CONTACT.
1) Connect connector to TCM and CCM. Check poor contact in TCM connector. <Ref. to
2) Lift-up the vehicle or set the vehicle on free FOREWORD [T3C1].>
rollers.
: Is there poor contact in TCM connec-
CAUTION: tor?
On AWD models, raise all wheels off ground.
: Repair poor contact in TCM connector.
3) Start the engine. : Replace TCM. <Ref. to 3-2 [W22A0].>
4) Cruise control main switch to ON.
5) TCS OFF switch to ON. (with TCS models only)
6) Move selector lever to “D” and slowly increase
vehicle speed to 50 km/h (31 MPH).
7) Cruise control set switch to ON.
8) Measure voltage between TCM and chassis
ground.
Connector & terminal
(B54) No. 11 (+) — Chassis ground (−):
B2M2683A
379
2-7 [T10CT0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
B2M2111
380
ON-BOARD DIAGNOSTICS II SYSTEM [T10CT2] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
10CT1 : CHECK HARNESS BETWEEN ECM 10CT2 : CHECK HARNESS BETWEEN ECM
AND TCM CONNECTOR. AND TCM CONNECTOR.
B2M2684A
B2M2685A
381
2-7 [T10CT3] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
B2M2684A
382
ON-BOARD DIAGNOSTICS II SYSTEM [T10CU1] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
B2M2401
383
2-7 [T10CV0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
B2M2403
384
ON-BOARD DIAGNOSTICS II SYSTEM [T10CW1] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
B2M2402
385
2-7 [T10CX0] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
B2M2111
386
ON-BOARD DIAGNOSTICS II SYSTEM [T10CX3] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
10CX1 : CHECK HARNESS BETWEEN ECM 10CX3 : CHECK HARNESS BETWEEN ECM
AND TCM CONNECTOR. AND TCM CONNECTOR.
1) Turn ignition switch to ON. Measure voltage between ECM connector and
2) Measure voltage between ECM and chassis chassis ground.
ground. Connector & terminal
Connector & terminal (B135) No. 4 (+) — Chassis ground (−):
(B135) No. 4 (+) — Chassis ground (−):
B2M2684A
B2M2684A
: Is the voltage less than 1 V?
: Is the voltage more than 10 V? : Repair poor contact in ECM connector.
: Repair battery short circuit in harness : Go to step 10CX4.
between ECM and TCM connector.
After repair, replace ECM. <Ref. to 2-7
[W15A0].>
: Go to step 10CX2.
B2M2684A
387
2-7 [T10CX4] ON-BOARD DIAGNOSTICS II SYSTEM
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
10CX4 : CHECK OUTPUT SIGNAL FROM 10CX5 : CHECK HARNESS BETWEEN ECM
ECM. AND TCM CONNECTOR.
Measure voltage between ECM and chassis Measure voltage between TCM and chassis
ground. ground.
Connector & terminal Connector & terminal
(B135) No. 4 (+) — Chassis ground (−): (B54) No. 4 (+) — Chassis ground (−):
B2M2684A B2M2686A
388
ON-BOARD DIAGNOSTICS II SYSTEM [T10CY2] 2-7
10. Diagnostics Chart with Trouble Code for 2200 cc California Spec. Vehicles
B2M2111
389
2-7 [T11A0] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
390
ON-BOARD DIAGNOSTICS II SYSTEM [T11A0] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
DTC
Item Index
No.
P0304 Cylinder 4 misfire detected <Ref. to 2-7
[T11AA0].>
P0325 Knock sensor circuit high input <Ref. to 2-7
[T11AB0].>
P0335 Crankshaft position sensor circuit malfunction <Ref. to 2-7
[T11AC0].>
P0336 Crankshaft position sensor circuit range/performance problem <Ref. to 2-7
[T11AD0].>
P0340 Camshaft position sensor circuit malfunction <Ref. to 2-7
[T11AE0].>
P0341 Camshaft position sensor circuit range/performance problem <Ref. to 2-7
[T11AF0].>
P0420 Catalyst system efficiency below threshold <Ref. to 2-7
[T11AG0].>
P0440 Evaporative emission control system malfunction <Ref. to 2-7
[T11AH0].>
P0443 Evaporative emission control system purge control valve circuit low input <Ref. to 2-7
[T11AI0].>
P0446 Evaporative emission control system vent control low input <Ref. to 2-7
[T11AJ0].>
P0451 Evaporative emission control system pressure sensor range/performance problem <Ref. to 2-7
[T11AK0].>
P0452 Evaporative emission control system pressure sensor low input <Ref. to 2-7
[T11AL0].>
P0453 Evaporative emission control system pressure sensor high input <Ref. to 2-7
[T11AM0].>
P0461 Fuel level sensor circuit range/performance problem <Ref. to 2-7
[T11AN0].>
P0462 Fuel level sensor circuit low input <Ref. to 2-7
[T11AO0].>
P0463 Fuel level sensor circuit high input <Ref. to 2-7
[T11AP0].>
P0480 Cooling fan relay 1 circuit low input <Ref. to 2-7
[T11AQ0].>
P0483 Cooling fan function problem <Ref. to 2-7
[T11AR0].>
P0500 Vehicle speed sensor malfunction <Ref. to 2-7
[T11AS0].>
P0506 Idle control system RPM lower than expected <Ref. to 2-7
[T11AT0].>
P0507 Idle control system RPM higher than expected <Ref. to 2-7
[T11AU0].>
P0601 Internal control module memory check sum error <Ref. to 2-7
[T11AV0].>
P0703 Brake switch input malfunction <Ref. to 2-7
[T11AW0].>
P0705 Transmission range sensor circuit malfunction <Ref. to 2-7
[T11AX0].>
P0710 Transmission fluid temperature sensor circuit malfunction <Ref. to 2-7
[T11AY0].>
P0715 Torque converter turbine speed sensor circuit malfunction <Ref. to 2-7
[T11AZ0].>
P0720 Output speed sensor (vehicle speed sensor 2) circuit malfunction <Ref. to 2-7
[T11BA0].>
391
2-7 [T11A0] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
DTC
Item Index
No.
P0725 Engine speed input circuit malfunction <Ref. to 2-7
[T11BB0].>
P0731 Gear 1 incorrect ratio <Ref. to 2-7
[T11BC0].>
P0732 Gear 2 incorrect ratio <Ref. to 2-7
[T11BD0].>
P0733 Gear 3 incorrect ratio <Ref. to 2-7
[T11BE0].>
P0734 Gear 4 incorrect ratio <Ref. to 2-7
[T11BF0].>
P0740 Torque converter clutch system malfunction <Ref. to 2-7
[T11BG0].>
P0743 Torque converter clutch system (Solenoid B) electrical <Ref. to 2-7
[T11BH0].>
P0748 Pressure control solenoid (Duty solenoid A) electrical <Ref. to 2-7
[T11BI0].>
P0753 Shift solenoid A (Shift solenoid 1) electrical <Ref. to 2-7
[T11BJ0].>
P0758 Shift solenoid B (Shift solenoid 2) electrical <Ref. to 2-7
[T11BK0].>
P1100 Starter switch circuit low input <Ref. to 2-7
[T11BL0].>
P1101 Neutral position switch circuit low input [MT vehicles] <Ref. to 2-7
[T11BM0].>
P1101 Neutral position switch circuit high input [AT vehicles] <Ref. to 2-7
[T11BN0].>
P1102 Pressure sources switching solenoid valve circuit low input <Ref. to 2-7
[T11BO0].>
P1103 Engine torque control signal 1 circuit malfunction <Ref. to 2-7
[T11BP0].>
P1106 Engine torque control signal 2 circuit malfunction <Ref. to 2-7
[T11BQ0].>
P1115 Engine torque control cut signal circuit high input <Ref. to 2-7
[T11BR0].>
P1116 Engine torque control cut signal circuit low input <Ref. to 2-7
[T11BS0].>
P1120 Starter switch circuit high input <Ref. to 2-7
[T11BT0].>
P1121 Neutral position switch circuit high input [MT vehicles] <Ref. to 2-7
[T11BU0].>
P1121 Neutral position switch circuit low input [AT vehicles] <Ref. to 2-7
[T11BV0].>
P1122 Pressure sources switching solenoid valve circuit high input <Ref. to 2-7
[T11BW0].>
P1141 Mass air flow sensor circuit range/performance problem (low input) <Ref. to 2-7
[T11BX0].>
P1142 Throttle position sensor circuit range/performance problem (low input) <Ref. to 2-7
[T11BY0].>
P1143 Pressure sensor circuit range/performance problem (low input) <Ref. to 2-7
[T11BZ0].>
P1144 Pressure sensor circuit range/performance problem (high input) <Ref. to 2-7
[T11CA0].>
P1150 Front oxygen sensor heater circuit high input <Ref. to 2-7
[T11CB0].>
392
ON-BOARD DIAGNOSTICS II SYSTEM [T11A0] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
DTC
Item Index
No.
P1151 Rear oxygen sensor heater circuit high input <Ref. to 2-7
[T11CC0].>
P1325 Knock sensor circuit low input <Ref. to 2-7
[T11CD0].>
P1400 Fuel tank pressure control solenoid valve circuit low input <Ref. to 2-7
[T11CE0].>
P1420 Fuel tank pressure control solenoid valve circuit high input <Ref. to 2-7
[T11CF0].>
P1422 Evaporative emission control system purge control valve circuit high input <Ref. to 2-7
[T11CG0].>
P1423 Evaporative emission control system vent control high input <Ref. to 2-7
[T11CH0].>
P1442 Fuel level sensor circuit range/performance problem 2 <Ref. to 2-7
[T11CI0].>
P1443 Evaporative emission control system vent control function problem <Ref. to 2-7
[T11CJ0].>
P1507 Idle control system malfunction (fail-safe) <Ref. to 2-7
[T11CK0].>
P1510 Idle air control solenoid valve signal 1 circuit low input <Ref. to 2-7
[T11CL0].>
P1511 Idle air control solenoid valve signal 1 circuit high input <Ref. to 2-7
[T11CM0].>
P1512 Idle air control solenoid valve signal 2 circuit low input <Ref. to 2-7
[T11CN0].>
P1513 Idle air control solenoid valve signal 2 circuit high input <Ref. to 2-7
[T11CO0].>
P1514 Idle air control solenoid valve signal 3 circuit low input <Ref. to 2-7
[T11CP0].>
P1515 Idle air control solenoid valve signal 3 circuit high input <Ref. to 2-7
[T11CQ0].>
P1516 Idle air control solenoid valve signal 4 circuit low input <Ref. to 2-7
[T11CR0].>
P1517 Idle air control solenoid valve signal 4 circuit high input <Ref. to 2-7
[T11CS0].>
P1520 Cooling fan relay 1 circuit high input <Ref. to 2-7
[T11CT0].>
P1540 Vehicle speed sensor malfunction 2 <Ref. to 2-7
[T11CU0].>
P1560 Back-up voltage circuit malfunction <Ref. to 2-7
[T11CV0].>
P1700 Throttle position sensor circuit malfunction for automatic transmission <Ref. to 2-7
[T11CW0].>
P1701 Cruise control set signal circuit malfunction for automatic transmission <Ref. to 2-7
[T11CX0].>
P1702 Automatic transmission diagnosis input signal circuit low input <Ref. to 2-7
[T11CY0].>
P1703 Low clutch timing control solenoid valve circuit malfunction <Ref. to 2-7
[T11CZ0].>
P1704 2-4 brake timing control solenoid valve circuit malfunction <Ref. to 2-7
[T11DA0].>
P1705 2-4 brake pressure control solenoid valve (Duty solenoid D) circuit malfunction <Ref. to 2-7
[T11DB0].>
P1722 Automatic transmission diagnosis input signal circuit high input <Ref. to 2-7
[T11DC0].>
393
2-7 [T11A0] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
DTC
Item Index
No.
P1742 Automatic transmission diagnosis input signal circuit malfunction <Ref. to 2-7
[T11DD0].>
394
ON-BOARD DIAGNOSTICS II SYSTEM [T11A0] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
MEMO:
395
2-7 [T11B0] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
H2M3024
396
ON-BOARD DIAGNOSTICS II SYSTEM [T11B3] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
B2M2691A
B2M2691A
397
2-7 [T11C0] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
I TROUBLE SYMPTOM:
I Erroneous idling
I Engine stalls.
I Poor driving performance
CAUTION:
After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].>
and INSPECTION MODE <Ref. to 2-7 [T3E0].>.
I WIRING DIAGRAM:
H2M3024
398
ON-BOARD DIAGNOSTICS II SYSTEM [T11C3] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11C1 : CONNECT SUBARU SELECT MONI- 11C2 : CHECK INPUT SIGNAL FOR ECM.
TOR OR THE OBD-II GENERAL
SCAN TOOL, AND READ DATA. Measure voltage between ECM connector and
chassis ground while engine is idling.
1) Turn ignition switch to OFF.
Connector & terminal
2) Connect Subaru Select Monitor or the OBD-II
(B136) No. 5 (+) — Chassis ground (−):
general scan tool to data link connector.
B2M2692A
S2M0258B
3) Turn ignition switch to ON and Subaru Select : Is the voltage less than 0.3 V?
Monitor or the OBD-II general scan tool switch to : Go to step 11C4.
ON. : Go to step 11C3.
4) Start engine.
5) Read data of mass air flow sensor signal using
Subaru Select Monitor or OBD-II general scan tool. 11C3 : CHECK INPUT SIGNAL FOR ECM.
(USING SUBARU SELECT MONI-
NOTE: TOR)
I Subaru Select Monitor
For detailed operation procedure, refer to the
“READ CURRENT DATA SHOWN ON DISPLAY Measure voltage between ECM connector and
FOR ENGINE”. <Ref. to 2-7 [T3C4].> chassis ground while engine is idling.
I OBD-II general scan tool : Does the voltage change more than
For detailed operation procedure, refer to the 0.3 V by shaking harness and con-
OBD-II General Scan Tool Instruction Manual. nector of ECM while monitoring the
: Is the value equal to or more than 0 value with Subaru Select Monitor?
g/sec (0 lb/min) or 0.3 V and equal to : Repair poor contact in ECM connector.
or less than 186 g/sec (25 lb/min) or : Contact with SOA service.
5.0 V?
NOTE:
: Even if MIL lights up, the circuit has Inspection by DTM is required, because probable
returned to a normal condition at this cause is deterioration of multiple parts.
time. A temporary poor contact of the
connector or harness may be the cause.
Repair harness or connector in the
mass air flow sensor.
NOTE:
In this case, repair the following:
I Open or ground short circuit in harness between
mass air flow sensor and ECM connector
I Poor contact in mass air flow sensor or ECM
connector
: Go to step 11C2.
399
2-7 [T11C4] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11C4 : CHECK POWER SUPPLY TO MASS 11C5 : CHECK POWER SUPPLY TO MASS
AIR FLOW SENSOR. AIR FLOW SENSOR.
1) Turn ignition switch to OFF. Measure voltage between mass air flow sensor
2) Disconnect connector from mass air flow sen- connector and engine ground.
sor. Connector & terminal
3) Turn ignition switch to ON. (E26) No. 4 (+) — Engine ground (−):
4) Measure voltage between mass air flow sensor
connector and engine ground.
Connector & terminal
(E26) No. 2 (+) — Engine ground (−):
B2M2694A
400
ON-BOARD DIAGNOSTICS II SYSTEM [T11C7] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11C6 : CHECK HARNESS BETWEEN ECM 11C7 : CHECK HARNESS BETWEEN ECM
AND MASS AIR FLOW SENSOR AND MASS AIR FLOW SENSOR
CONNECTOR. CONNECTOR.
1) Turn ignition switch to OFF. Measure resistance of harness between ECM and
2) Disconnect connector from ECM. mass air flow sensor connector.
3) Measure resistance of harness between ECM Connector & terminal
and mass air flow sensor connector. (B136) No. 8 — (E26) No. 3:
Connector & terminal
(B136) No. 5 — (E26) No. 5:
B2M2696A
401
2-7 [T11C8] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
B2M2697A
402
ON-BOARD DIAGNOSTICS II SYSTEM [T11C8] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
MEMO:
403
2-7 [T11D0] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
I TROUBLE SYMPTOM:
I Erroneous idling
I Engine stalls.
I Poor driving performance
CAUTION:
After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].>
and INSPECTION MODE <Ref. to 2-7 [T3E0].>.
I WIRING DIAGRAM:
H2M3024
404
ON-BOARD DIAGNOSTICS II SYSTEM [T11D2] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11D1 : CONNECT SUBARU SELECT MONI- 11D2 : CHECK HARNESS BETWEEN ECM
TOR OR THE OBD-II GENERAL AND MASS AIR FLOW SENSOR
SCAN TOOL, AND READ DATA. CONNECTOR.
1) Turn ignition switch to OFF. 1) Turn ignition switch to OFF and Subaru Select
2) Connect Subaru Select Monitor or the OBD-II Monitor or the OBD-II general scan tool switch to
general scan tool to data link connector. OFF.
2) Disconnect connector from mass air flow sen-
sor.
3) Turn ignition switch to ON and Subaru Select
Monitor or the OBD-II general scan tool switch to
ON.
4) Read data of mass air flow sensor signal using
Subaru Select Monitor or OBD-II general scan tool.
NOTE:
I Subaru Select Monitor
For detailed operation procedure, refer to the
S2M0258B
“READ CURRENT DATA SHOWN ON DISPLAY
3) Turn ignition switch to ON and Subaru Select FOR ENGINE”. <Ref. to 2-7 [T3C4].>
Monitor or the OBD-II general scan tool switch to I OBD-II general scan tool
ON. For detailed operation procedures, refer to the
4) Start engine. OBD-II General Scan Tool Instruction Manual.
5) Read data of mass air flow sensor signal using
Subaru Select Monitor or OBD-II general scan tool. : Is the value more than 186 g/sec (25
lb/min) or 5 V?
NOTE:
: Repair battery short circuit in harness
I Subaru Select Monitor
For detailed operation procedure, refer to the between mass air flow sensor and ECM
“READ CURRENT DATA SHOWN ON DISPLAY connector. After repair, replace ECM.
FOR ENGINE”. <Ref. to 2-7 [T3C4].> <Ref. to 2-7 [W15A0].>
I OBD-II general scan tool : Replace mass air flow sensor. <Ref. to
For detailed operation procedures, refer to the 2-7 [W2A0].>
OBD-II General Scan Tool Instruction Manual.
: Is the value equal to or more than 0
g/sec (0 lb/min) or 0.3 V and equal to
or less than 186 g/sec (25 lb/min) or
5.0 V?
: Even if MIL lights up, the circuit has
returned to a normal condition at this
time.
: Go to step 11D2.
405
2-7 [T11E0] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
CAUTION:
After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].>
and INSPECTION MODE <Ref. to 2-7 [T3E0].>.
I WIRING DIAGRAM:
H2M3025
NOTE:
In this case, it is not necessary to inspect DTC
P0106.
: Does the Subaru Select Monitor or
OBD-II general scan tool indicate
DTC P0107, P0108, P1102 OR P1122?
: Inspect DTC P0107, P0108, P1102 OR
P1122 using “11. Diagnostics Chart with
Trouble Code for Except 2200 cc Cali-
fornia Spec. Vehicles”. <Ref. to 2-7
[T11A0].>
: Go to step 11E2.
406
ON-BOARD DIAGNOSTICS II SYSTEM [T11E4] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11E2 : CHECK IDLE SWITCH SIGNAL. 11E3 : CHECK DATA FOR CONTROL.
S2M0258B S2M0258B
3) Turn ignition switch to ON and Subaru Select 3) Turn ignition switch ON and Subaru Select
Monitor switch to ON. Monitor or the OBD-II general scan tool switch ON.
4) Operate the LED operation mode for engine 4) Start engine.
using Subaru Select Monitor. 5) Read data of intake manifold absolute pressure
NOTE: signal using Subaru Select Monitor or OBD-II gen-
I Subaru Select Monitor eral scan tool.
For detailed operation procedure, refer to the “LED NOTE:
OPERATION MODE FOR ENGINE”. <Ref. to 2-7 I Subaru Select Monitor
[T3C8].> For detailed operation procedure, refer to the
: Does the LED of {Idle Switch Signal} “READ CURRENT DATA SHOWN ON DISPLAY
come on? FOR ENGINE”. <Ref. to 2-7 [T3C4].>
I OBD-II general scan tool
: Go to step 11E3. For detailed operation procedures, refer to the
: Check throttle position sensor circuit. OBD-II General Scan Tool Instruction Manual.
<Ref. to 2-7 [T11K0].>
: Is the value more than 85 kPa (638
NOTE: mmHg, 25.12 inHg)?
In this case, it is not necessary to inspect DTC : Go to step 11E6.
P0106.
: Go to step 11E4.
407
2-7 [T11E5] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
S2M0259B
11E6 : CHECK VACUUM HOSES.
3) Turn ignition switch to ON.
Check the following items. NOTE:
I Disconnection of the vacuum hose from pres- Pressure sources switching solenoid valve opera-
sure sources switching solenoid valve to intake tion check can also be executed using Subaru
manifold Select Monitor. For the procedure, refer to the
I Holes in the vacuum hose between pressure “COMPULSORY VALVE OPERATION CHECK
sources switching solenoid valve to intake mani- MODE”. <Ref. to 2-7 [T3F0].>
fold : Does pressure sources switching
I Clogging of the vacuum hose between pressure solenoid valve produce operating
sources switching solenoid valve to intake mani- sound? (ON ⇔ OFF each 1.5 sec.)
fold : Replace pressure sensor. <Ref. to 2-7
I Disconnection of the vacuum hose from pres- [W11A0].>
sure sensor to pressure sources switching sole-
noid valve : Replace pressure sources switching
solenoid valve. <Ref. to 2-7 [W13A0].>
I Holes in the vacuum hose between pressure
sensor and pressure sources switching solenoid
valve
I Clogging of the vacuum hose between pressure
sensor and pressure sources switching solenoid
valve
I Clogging of the filter
B2M1063G
408
ON-BOARD DIAGNOSTICS II SYSTEM [T11E7] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
MEMO:
409
2-7 [T11F0] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
CAUTION:
After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].>
and INSPECTION MODE <Ref. to 2-7 [T3E0].>.
I WIRING DIAGRAM:
H2M3025
410
ON-BOARD DIAGNOSTICS II SYSTEM [T11F4] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11F1 : CONNECT SUBARU SELECT MONI- 11F3 : CHECK INPUT SIGNAL FOR ECM.
TOR OR THE OBD-II GENERAL
SCAN TOOL, AND READ DATA. Measure voltage between ECM connector and
chassis ground.
1) Turn ignition switch to OFF.
Connector & terminal
2) Connect Subaru Select Monitor or the OBD-II
(B136) No. 15 (+) — Chassis ground (−):
general scan tool to data link connector.
B2M2443A
S2M0258B
3) Turn ignition switch to ON and Subaru Select : Is the voltage more than 4.5 V?
Monitor or the OBD-II general scan tool switch to : Go to step 11F5.
ON. : Go to step 11F4.
4) Start engine.
5) Read the data of intake manifold absolute pres-
sure signal using Subaru Select Monitor or OBD-II 11F4 : CHECK INPUT SIGNAL FOR ECM.
general scan tool.
NOTE: Measure voltage between ECM connector and
I Subaru Select Monitor chassis ground.
For detailed operation procedure, refer to the Connector & terminal
“READ CURRENT DATA SHOWN ON DISPLAY (B136) No. 15 (+) — Chassis ground (−):
FOR ENGINE”. <Ref. to 2-7 [T3C4].>
I OBD-II general scan tool
For detailed operation procedures, refer to the
OBD-II General Scan Tool Instruction Manual.
: Is the value less than 0 kPa (0 mmHg,
0 inHg)?
: Go to step 11F3.
: Go to step 11F2.
Check poor contact in ECM and pressure sensor : Does the voltage change more than
connector. <Ref. to FOREWORD [T3C1].> 4.5 V by shaking harness and con-
nector of ECM while monitoring the
: Is there poor contact in ECM or pres- value with voltage meter?
sure sensor connector? : Repair poor contact in ECM connector.
: Repair poor contact in ECM or pressure : Contact with SOA service.
sensor connector.
: Even if MIL lights up, the circuit has NOTE:
returned to a normal condition at this Inspection by DTM is required, because probable
time. cause is deterioration of multiple parts.
411
2-7 [T11F5] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11F5 : CHECK INPUT SIGNAL FOR ECM. 11F7 : CHECK HARNESS BETWEEN ECM
AND PRESSURE SENSOR CONNEC-
TOR.
Measure voltage between ECM and chassis
ground.
1) Turn ignition switch to OFF.
Connector & terminal
2) Disconnect connector from pressure sensor.
(B136) No. 29 (+) — Chassis ground (−):
3) Turn ignition switch to ON.
4) Measure voltage between pressure sensor con-
nector and engine ground.
Connector & terminal
(E21) No. 3 (+) — Engine ground (−):
B2M2699A
11F6 : CHECK INPUT SIGNAL FOR ECM. : Is the voltage more than 4.5 V?
(USING SUBARU SELECT MONI- : Go to step 11F8.
TOR.)
: Repair harness and connector.
Read data of atmospheric absolute pressure signal NOTE:
using Subaru Select Monitor. In this case, repair the following:
I Open circuit in harness between ECM and pres-
NOTE: sure sensor connector
I Subaru Select Monitor I Poor contact in coupling connector (B21)
For detailed operation procedure, refer to the
“READ CURRENT DATA SHOWN ON DISPLAY
FOR ENGINE”. <Ref. to 2-7 [T3C4].>
: Does the value change more than 0
kPa (0 mmHg, 0 inHg) by shaking har-
ness and connector of ECM while
monitoring the value with Subaru
select monitor?
: Repair poor contact in ECM connector.
: Go to step 11F7.
412
ON-BOARD DIAGNOSTICS II SYSTEM [T11F10] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11F8 : CHECK HARNESS BETWEEN ECM 11F9 : CHECK HARNESS BETWEEN ECM
AND PRESSURE SENSOR CONNEC- AND PRESSURE SENSOR CONNEC-
TOR. TOR.
OBD0695C
B2M2700A
: Is the resistance more than 500 kΩ?
: Go to step 11F10.
: Is the resistance less than 1 Ω? : Repair ground short circuit in harness
: Go to step 11F9. between ECM and pressure sensor con-
nector.
: Repair harness and connector.
NOTE: 11F10 : CHECK POOR CONTACT.
In this case, repair the following:
I Open circuit in harness between ECM and pres-
sure sensor connector Check poor contact in pressure sensor connector.
I Poor contact in coupling connector (B21) <Ref. to FOREWORD [T3C1].>
: Is there poor contact in pressure sen-
sor connector?
: Repair poor contact in pressure sensor
connector.
: Replace pressure sensor. <Ref. to 2-7
[W11A0].>
413
2-7 [T11G0] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
CAUTION:
After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].>
and INSPECTION MODE <Ref. to 2-7 [T3E0].>.
I WIRING DIAGRAM:
H2M3025
414
ON-BOARD DIAGNOSTICS II SYSTEM [T11G3] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11G1 : CONNECT SUBARU SELECT MONI- 11G2 : CHECK INPUT SIGNAL FOR ECM.
TOR OR THE OBD-II GENERAL
SCAN TOOL, AND READ DATA. Measure voltage between ECM connector and
chassis ground.
1) Turn ignition switch to OFF.
Connector & terminal
2) Connect Subaru Select Monitor or the OBD-II
(B136) No. 15 (+) — Chassis ground (−):
general scan tool to data link connector.
B2M2443A
S2M0258B
3) Turn ignition switch to ON and Subaru Select : Is the voltage more than 4.5 V?
Monitor or the OBD-II general scan tool switch to : Go to step 11G4.
ON. : Go to step 11G3.
4) Start engine.
5) Read the data of intake manifold absolute pres-
sure signal using Subaru Select Monitor or OBD-II 11G3 : CHECK INPUT SIGNAL FOR ECM.
general scan tool.
NOTE: Measure voltage between ECM connector and
I Subaru Select Monitor chassis ground.
For detailed operation procedure, refer to the Connector & terminal
“READ CURRENT DATA SHOWN ON DISPLAY (B136) No. 15 (+) — Chassis ground (−):
FOR ENGINE”. <Ref. to 2-7 [T3C4].>
I OBD-II general scan tool
For detailed operation procedures, refer to the
OBD-II General Scan Tool Instruction Manual.
: Is the value more than 140 kPa (1,050
mmHg, 41.34 inHg)?
: Go to step 11G10.
: Go to step 11G2.
B2M2443A
415
2-7 [T11G4] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11G4 : CHECK INPUT SIGNAL FOR ECM. 11G6 : CHECK HARNESS BETWEEN ECM
AND PRESSURE SENSOR CON-
NECTOR.
Measure voltage between ECM connector and
chassis ground.
1) Turn ignition switch to OFF.
Connector & terminal
2) Disconnect connector from pressure sensor.
(B136) No. 29 (+) — Chassis ground (−):
3) Turn ignition switch to ON.
4) Measure voltage between pressure sensor con-
nector and engine ground.
Connector & terminal
(E21) No. 3 (+) — Engine ground (−):
B2M2699A
11G5 : CHECK INPUT SIGNAL FOR ECM. : Is the voltage more than 4.5 V?
(USING SUBARU SELECT MONI- : Go to step 11G7.
TOR.)
: Repair harness and connector.
Read data of atmospheric absolute pressure signal NOTE:
using Subaru Select Monitor. In this case, repair the following:
I Open circuit in harness between ECM and pres-
NOTE: sure sensor connector
I Subaru Select Monitor I Poor contact in coupling connector (B21)
For detailed operation procedure, refer to the
“READ CURRENT DATA SHOWN ON DISPLAY
FOR ENGINE”. <Ref. to 2-7 [T3C4].>
: Does the value change more than 0
kPa (0 mmHg, 0 inHg) by shaking har-
ness and connector of ECM while
monitoring the value with Subaru
select monitor?
: Repair poor contact in ECM connector.
: Go to step 11G6.
416
ON-BOARD DIAGNOSTICS II SYSTEM [T11G9] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11G7 : CHECK HARNESS BETWEEN ECM 11G8 : CHECK HARNESS BETWEEN ECM
AND PRESSURE SENSOR CON- AND PRESSURE SENSOR CON-
NECTOR. NECTOR.
1) Turn ignition switch to OFF. Measure resistance of harness between ECM and
2) Disconnect connector from ECM. pressure sensor connector.
3) Measure resistance of harness between ECM Connector & terminal
and pressure sensor connector. (B136) No. 16 — (E21) No. 1:
Connector & terminal
(B136) No. 29 — (E21) No. 2:
B2M2701A
417
2-7 [T11G10] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
418
ON-BOARD DIAGNOSTICS II SYSTEM [T11G10] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
MEMO:
419
2-7 [T11H0] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
I TROUBLE SYMPTOM:
I Hard to start
I Erroneous idling
I Poor driving performance
CAUTION:
After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].>
and INSPECTION MODE <Ref. to 2-7 [T3E0].>.
I WIRING DIAGRAM:
H2M3026
420
ON-BOARD DIAGNOSTICS II SYSTEM [T11H2] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
S2M0258B S2M1001
3) Turn ignition switch to ON and Subaru Select 3) Remove engine harness connector bracket
Monitor or OBD-II general scan tool switch to ON. from cylinder block.
4) Start engine.
5) Read data of engine coolant temperature sen-
sor signal using Subaru Select Monitor or OBD-II
general scan tool.
NOTE:
I Subaru Select Monitor
For detailed operation procedure, refer to the
“READ CURRENT DATA SHOWN ON DISPLAY
FOR ENGINE”. <Ref. to 2-7 [T3C4].>
I OBD-II general scan tool
For detailed operation procedures, refer to the B2M2451
OBD-II General Scan Tool Instruction Manual.
4) Remove blow-by hoses.
: Is the value greater than 150°C
(300°F)?
: Go to step 11H2.
: Repair poor contact.
NOTE:
In this case, repair the following:
I Poor contact in engine coolant temperature sen-
sor
I Poor contact in ECM
I Poor contact in coupling connector (B21)
B2M2450
421
2-7 [T11H2] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
422
ON-BOARD DIAGNOSTICS II SYSTEM [T11H2] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
MEMO:
423
2-7 [T11I0] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
H2M3026
424
ON-BOARD DIAGNOSTICS II SYSTEM [T11I2] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
S2M0258B S2M1001
3) Turn ignition switch to ON and Subaru Select 3) Remove engine harness connector bracket
Monitor or OBD-II general scan tool switch to ON. from cylinder block.
4) Start engine.
5) Read data of engine coolant temperature sen-
sor signal using Subaru Select Monitor or OBD-II
general scan tool.
NOTE:
I Subaru Select Monitor
For detailed operation procedure, refer to the
“READ CURRENT DATA SHOWN ON DISPLAY
FOR ENGINE”. <Ref. to 2-7 [T3C4].>
I OBD-II general scan tool
For detailed operation procedures, refer to the B2M2451
OBD-II General Scan Tool Instruction Manual.
: Is the value less than −40°C (−40°F)? 4) Remove blow-by hoses.
: Go to step 11I2.
: Repair poor contact.
NOTE:
In this case, repair the following:
I Poor contact in engine coolant temperature sen-
sor
I Poor contact in ECM
I Poor contact in coupling connector (B21)
B2M2450
425
2-7 [T11I3] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
6) Measure voltage between engine coolant tem- 11I4 : CHECK HARNESS BETWEEN
perature sensor connector and engine ground. ENGINE COOLANT TEMPERATURE
Connector & terminal SENSOR AND ECM CONNECTOR.
(E8) No. 1 (+) — Engine ground (−):
Measure voltage between engine coolant tempera-
ture sensor connector and engine ground.
Connector & terminal
(E8) No. 1 (+) — Engine ground (−):
H2M3150A
H2M3150A
426
ON-BOARD DIAGNOSTICS II SYSTEM [T11I5] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
H2M3151A
427
2-7 [T11J0] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
H2M3027
428
ON-BOARD DIAGNOSTICS II SYSTEM [T11J1] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
429
2-7 [T11K0] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
I TROUBLE SYMPTOM:
I Erroneous idling
I Engine stalls.
I Poor driving performance
CAUTION:
After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].>
and INSPECTION MODE <Ref. to 2-7 [T3E0].>.
I WIRING DIAGRAM:
H2M3027
430
ON-BOARD DIAGNOSTICS II SYSTEM [T11K3] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11K1 : CONNECT SUBARU SELECT MONI- 11K2 : CHECK INPUT SIGNAL FOR ECM.
TOR OR THE OBD-II GENERAL
SCAN TOOL, AND READ DATA. Measure voltage between ECM connector and
chassis ground while throttle valve is fully closed.
1) Turn ignition switch to OFF.
Connector & terminal
2) Connect Subaru Select Monitor or the OBD-II
(B136) No. 15 (+) — Chassis ground (−):
general scan tool to data link connector.
B2M2443A
S2M0258B
3) Turn ignition switch to ON and Subaru Select : Is the voltage more than 4.5 V?
Monitor or OBD-II general scan tool switch to ON. : Go to step 11K4.
4) Start engine. : Go to step 11K3.
5) Read data of throttle position sensor signal
using Subaru Select Monitor or OBD-II general
scan tool. 11K3 : CHECK INPUT SIGNAL FOR ECM.
NOTE:
I Subaru Select Monitor Measure voltage between ECM connector and
For detailed operation procedure, refer to the chassis ground.
“READ CURRENT DATA SHOWN ON DISPLAY Connector & terminal
FOR ENGINE”. <Ref. to 2-7 [T3C4].> (B136) No. 15 (+) — Chassis ground (−):
I OBD-II general scan tool
For detailed operation procedures, refer to the
OBD-II General Scan Tool Instruction Manual.
: Is the value less than 0.1 V?
: Go to step 11K2.
: Even if MIL lights up, the circuit has
returned to a normal condition at this
time. A temporary poor contact of the
connector may be the cause.
NOTE: B2M2443A
431
2-7 [T11K4] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11K4 : CHECK INPUT SIGNAL FOR ECM. 11K6 : CHECK HARNESS BETWEEN ECM
AND THROTTLE POSITION SENSOR
CONNECTOR.
Measure voltage between ECM connector and
chassis ground.
1) Turn ignition switch to OFF.
Connector & terminal
2) Disconnect connectors from throttle position
(B136) No. 17 (+) — Chassis ground (−):
sensor.
3) Turn ignition switch to ON.
4) Measure voltage between throttle position sen-
sor connector and engine ground.
Connector & terminal
(E13) No. 4 (+) — Engine ground (−):
B2M2703A
432
ON-BOARD DIAGNOSTICS II SYSTEM [T11K9] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11K7 : CHECK HARNESS BETWEEN ECM 11K8 : CHECK HARNESS BETWEEN ECM
AND THROTTLE POSITION SENSOR AND THROTTLE POSITION SENSOR
CONNECTOR. CONNECTOR.
B2M2706A
B2M2705A
: Is the resistance less than 10 Ω?
: Is the resistance less than 1 Ω? : Repair ground short circuit in harness
: Go to step 11K8. between throttle position sensor and
: Repair harness and connector. ECM connector.
NOTE: : Go to step 11K9.
In this case, repair the following:
I Open circuit in harness between throttle position 11K9 : CHECK POOR CONTACT.
sensor and ECM connector
I Poor contact in ECM connector Check poor contact in throttle position sensor con-
I Poor contact in throttle position sensor connec- nector. <Ref. to FOREWORD [T3C1].>
tor
I Poor contact in coupling connector (B21) : Is there poor contact in throttle posi-
tion sensor connector?
: Repair poor contact in throttle position
sensor connector.
: Replace throttle position sensor. <Ref.
to 2-7 [W9A2].>
433
2-7 [T11L0] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
I TROUBLE SYMPTOM:
I Erroneous idling
I Engine stalls.
I Poor driving performance
CAUTION:
After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].>
and INSPECTION MODE <Ref. to 2-7 [T3E0].>.
I WIRING DIAGRAM:
H2M3027
434
ON-BOARD DIAGNOSTICS II SYSTEM [T11L2] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
S2M0258B
435
2-7 [T11L3] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
B2M2708A
436
ON-BOARD DIAGNOSTICS II SYSTEM [T11M1] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
H2M3026
437
2-7 [T11N0] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
CAUTION:
After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].>
and INSPECTION MODE <Ref. to 2-7 [T3E0].>.
I WIRING DIAGRAM:
H2M3028
NOTE:
I Check for use of improper fuel.
I Check if engine oil or coolant level is extremely
low.
: Is CO % more than 2 % after engine
warm-up?
: Check fuel system.
: Go to step 11N2.
438
ON-BOARD DIAGNOSTICS II SYSTEM [T11N4] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
S2M0258B
439
2-7 [T11O0] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
H2M3028
11O1 : CHECK ANY OTHER DTC ON DIS- 11O2 : CHECK EXHAUST SYSTEM.
PLAY.
NOTE:
: Does the Subaru Select Monitor or Check the following items.
OBD-II general scan tool indicate I Loose installation of front portion of exhaust pipe
DTC P0130? onto cylinder heads
: Inspect DTC P0130 using “11. Diagnos- I Loose connection between front exhaust pipe
tics Chart with Trouble Code for Except and front catalytic converter
I Damage of exhaust pipe resulting in a hole
2200 cc California Spec. Vehicles”.
<Ref. to 2-7 [T11A0].> : Is there a fault in exhaust system?
NOTE: : Repair exhaust system.
In this case, it is not necessary to inspect DTC : Replace front oxygen sensor. <Ref. to
P0133. 2-7 [W7A0].>
: Go to step 11O2.
440
ON-BOARD DIAGNOSTICS II SYSTEM [T11O2] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
MEMO:
441
2-7 [T11P0] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
CAUTION:
After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].>
and INSPECTION MODE <Ref. to 2-7 [T3E0].>.
I WIRING DIAGRAM:
H2M3029
442
ON-BOARD DIAGNOSTICS II SYSTEM [T11P3] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11P2 : CHECK GROUND CIRCUIT OF ECM. 11P3 : CHECK GROUND CIRCUIT OF ECM.
B2M2467A
443
2-7 [T11P4] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11P4 : CONNECT SUBARU SELECT MONI- 11P5 : CHECK OUTPUT SIGNAL FROM
TOR OR THE OBD-II GENERAL ECM.
SCAN TOOL, AND READ DATA.
1) Start and idle the engine.
1) Turn ignition switch to OFF. 2) Measure voltage between ECM connector and
2) Connect Subaru Select Monitor or the OBD-II chassis ground.
general scan tool to data link connector.
Connector & terminal
(B134) No. 22 (+) — Chassis ground (−):
S2M0258B
B2M2468A
444
ON-BOARD DIAGNOSTICS II SYSTEM [T11P10] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11P7 : CHECK OUTPUT SIGNAL FROM 11P9 : CHECK OUTPUT SIGNAL FROM
ECM. ECM.
Measure voltage between ECM connector and 1) Disconnect connector from front oxygen sen-
chassis ground. sor.
Connector & terminal 2) Measure voltage between ECM connector and
(B134) No. 23 (+) — Chassis ground (−): chassis ground.
Connector & terminal
(B134) No. 22 (+) — Chassis ground (−):
B2M2469A
: Go to step 11P11.
: Is the voltage less than 1.0 V?
: Go to step 11P8.
: Go to step 11P10.
11P8 : CHECK OUTPUT SIGNAL FROM : Repair battery short circuit in harness
ECM. between ECM and front oxygen sensor
connector. After repair, replace ECM.
<Ref. to 2-7 [W15A0].>
Measure voltage between ECM connector and
chassis ground.
11P10 : CHECK OUTPUT SIGNAL FROM
Connector & terminal ECM.
(B134) No. 23 (+) — Chassis ground (−):
Measure voltage between ECM connector and
chassis ground.
Connector & terminal
(B134) No. 23 (+) — Chassis ground (−):
B2M2469A
: Repair poor contact in ECM connector. : Is the voltage less than 1.0 V?
: Go to step 11P9. : Replace ECM. <Ref. to 2-7 [W15A0].>
: Repair battery short circuit in harness
between ECM and front oxygen sensor
connector. After repair, replace ECM.
<Ref. to 2-7 [W15A0].>
445
2-7 [T11P11] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
B2M0768
446
ON-BOARD DIAGNOSTICS II SYSTEM [T11Q2] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
H2M3030
11Q1 : CHECK ANY OTHER DTC ON DIS- 11Q2 : CHECK FAILURE CAUSE OF P0130.
PLAY.
Inspect DTC P0130 using “11. Diagnostics Chart
: Does the Subaru Select Monitor or with Trouble Code for Except 2200 cc California
OBD-II general scan tool indicate Spec. Vehicles”. <Ref. to 2-7 [T11A0].>
DTC P0130? : Is the failure cause of P0130 in the
: Go to step 11Q2. fuel system?
: Go to step 11Q3. : Check fuel system.
NOTE:
In this case, it is not necessary to inspect DTC
P0136.
: Go to step 11Q3.
447
2-7 [T11Q3] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11Q3 : CHECK REAR OXYGEN SENSOR 11Q5 : CHECK HARNESS BETWEEN ECM
DATA. AND REAR OXYGEN SENSOR CON-
NECTOR.
1) Turn ignition switch to OFF.
2) Connect Subaru Select Monitor or OBD-II gen- 1) Turn ignition switch to OFF.
eral scan tool to data link connector. 2) Disconnect connectors from ECM and rear oxy-
gen sensor.
3) Measure resistance of harness between ECM
and rear oxygen sensor connector.
Connector & terminal
(B136) No. 16 — (E25) No. 3:
S2M0258B
448
ON-BOARD DIAGNOSTICS II SYSTEM [T11Q7] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
B2M2478A
449
2-7 [T11R0] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
H2M3030
450
ON-BOARD DIAGNOSTICS II SYSTEM [T11S1] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
H2M3031
451
2-7 [T11S2] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11S2 : CHECK GROUND CIRCUIT OF ECM. 11S3 : CHECK GROUND CIRCUIT OF ECM.
B2M2467A
452
ON-BOARD DIAGNOSTICS II SYSTEM [T11S6] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11S4 : CONNECT SUBARU SELECT MONI- 11S5 : CHECK OUTPUT SIGNAL FROM
TOR OR THE OBD-II GENERAL ECM.
SCAN TOOL, AND READ DATA.
1) Start and idle the engine.
1) Turn ignition switch to OFF. 2) Measure voltage between ECM connector and
2) Connect Subaru Select Monitor or the OBD-II chassis ground.
general scan tool to data link connector.
Connector & terminal
(B134) No. 21 (+) — Chassis ground (−):
S2M0258B
453
2-7 [T11S7] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11S7 : CHECK OUTPUT SIGNAL FROM 11S8 : CHECK POWER SUPPLY TO REAR
ECM. OXYGEN SENSOR.
1) Disconnect connector from rear oxygen sensor. 1) Turn ignition switch to OFF.
2) Measure voltage between ECM connector and 2) Disconnect connector from rear oxygen sensor.
chassis ground. 3) Turn ignition switch to ON.
Connector & terminal 4) Measure voltage between rear oxygen sensor
(B134) No. 21 (+) — Chassis ground (−): connector and engine ground or chassis ground.
Connector & terminal
(E25) No. 2 (+) — Chassis ground (−):
B2M2710A
454
ON-BOARD DIAGNOSTICS II SYSTEM [T11S9] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
OBD0706
455
2-7 [T11S9] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
MEMO:
456
ON-BOARD DIAGNOSTICS II SYSTEM [T11T3] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11T1 : CHECK EXHAUST SYSTEM. (2) Disconnect connector from fuel tank.
B2M0047
S2M0392
B2M2484
457
2-7 [T11T4] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
5) Start the engine and idle while gear position is 11T4 : CHECK FUEL PRESSURE.
neutral.
6) Measure fuel pressure while disconnecting
pressure regulator vacuum hose from intake mani- After connecting pressure regulator vacuum hose,
fold. measure fuel pressure.
WARNING: WARNING:
Before removing fuel pressure gauge, release Before removing fuel pressure gauge, release
fuel pressure. fuel pressure.
NOTE: NOTE:
If fuel pressure does not increase, squeeze fuel I If fuel pressure does not increase, squeeze fuel
return hose 2 to 3 times, then measure fuel pres- return hose 2 to 3 times, then measure fuel pres-
sure again. sure again.
I If out of specification as measured at this step,
check or replace pressure regulator and pressure
regulator vacuum hose.
S2M0400
: Go to step 11T4.
: Is fuel pressure between 206 and 235
: Repair the following items.
kPa (2.1 — 2.4 kg/cm2, 30 — 34 psi)?
I Clogged fuel return line or bent : Go to step 11T5.
Fuel pressure too high
hose
: Repair the following items.
I Improper fuel pump discharge
Fuel pressure too low
I Clogged fuel supply line I Faulty pressure regulator
Fuel pressure too high I Clogged fuel return line or bent
hose
I Faulty pressure regulator
Fuel pressure too low I Improper fuel pump discharge
I Clogged fuel supply line
NOTE:
The fuel pressure gauge resisters 10 to 20 kPa
(0.1 to 0.2 kg/cm2, 1.4 to 2.8 psi) higher than stan-
dard values during high-altitude operations.
458
ON-BOARD DIAGNOSTICS II SYSTEM [T11T6] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11T5 : CHECK ENGINE COOLANT TEM- 11T6 : CHECK MASS AIR FLOW SENSOR.
PERATURE SENSOR. < REF. TO 2-7
[T11H0].> OR <REF. TO 2-7 [T11I0].> 1) Start the engine and warm-up engine until cool-
ant temperature is greater than 60°C (140°F).
1) Turn ignition switch to OFF. 2) Place the selector lever in “N” or “P” position.
2) Connect the Subaru Select Monitor or the 3) Turn A/C switch to OFF.
OBD-II general scan tool to data link connector. 4) Turn all accessory switches to OFF.
5) Read data of mass flow sensor signal using
Subaru Select Monitor or OBD-II general scan tool.
NOTE:
I Subaru Select Monitor
For detailed operation procedure, refer to the
“READ CURRENT DATA SHOWN ON DISPLAY
FOR ENGINE”. <Ref. to 2-7 [T3C4].>
I OBD-II general scan tool
For detailed operation procedures, refer to the
OBD-II General Scan Tool Instruction Manual.
S2M0258B Specification:
3) Start the engine and warm-up completely. Engine speed Specified value
4) Read data of engine coolant temperature sen- Idling 2.2 — 4.2 (g/sec)
sor signal using Subaru Select Monitor or OBD-II 2,500 rpm 8.6 — 14.5 (g/sec)
general scan tool.
: Is the voltage within the specifica-
NOTE:
tions?
I Subaru Select Monitor
For detailed operation procedure, refer to the : Contact with SOA service.
“READ CURRENT DATA SHOWN ON DISPLAY NOTE:
FOR ENGINE”. <Ref. to 2-7 [T3C4].> Inspection by DTM is required, because probable
I OBD-II general scan tool cause is deterioration of multiple parts.
For detailed operation procedures, refer to the : Replace mass air flow sensor. <Ref. to
OBD-II General Scan Tool Instruction Manual. 2-7 [W2A0].>
: Is temperature greater than 60°C
(140°F)?
: Go to step 11T6.
: Replace engine coolant temperature
sensor. <Ref. to 2-7 [W5A2].>
459
2-7 [T11U0] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
H2M3032
460
ON-BOARD DIAGNOSTICS II SYSTEM [T11V0] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
H2M3032
461
2-7 [T11V1] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11V1 : CONNECT SUBARU SELECT MONI- 11V2 : CHECK HARNESS BETWEEN FUEL
TOR OR THE OBD-II GENERAL TEMPERATURE SENSOR AND ECM
SCAN TOOL, AND READ DATA. CONNECTOR.
S2M0392
S2M0258B
3) Disconnect connector from fuel pump.
3) Turn ignition switch to ON and Subaru Select 4) Connect Subaru Select Monitor or the OBD-II
Monitor or OBD-II general scan tool switch to ON. general scan tool to data link connector.
4) Start engine.
5) Read data of fuel temperature sensor signal
using Subaru Select Monitor or OBD-II general
scan tool.
NOTE:
I Subaru Select Monitor
For detailed operation procedure, refer to the
“READ CURRENT DATA SHOWN ON DISPLAY
FOR ENGINE”. <Ref. to 2-7 [T3C4].>
I OBD-II general scan tool
S2M0258B
For detailed operation procedures, refer to the
OBD-II General Scan Tool Instruction Manual. 5) Turn ignition switch and Subaru Select Monitor
: Is the value greater than 150°C or OBD-II general scan tool switch to ON.
(300°F)? 6) Read data of fuel temperature sensor signal
: Go to step 11V2. using Subaru Select Monitor or the OBD-II general
scan tool.
: Even if MIL lights up, the circuit has
returned to a normal condition at this NOTE:
time. I Subaru Select Monitor
For detailed operation procedure, refer to the
“READ CURRENT DATA SHOWN ON DISPLAY
FOR ENGINE”. <Ref. to 2-7 [T3C4].>
I OBD-II general scan tool
For detailed operation procedures, refer to the
OBD-II General Scan Tool Instruction Manual.
: Is the value less than −40°C (−40°F)?
: Replace fuel temperature sensor. <Ref.
to 2-1 [W5A0].>
: Repair ground short circuit in harness
between fuel pump and ECM connector.
462
ON-BOARD DIAGNOSTICS II SYSTEM [T11W0] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
CAUTION:
After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].>
and INSPECTION MODE <Ref. to 2-7 [T3E0].>.
I WIRING DIAGRAM:
H2M3032
463
2-7 [T11W1] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11W1 : CONNECT SUBARU SELECT MONI- 11W2 : CHECK HARNESS BETWEEN FUEL
TOR OR THE OBD-II GENERAL TEMPERATURE SENSOR AND ECM
SCAN TOOL, AND READ DATA. CONNECTOR.
S2M0392
S2M0258B
3) Disconnect connector from fuel pump.
3) Turn ignition switch to ON and Subaru Select 4) Measure voltage between fuel pump connector
Monitor or OBD-II general scan tool switch to ON. and chassis ground.
4) Start engine. Connector & terminal
5) Read data of fuel temperature sensor signal (R58) No. 6 (+) — Chassis ground (−):
using Subaru Select Monitor or OBD-II general
scan tool.
NOTE:
I Subaru Select Monitor
For detailed operation procedure, refer to the
“READ CURRENT DATA SHOWN ON DISPLAY
FOR ENGINE”. <Ref. to 2-7 [T3C4].>
I OBD-II general scan tool
For detailed operation procedures, refer to the
OBD-II General Scan Tool Instruction Manual.
S2M0403A
: Is the value less than −40°C (−40°F)?
: Go to step 11W2.
: Is the voltage more than 10 V?
: Repair poor contact.
: Repair battery short circuit in harness
NOTE: between ECM and fuel pump connector.
In this case, repair the following: : Go to step 11W3.
I Poor contact in fuel pump connector
I Poor contact in ECM connector
I Poor contact in coupling connectors (B22),
(B98), (B97) and (R57)
464
ON-BOARD DIAGNOSTICS II SYSTEM [T11W4] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11W3 : CHECK HARNESS BETWEEN FUEL 11W4 : CHECK HARNESS BETWEEN FUEL
TEMPERATURE SENSOR AND ECM TEMPERATURE SENSOR AND ECM
CONNECTOR. CONNECTOR.
1) Turn ignition switch to ON. Measure voltage between fuel pump connector
2) Measure voltage between fuel pump connector and chassis ground.
and chassis ground. Connector & terminal
Connector & terminal (R58) No. 6 (+) — Chassis ground (−):
(R58) No. 6 (+) — Chassis ground (−):
S2M0403A
S2M0403A
: Is the voltage more than 4 V?
: Is the voltage more than 10 V? : Go to step 11W5.
: Repair battery short circuit in harness : Repair harness and connector.
between ECM and fuel pump connector.
NOTE:
: Go to step 11W4. In this case, repair the following:
I Open circuit in harness between ECM and fuel
pump connector
I Poor contact in fuel pump connector
I Poor contact in ECM connector
I Poor contact in coupling connectors (B98) and
(R57)
465
2-7 [T11W5] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
S2M0404A
466
ON-BOARD DIAGNOSTICS II SYSTEM [T11AA0] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
H2M3033
467
2-7 [T11AA1] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11AA1 : CHECK ANY OTHER DTC ON DIS- 11AA3 : CHECK HARNESS BETWEEN
PLAY. FUEL INJECTOR AND ECM CON-
NECTOR.
: Does the Subaru Select Monitor or
OBD-II general scan tool indicate 1) Turn ignition switch to OFF.
DTC P0101, P0102, P0103, P0116, 2) Disconnect connector from fuel injector on
P0117 or P0125? faulty cylinders.
: Inspect DTC P0101, P0102, P0103, 3) Measure voltage between ECM connector and
P0116, P0117 or P0125 using “11. Diag- engine ground on faulty cylinders.
nostics Chart with Trouble Code for Connector & terminal
Except 2200 cc California Spec. #1; (E5) No. 1 — Engine ground:
Vehicles”. <Ref. to 2-7 [T11A0].> #2; (E16) No. 1 — Engine ground:
NOTE: #3; (E6) No. 1 — Engine ground:
In this case, it is not necessary to inspect DTC #4; (E17) No. 1 — Engine ground:
P0301, P0302, P0303 and P0304.
: Go to step 11AA2.
B2M2068A
468
ON-BOARD DIAGNOSTICS II SYSTEM [T11AA5] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
S2M0405
469
2-7 [T11AA6] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
OBD0715A
470
ON-BOARD DIAGNOSTICS II SYSTEM [T11AA10] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
S2M0405 S2M0258B
H2M2446C
471
2-7 [T11AA11] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
cylinders
3) Turn ignition switch to ON, and turn Subaru
I Poor contact in ECM connector
Select Monitor or OBD-II general scan tool switch
I Poor contact in coupling connector (B22)
to ON.
4) Read diagnostic trouble code (DTC).
11AA12 : CHECK AIR INTAKE SYSTEM.
I Subaru Select Monitor
<Ref. to 2-7 [T3C2].>
: Is there a fault in air intake system? I OBD-II general scan tool
: Repair air intake system. For detailed operation procedures, refer to the
OBD-II General Scan Tool Operation Manual.
NOTE:
Check the following items: NOTE:
I Are there air leaks or air suction caused by loose Perform diagnosis according to the items listed
or dislocated nuts and bolts? below.
I Are there cracks or any disconnection of hoses? : Does the Subaru Select Monitor or
: Go to step 11AA13. OBD-II general scan tool indicate
only one DTC?
: Go to step 11AA18.
: Go to step 11AA14.
472
ON-BOARD DIAGNOSTICS II SYSTEM [T11AA22] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
: Does the Subaru Select Monitor or : Are there faults in #3 and #4 cylin-
OBD-II general scan tool indicate ders?
DTC P0301 and P0303? : Repair or replace faulty parts.
: Go to step 11AA21. NOTE:
: Go to step 11AA17. I Check the following items.
I Spark plugs
11AA17 : CHECK DIAGNOSTIC TROUBLE I Fuel injectors
CODE (DTC) ON DISPLAY. I Ignition coil
I If no abnormal is discovered, check for “8. D:
IGNITION CONTROL SYSTEM” of #3 and #4 cyl-
: Does the Subaru Select Monitor or
inders side. <Ref. to 2-7 [T8D0].>
OBD-II general scan tool indicate
DTC P0302 and P0304? : Go to DTC P0170. <Ref. to 2-7
[T11T0].>
: Go to step 11AA22.
: Go to step 11AA18. 11AA21 : GROUP OF #1 AND #3 CYLIN-
DERS
11AA18 : ONLY ONE CYLINDER
: Are there faults in #1 and #3 cylin-
: Is there a fault in that cylinder? ders?
: Repair or replace faulty parts. : Repair or replace faulty parts.
NOTE: NOTE:
Check the following items. Check the following items.
I Spark plug I Spark plugs
I Spark plug cord I Fuel injectors
I Fuel injector I Skipping timing belt teeth
I Compression ratio : Go to DTC P0170. <Ref. to 2-7
: Go to DTC P0170. <Ref. to 2-7 [T11T0].>
[T11T0].>
11AA22 : GROUP OF #2 AND #4 CYLIN-
11AA19 : GROUP OF #1 AND #2 CYLIN- DERS
DERS
: Are there faults in #2 and #4 cylin-
: Are there faults in #1 and #2 cylin- ders?
ders? : Repair or replace faulty parts.
: Repair or replace faulty parts. NOTE:
NOTE: Check the following items.
I Check the following items. I Spark plugs
I Spark plugs I Fuel injectors
I Fuel injectors I Compression ratio
I Ignition coil I Skipping timing belt teeth
I Compression ratio : Go to DTC P0170. <Ref. to 2-7
I If no abnormal is discovered, check for “8. D: [T11T0].>
IGNITION CONTROL SYSTEM” of #1 and #2 cyl-
inders side. <Ref. to 2-7 [T8D0].>
: Go to DTC P0170. <Ref. to 2-7
[T11T0].>
473
2-7 [T11AA23] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
474
ON-BOARD DIAGNOSTICS II SYSTEM [T11AB0] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
H2M3034
475
2-7 [T11AB1] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
B2M1090
B2M2487A
476
ON-BOARD DIAGNOSTICS II SYSTEM [T11AB6] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11AB5 : CHECK KNOCK SENSOR. 11AB6 : CHECK INPUT SIGNAL FOR ECM.
1) Disconnect connector from knock sensor. 1) Connect connectors to ECM and knock sensor.
2) Measure resistance between knock sensor 2) Turn ignition switch to ON.
connector terminal and engine ground. 3) Measure voltage between ECM and chassis
ground.
Terminal
No. 2 — Engine ground: Connector & terminal
(B136) No. 4 (+) — Chassis ground (−):
B2M1090
B2M2488A
477
2-7 [T11AB6] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
MEMO:
478
ON-BOARD DIAGNOSTICS II SYSTEM [T11AC0] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
B2M2069
479
2-7 [T11AC1] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
OBD0718A
480
ON-BOARD DIAGNOSTICS II SYSTEM [T11AC5] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
H2M1632A
OBD0719A
: Is the resistance between 1 and 4
: Is the resistance less than 5 Ω? kΩ?
: Go to step 11AC4. : Repair poor contact in crankshaft posi-
tion sensor connector.
: Repair harness and connector.
: Replace crankshaft position sensor.
NOTE: <Ref. to 2-7 [W6A0].>
In this case, repair the following:
I Open circuit in harness between crankshaft
position sensor and ECM connector
I Poor contact in ECM connector
I Poor contact in coupling connector (B21)
481
2-7 [T11AC5] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
MEMO:
482
ON-BOARD DIAGNOSTICS II SYSTEM [T11AD2] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
B2M2069
11AD1 : CHECK ANY OTHER DTC ON DIS- 11AD2 : CHECK CONDITION OF CRANK-
PLAY. SHAFT POSITION SENSOR.
483
2-7 [T11AD3] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
Remove front belt cover. <Ref. to 2-3 [W2A1].> Turn crankshaft using ST, and align alignment
mark on crankshaft sprocket. Then, make sure left
: Are there any cracks or damages in
and right camshaft sprockets are matched with
the crankshaft sprocket teeth? notches (alignment marks of belt cover and cylin-
: Replace crankshaft sprocket. <Ref. to der head).
2-3 [W2A4].> ST 499987500 CRANKSHAFT SOCKET
: Go to step 11AD4.
B2M2489A
B2M2589B
484
ON-BOARD DIAGNOSTICS II SYSTEM [T11AE0] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
B2M2070
485
2-7 [T11AE1] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
OBD0720A
486
ON-BOARD DIAGNOSTICS II SYSTEM [T11AE5] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
OBD0721A H2M1632A
487
2-7 [T11AE5] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
MEMO:
488
ON-BOARD DIAGNOSTICS II SYSTEM [T11AF1] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
B2M2070
489
2-7 [T11AF2] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
H2M3152A
490
ON-BOARD DIAGNOSTICS II SYSTEM [T11AF7] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
H2M3153A H2M1632A
491
2-7 [T11AF8] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
B2M2489A
B2M2589B
492
ON-BOARD DIAGNOSTICS II SYSTEM [T11AG0] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
H2M3037
493
2-7 [T11AG1] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11AG1 : CHECK ANY OTHER DTC ON DIS- 11AG3 : CHECK REAR CATALYTIC CON-
PLAY. VERTER.
: Does the Subaru Select Monitor or Separate rear catalytic converter from rear exhaust
OBD-II general scan tool indicate pipe.
DTC P0130, P0133, P0135, P0136,
P0139, P0141, P0301, P0302, P0303,
P0304, P1150 and P1151?
: Inspect the relevant DTC using “11.
Diagnostics Chart with Trouble Code for
Except 2200 cc California Spec.
Vehicles”. <Ref. to 2-7 [T11A0].>
NOTE:
In this case, it is not necessary to inspect DTC
P0420. OBD0525B
: Go to step 11AG2.
: Is there damage at rear face of rear
11AG2 : CHECK EXHAUST SYSTEM. catalyst?
: Replace front catalytic converter <Ref.
Check for gas leaks or air suction caused by loose to 2-1 [W1A0].> and rear catalytic con-
or dislocated nuts and bolts, and open hole at verter <Ref. to 2-1 [W2A0].>.
exhaust pipes. : Go to step 11AG4.
NOTE:
Check the following positions. 11AG4 : CHECK FRONT CATALYTIC CON-
I Between cylinder head and front exhaust pipe VERTER.
I Between front exhaust pipe and front catalytic
converter Remove front catalytic converter.
I Between front catalytic converter and rear cata-
lytic converter
: Is there a fault in exhaust system?
: Repair or replace exhaust system. <Ref.
to 2-9 [W1A0].>
: Go to step 11AG3.
S2M1059A
494
ON-BOARD DIAGNOSTICS II SYSTEM [T11AH2] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
H2M3038
11AH1 : CHECK ANY OTHER DTC ON DIS- 11AH2 : CHECK FUEL FILLER CAP.
PLAY.
1) Turn ignition switch to OFF.
: Is there any other DTC on display? 2) Open the fuel flap.
: Inspect the relevant DTC using “11. : Is the fuel filler cap tightened
Diagnostics Chart with Trouble Code for securely?
Except 2200 cc California Spec.
: Go to step 11AH3.
Vehicles”. <Ref. to 2-7 [T11A0].>
: Tighten fuel filler cap securely.
: Go to step 11AH2.
495
2-7 [T11AH3] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11AH3 : CHECK FUEL FILLER PIPE PACK- 11AH5 : CHECK PURGE CONTROL SOLE-
ING. NOID VALVE.
B2M2254C
B2M1873E
: Go to step 11AH5.
: Does pressure control solenoid valve
: Replace drain valve. <Ref. to 2-1
produce operating sound?
[W13A0].>
: Go to step 11AH7.
: Replace pressure control solenoid
valve. <Ref. to 2-1 [W7A0].>
496
ON-BOARD DIAGNOSTICS II SYSTEM [T11AH10] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
497
2-7 [T11AH10] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
MEMO:
498
ON-BOARD DIAGNOSTICS II SYSTEM [T11AI0] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
H2M3039
499
2-7 [T11AI1] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
B2M2493A
500
ON-BOARD DIAGNOSTICS II SYSTEM [T11AI5] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
B2M2494A S2M0568
OBD0339A
501
2-7 [T11AI6] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
502
ON-BOARD DIAGNOSTICS II SYSTEM [T11AJ0] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
H2M3040
503
2-7 [T11AJ1] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
B2M2495A
504
ON-BOARD DIAGNOSTICS II SYSTEM [T11AJ7] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
B2M2496A S2M0466A
Measure resistance between drain valve terminals. Check poor contact in drain valve connector. <Ref.
Terminals to FOREWORD [T3C1].>
No. 1 — No. 2: : Is there poor contact in drain valve
connector?
: Repair poor contact in drain valve con-
nector.
: Contact with SOA service.
NOTE:
Inspection by DTM is required, because probable
cause is deterioration of multiple parts.
S2M0465
505
2-7 [T11AJ7] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
MEMO:
506
ON-BOARD DIAGNOSTICS II SYSTEM [T11AK2] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
H2M3041
11AK1 : CHECK ANY OTHER DTC ON DIS- 11AK2 : CHECK FUEL FILLER CAP.
PLAY.
1) Turn ignition switch to OFF.
: Is there any DTC on display? 2) Open the fuel flap.
: Inspect the relevant DTC using “11. : Is the fuel filler cap tightened
Diagnostics Chart with Trouble Code for securely?
Except 2200 cc California Spec.
: Go to step 11AK3.
Vehicles”. <Ref. to 2-7 [T11A0].>
: Tighten fuel filler cap securely.
: Go to step 11AK2.
507
2-7 [T11AK3] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
NOTE:
Check the following items.
I Disconnection, leakage and clogging of the
vacuum hoses and pipes between fuel tank pres-
sure sensor and fuel tank
I Disconnection, leakage and clogging of air ven-
tilation hoses and pipes between fuel filler pipe and
fuel tank
: Is there a fault in pressure/vacuum
line?
: Repair or replace hoses and pipes.
: Replace fuel tank pressure sensor.
<Ref. to 2-1 [W6A0].>
508
ON-BOARD DIAGNOSTICS II SYSTEM [T11AL0] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
H2M3041
509
2-7 [T11AL1] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
B2M2497A
510
ON-BOARD DIAGNOSTICS II SYSTEM [T11AL6] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11AL4 : CHECK INPUT SIGNAL FOR ECM. 11AL6 : CHECK HARNESS BETWEEN ECM
AND COUPLING CONNECTOR IN
REAR WIRING HARNESS.
Measure voltage between ECM and chassis
ground.
1) Turn ignition switch to OFF.
Connector & terminal
2) Remove rear seat cushion (Sedan) or move
(B136) No. 12 (+) — Chassis ground (−):
rear seat cushion (Wagon).
3) Separate rear wiring harness and fuel tank
cord.
4) Turn ignition switch to ON.
5) Measure voltage between rear wiring harness
connector and chassis ground.
Connector & terminal
(R83) No. 1 (+) — Chassis ground (−):
B2M2498A
511
2-7 [T11AL7] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11AL7 : CHECK HARNESS BETWEEN ECM 11AL8 : CHECK HARNESS BETWEEN ECM
AND COUPLING CONNECTOR IN AND COUPLING CONNECTOR IN
REAR WIRING HARNESS. REAR WIRING HARNESS.
1) Turn ignition switch to OFF. Measure resistance of harness between rear wir-
2) Disconnect connector from ECM. ing harness connector and chassis ground.
3) Measure resistance of harness between ECM Connector & terminal
and rear wiring harness connector. (R15) No. 11 — Chassis ground:
Connector & terminal
(B136) No. 16 — (R15) No. 11:
H2M3156A
H2M3157A
512
ON-BOARD DIAGNOSTICS II SYSTEM [T11AL12] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
Measure resistance of fuel tank cord. Check poor contact in fuel tank pressure sensor
connector. <Ref. to FOREWORD [T3C1].>
Connector & terminal
(R57) No. 10 — (R47) No. 1: : Is there poor contact in fuel tank
pressure sensor connector?
: Repair poor contact in fuel tank pres-
sure sensor connector.
: Replace fuel tank pressure sensor.
<Ref. to 2-1 [W6A0].>
H2M3158A
B2M1882A
513
2-7 [T11AL12] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
MEMO:
514
ON-BOARD DIAGNOSTICS II SYSTEM [T11AM0] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
H2M3041
515
2-7 [T11AM1] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
B2M2497A
B2M2497A
516
ON-BOARD DIAGNOSTICS II SYSTEM [T11AM6] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11AM4 : CHECK INPUT SIGNAL FOR ECM. 11AM6 : CHECK HARNESS BETWEEN ECM
AND COUPLING CONNECTOR IN
REAR WIRING HARNESS.
Measure voltage between ECM and chassis
ground.
1) Turn ignition switch to OFF.
Connector & terminal
2) Remove rear seat cushion (Sedan) or move
(B136) No. 12 (+) — Chassis ground (−):
rear seat cushion (Wagon).
3) Separate rear wiring harness and fuel tank
cord.
4) Turn ignition switch to ON.
5) Measure voltage between rear wiring harness
connector and chassis ground.
Connector & terminal
(R15) No. 9 (+) — Chassis ground (−):
B2M2498A
517
2-7 [T11AM7] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11AM7 : CHECK HARNESS BETWEEN ECM 11AM8 : CHECK HARNESS BETWEEN ECM
AND COUPLING CONNECTOR IN AND COUPLING CONNECTOR IN
REAR WIRING HARNESS. REAR WIRING HARNESS.
1) Turn ignition switch to OFF. Measure resistance of harness between rear wir-
2) Disconnect connector from ECM. ing harness connector and chassis ground.
3) Measure resistance of harness between ECM Connector & terminal
and rear wiring harness connector. (B136) No. 16 — (R15) No. 11:
Connector & terminal
(B136) No. 12 — (R15) No. 10:
H2M3161A
H2M3162A
518
ON-BOARD DIAGNOSTICS II SYSTEM [T11AM12] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
519
2-7 [T11AN0] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
H2M3042
520
ON-BOARD DIAGNOSTICS II SYSTEM [T11AO1] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
H2M3042
521
2-7 [T11AO2] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11AO2 : CHECK GROUND CIRCUIT OF 11AO3 : CHECK INPUT SIGNAL FOR ECM.
COMBINATION METER.
1) Turn ignition switch to ON. (Engine OFF)
1) Turn ignition switch to OFF. 2) Measure voltage between ECM connector and
2) Pull out combination meter from instrument chassis ground.
panel. <Ref. to 6-2 [W8A0].>
Connector & terminal
(B136) No. 27 (+) — Chassis ground (−):
H6M0522A
522
ON-BOARD DIAGNOSTICS II SYSTEM [T11AO6] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
G2M0863
B2M0940A
523
2-7 [T11AO7] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11AO7 : CHECK REAR WIRING HARNESS. 11AO9 : CHECK REAR WIRING HARNESS.
1) Separate fuel tank cord connector (R57) and 1) Separate rear wiring harness connector (R3)
rear wiring harness connector (R15). and bulkhead wiring harness connector (B99).
2) Measure resistance of harness between fuel 2) Measure resistance of harness between rear
sub meter unit connector and chassis ground. wiring harness connector and chassis ground.
Connector & terminal Connector & terminal
(R59) No. 1 — Chassis ground: (R3) No. 5 — Chassis ground:
B2M0941A H2M3165A
H2M3164A
H2M3166A
524
ON-BOARD DIAGNOSTICS II SYSTEM [T11AO13] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
H6M0522A
: Is there flaw or burning on printed
circuit plate assembly?
3) Disconnect connector from combination meter. : Replace printed circuit plate assembly.
4) Measure resistance of harness between com- : Replace fuel meter assembly. <Ref. to
bination meter connector and chassis ground. 6-2 [W8A0].>
Connector & terminal
(i10) No. 8 — Chassis ground:
H2M3167A
525
2-7 [T11AO13] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
MEMO:
526
ON-BOARD DIAGNOSTICS II SYSTEM [T11AP1] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
H2M3042
527
2-7 [T11AP2] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11AP2 : CHECK GROUND CIRCUIT OF 11AP3 : CHECK INPUT SIGNAL FOR ECM.
COMBINATION METER.
1) Turn ignition switch to ON. (Engine OFF)
1) Turn ignition switch to OFF. 2) Measure voltage between ECM connector and
2) Pull out combination meter from instrument chassis ground.
panel. <Ref. to 6-2 [W8A0].>
Connector & terminal
(B136) No. 27 (+) — Chassis ground (−):
H6M0522A
528
ON-BOARD DIAGNOSTICS II SYSTEM [T11AP5] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11AP4 : CHECK FUEL LEVEL SENSOR. 11AP5 : CHECK FUEL SUB LEVEL SEN-
SOR.
1) Turn ignition switch to OFF.
2) Remove fuel pump access hole lid located on 1) Remove service hole cover located on the left
the right rear of trunk compartment floor (Sedan) or rear of trunk compartment floor (Sedan) or luggage
luggage compartment floor (Wagon). compartment floor (Wagon).
S2M0392 G2M0863
3) Disconnect connector from fuel pump. 2) Disconnect connector from fuel sub meter unit.
4) Measure resistance between connector termi- 3) Measure resistance between connector termi-
nals of fuel pump. nals of fuel sub meter unit.
Terminals Terminals
No. 3 — No. 5: No. 1 — No. 2:
B2M0935 B2M0936
: Is the resistance less than 100 Ω? : Is the resistance less than 100 Ω?
: Go to step 11AP5. : Go to step 11AP6.
: Replace fuel sending unit. <Ref. to 2-1 : Replace fuel sub meter unit. <Ref. to 2-1
[W8A0].> [W10A0].>
529
2-7 [T11AP6] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
B2M0938A
B2M0937A
: Is the resistance less than 5 Ω?
: Is the resistance less than 1 Ω? : Go to step 11AP8.
: Go to step 11AP7. : Repair harness and connector.
: Repair open circuit in harness between
NOTE:
fuel pump and fuel sub meter unit con-
In this case, repair the following:
nector.
I Open circuit in harness between fuel pump con-
nector and chassis grounding terminal
I Poor contact in fuel pump connector
I Poor contact in coupling connectors (R57),
(B97) and (B22)
530
ON-BOARD DIAGNOSTICS II SYSTEM [T11AP9] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11AP8 : CHECK HARNESS BETWEEN ECM 11AP9 : CHECK HARNESS BETWEEN ECM
AND FUEL PUMP CONNECTOR. AND FUEL PUMP CONNECTOR.
1) Connect connector to fuel sub meter unit. 1) Turn ignition switch to OFF.
2) Turn ignition switch to ON. 2) Disconnect connector from ECM.
3) Measure voltage between fuel pump connector 3) Turn ignition switch to ON.
and chassis ground. 4) Measure voltage between ECM connector and
chassis ground.
Connector & terminal
(R58) No. 3 (+) — Chassis ground (−): Connector & terminal
(B136) No. 27 (+) — Chassis ground (−):
B2M0939A
B2M2653A
531
2-7 [T11AP9] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
MEMO:
532
ON-BOARD DIAGNOSTICS II SYSTEM [T11AQ0] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
H2M3043
533
2-7 [T11AQ1] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11AQ1 : CHECK OUTPUT SIGNAL FROM 11AQ2 : CHECK GROUND SHORT CIRCUIT
ECM. IN RADIATOR FAN RELAY 1 CON-
TROL CIRCUIT.
1) Turn ignition switch to OFF.
2) Connect test mode connector at the lower por- 1) Turn ignition switch to OFF.
tion of instrument panel (on the driver’s side), to 2) Disconnect connectors from ECM.
the side of the center console box. 3) Measure resistance of harness between ECM
connector and chassis ground.
Connector & terminal
(B134) No. 3 — Chassis ground:
S2M0259B
B2M2654A
H2M3234A
534
ON-BOARD DIAGNOSTICS II SYSTEM [T11AQ6] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
1) Turn ignition switch to OFF. Check poor contact in ECM or main fan relay 1
2) Measure resistance between main fan relay 1 connector. <Ref. to FOREWORD [T3C1].>
terminals. : Is there poor contact in ECM or main
Terminal fan relay 1 connector?
No. 27 — No. 28: : Repair poor contact in ECM or main fan
relay 1 connector.
: Contact with SOA service.
S2M0434
S2M1034A
535
2-7 [T11AQ6] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
MEMO:
536
ON-BOARD DIAGNOSTICS II SYSTEM [T11AR0] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
H2M3044
537
2-7 [T11AR1] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
538
ON-BOARD DIAGNOSTICS II SYSTEM [T11AS3] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
H2M3045
539
2-7 [T11AS4] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11AS4 : CHECK HARNESS BETWEEN ECM 11AS5 : CHECK HARNESS BETWEEN ECM
AND COMBINATION METER CON- AND COMBINATION METER CON-
NECTOR. NECTOR.
B2M2659A
B2M2658A
: Is the resistance less than 10 Ω?
: Is the voltage more than 2 V? : Repair ground short circuit in harness
between ECM and combination meter
: Repair harness and connector.
connector.
NOTE: : Repair poor contact in ECM connector.
In this case, repair the following:
I Open circuit in harness between ECM and com-
bination meter connector
I Poor contact in ECM connector
I Poor contact in combination meter connector
I Poor contact in coupling connector (B36)
: Go to step 11AS5.
540
ON-BOARD DIAGNOSTICS II SYSTEM [T11AT0] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
AT: DTC P0506 — IDLE CONTROL SYSTEM RPM LOWER THAN EXPECTED
—
I DTC DETECTING CONDITION:
I Two consecutive driving cycles with fault
I TROUBLE SYMPTOM:
I Engine is difficult to start.
I Engine does not start.
I Erroneous idling
I Engine stalls.
CAUTION:
After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].>
and INSPECTION MODE <Ref. to 2-7 [T3E0].>.
I WIRING DIAGRAM:
H2M3046
541
2-7 [T11AT1] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
542
ON-BOARD DIAGNOSTICS II SYSTEM [T11AU0] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
AU: DTC P0507 — IDLE CONTROL SYSTEM RPM HIGHER THAN EXPECTED
—
I DTC DETECTING CONDITION:
I Two consecutive driving cycles with fault
I TROUBLE SYMPTOM:
I Engine keeps running at higher revolution than specified idling revolution.
CAUTION:
After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].>
and INSPECTION MODE <Ref. to 2-7 [T3E0].>.
I WIRING DIAGRAM:
H2M3046
543
2-7 [T11AU1] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11AU1 : CHECK ANY OTHER DTC ON DIS- 11AU3 : CHECK AIR BY-PASS LINE.
PLAY.
1) Turn ignition switch to OFF.
: Does the Subaru Select Monitor or 2) Remove idle air control solenoid valve from
OBD-II general scan tool indicate throttle body. <Ref. to 2-7 [W12A2].>
DTC P1510, P1511, P1512, P1513, 3) Confirm that there are no foreign particles in
P1514, P1515, P1516 or P1517? by-pass air line.
: Inspect DTC P1510, P1511, P1512, : Are foreign particles in by-pass air
P1513, P1514, P1515, P1516 or P1517 line?
using “11. Diagnostics Chart with : Remove foreign particles from by-pass
Trouble Code for Except 2200 cc Cali- air line.
fornia Spec. Vehicles”. <Ref. to 2-7
[T11A0].> : Replace idle air control solenoid valve.
<Ref. to 2-7 [W12A2].>
NOTE:
In this case, it is not necessary to inspect DTC
P0507.
: Go to step 11AU2.
544
ON-BOARD DIAGNOSTICS II SYSTEM [T11AV1] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
H2M3047
545
2-7 [T11AV1] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
MEMO:
546
ON-BOARD DIAGNOSTICS II SYSTEM [T11AW1] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
H2M3048
547
2-7 [T11AW2] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11AW2 : CHECK HARNESS BETWEEN TCM 11AW3 : CHECK HARNESS BETWEEN TCM
AND BRAKE LIGHT SWITCH CON- AND BRAKE LIGHT SWITCH CON-
NECTOR. NECTOR.
1) Disconnect connectors from TCM and brake Measure resistance of harness between TCM and
light switch. chassis ground.
2) Measure resistance of harness between TCM Connector & terminal
and brake light switch connector. (B55) No. 24 — Chassis ground:
Connector & terminal
(B55) No. 24 — (B64) No. 2:
(B55) No. 24 — (B65) No. 3 (With cruise
control):
B2M2548A
B2M2549A
548
ON-BOARD DIAGNOSTICS II SYSTEM [T11AW6] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
B2M2549A
549
2-7 [T11AW6] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
MEMO:
550
ON-BOARD DIAGNOSTICS II SYSTEM [T11AX0] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
B2M2218
551
2-7 [T11AX1] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11AX1 : CHECK HARNESS BETWEEN TCM 11AX2 : CHECK HARNESS BETWEEN TCM
AND INHIBITOR SWITCH CON- AND INHIBITOR SWITCH CON-
NECTOR. NECTOR.
1) Turn ignition switch to OFF. Measure resistance of harness between TCM and
2) Disconnect connectors from TCM and trans- transmission harness connector.
mission. Connector & terminal
3) Measure resistance of harness between TCM (B55) No. 17 — (T7) No. 9:
and transmission harness connector.
Connector & terminal
(B55) No. 23 — (T7) No. 8:
B2M2552A
552
ON-BOARD DIAGNOSTICS II SYSTEM [T11AX4] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11AX3 : CHECK HARNESS BETWEEN TCM 11AX4 : CHECK HARNESS BETWEEN TCM
AND INHIBITOR SWITCH CON- AND INHIBITOR SWITCH CON-
NECTOR. NECTOR.
Measure resistance of harness between TCM and Measure resistance of harness between TCM and
transmission harness connector. transmission harness connector.
Connector & terminal Connector & terminal
(B55) No. 22 — (T7) No. 5: (B55) No. 8 — (T7) No. 6:
B2M2553A B2M2554A
553
2-7 [T11AX5] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11AX5 : CHECK HARNESS BETWEEN TCM 11AX6 : CHECK HARNESS BETWEEN TCM
AND INHIBITOR SWITCH CON- AND INHIBITOR SWITCH CON-
NECTOR. NECTOR.
Measure resistance of harness between TCM and Measure resistance of harness between TCM and
transmission harness connector. transmission harness connector.
Connector & terminal Connector & terminal
(B55) No. 18 — (T7) No. 4: (B54) No. 10 — (T7) No. 11:
B2M2555A B2M2556A
554
ON-BOARD DIAGNOSTICS II SYSTEM [T11AX9] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11AX7 : CHECK HARNESS BETWEEN TCM 11AX8 : CHECK HARNESS BETWEEN TCM
AND INHIBITOR SWITCH CON- AND INHIBITOR SWITCH CON-
NECTOR. NECTOR.
Measure resistance of harness between TCM and Measure resistance of harness between TCM and
transmission harness connector. chassis ground.
Connector & terminal Connector & terminal
(B54) No. 1 — (T7) No. 3: (B55) No. 23 — Chassis ground:
B2M2063A B2M2558A
B2M2559A
555
2-7 [T11AX10] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
Measure resistance of harness between TCM and Measure resistance of harness between TCM and
chassis ground. chassis ground.
Connector & terminal Connector & terminal
(B55) No. 22 — Chassis ground: (B55) No. 18 — Chassis ground:
B2M2560A B2M2562A
: Is the resistance more than 1 MΩ? : Is the resistance more than 1 MΩ?
: Go to step 11AX11. : Go to step 11AX13.
: Repair ground short circuit in harness : Repair ground short circuit in harness
between TCM and transmission harness between TCM and transmission harness
connector. connector.
Measure resistance of harness between TCM and Measure resistance of harness between TCM and
chassis ground. chassis ground.
Connector & terminal Connector & terminal
(B55) No. 8 — Chassis ground: (B54) No. 10 — Chassis ground:
B2M2561A B2M2563A
: Is the resistance more than 1 MΩ? : Is the resistance more than 1 MΩ?
: Go to step 11AX12. : Go to step 11AX14.
: Repair ground short circuit in harness : Repair ground short circuit in harness
between TCM and transmission harness between TCM and transmission harness
connector. connector.
556
ON-BOARD DIAGNOSTICS II SYSTEM [T11AX17] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
H2M1673
B2M2090A
H2M1674
557
2-7 [T11AX18] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
Measure resistance between inhibitor switch con- Measure resistance between inhibitor switch con-
nector receptacle’s terminals in selector lever nector receptacle’s terminals in selector lever
except for “R” position. except for “N” position.
Terminals Terminals
No. 9 — No. 10: No. 5 — No. 10:
H2M1674 B2M2798
: Is the resistance more than 1 MΩ? : Is the resistance more than 1 MΩ?
: Go to step 11AX19. : Go to step 11AX21.
: Go to step 11AX29. : Go to step 11AX29.
Measure resistance between inhibitor switch con- Measure resistance between inhibitor switch con-
nector receptacle’s terminals in selector lever for nector receptacle’s terminals in selector lever
“N” position. except for “D” position.
Terminals Terminals
No. 5 — No. 10: No. 6 — No. 10:
B2M2798 H2M1676
558
ON-BOARD DIAGNOSTICS II SYSTEM [T11AX25] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
Measure resistance between inhibitor switch con- Measure resistance between inhibitor switch con-
nector receptacle’s terminals in selector lever nector receptacle’s terminals in selector lever
except for “D” position. except for “3” position.
Terminals Terminals
No. 6 — No. 10: No. 4 — No. 10:
H2M1676 H2M1677
: Is the resistance more than 1 MΩ? : Is the resistance more than 1 MΩ?
: Go to step 11AX23. : Go to step 11AX25.
: Go to step 11AX29. : Go to step 11AX29.
Measure resistance between inhibitor switch con- Measure resistance between inhibitor switch con-
nector receptacle’s terminals in selector lever for nector receptacle’s terminals in selector lever
“3” position. except for “2” position.
Terminals Terminals
No. 4 — No. 10: No. 11 — No. 10:
H2M1677 H2M1678
559
2-7 [T11AX26] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
Measure resistance between inhibitor switch con- Measure resistance between inhibitor switch con-
nector receptacle’s terminals in selector lever nector receptacle’s terminals in selector lever
except for “R” position. except for “1” position.
Terminals Terminals
No. 11 — No. 10: No. 3 — No. 10:
H2M1678 H2M1679
: Is the resistance more than 1 MΩ? : Is the resistance more than 1 MΩ?
: Go to step 11AX27. : Go to step 11AX30.
: Go to step 11AX29. : Go to step 11AX29.
Measure resistance between inhibitor switch con- : Is there faulty connection in the
nector receptacle’s terminals in selector lever selector cable?
except for “1” position. : Repair connection of selector cable.
Terminals : Replace inhibitor switch. <Ref. to 3-2
No. 3 — No. 10: [W2C0].>
H2M1679
560
ON-BOARD DIAGNOSTICS II SYSTEM [T11AX33] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11AX30 : CHECK INPUT SIGNAL FOR TCM. 11AX32 : CHECK INPUT SIGNAL FOR TCM.
1) Turn ignition switch to OFF. Measure voltage between TCM chassis ground in
2) Connect connector to TCM and transmission. selector lever “R” position.
3) Turn ignition switch to ON. Connector & terminal
4) Measure voltage between TCM and chassis (B55) No. 17 (+) — Chassis ground (−):
ground.
Connector & terminal
(B55) No. 23 (+) — Chassis ground (−):
B2M2566A
B2M2566A
561
2-7 [T11AX34] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11AX34 : CHECK INPUT SIGNAL FOR TCM. 11AX36 : CHECK INPUT SIGNAL FOR TCM.
Measure voltage between TCM chassis ground in Measure voltage between TCM and chassis
selector lever “P” and “N” positions. ground in selector lever “D” position.
Connector & terminal Connector & terminal
(B55) No. 22 (+) — Chassis ground (−): (B55) No. 8 (+) — Chassis ground (−):
B2M2567A B2M2568A
11AX35 : CHECK INPUT SIGNAL FOR TCM. 11AX37 : CHECK INPUT SIGNAL FOR TCM.
Measure voltage between TCM chassis ground in Measure voltage between TCM chassis ground in
selector lever except for “N” and “P” positions. selector lever except for “N” and “P” positions.
Connector & terminal Connector & terminal
(B55) No. 22 (+) — Chassis ground (−): (B55) No. 8 (+) — Chassis ground (−):
B2M2567A B2M2568A
562
ON-BOARD DIAGNOSTICS II SYSTEM [T11AX41] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11AX38 : CHECK INPUT SIGNAL FOR TCM. 11AX40 : CHECK INPUT SIGNAL FOR TCM.
Measure voltage between TCM chassis ground in Measure voltage between TCM chassis ground in
selector lever “3” position. selector lever “2” position.
Connector & terminal Connector & terminal
(B55) No. 18 (+) — Chassis ground (−): (B54) No. 10 (+) — Chassis ground (−):
B2M2569A B2M2570A
11AX39 : CHECK INPUT SIGNAL FOR TCM. 11AX41 : CHECK INPUT SIGNAL FOR TCM.
Measure voltage between TCM and chassis Measure voltage between TCM and chassis
ground in selector lever except for “3” position. ground in selector lever except for “2” position.
Connector & terminal Connector & terminal
(B55) No. 18 (+) — Chassis ground (−): (B54) No. 10 (+) — Chassis ground (−):
B2M2569A B2M2570A
563
2-7 [T11AX42] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11AX42 : CHECK INPUT SIGNAL FOR TCM. 11AX44 : CHECK POOR CONTACT.
Measure voltage between TCM chassis ground in Check poor contact in TCM connector. <Ref. to
selector lever “1” position. FOREWORD [T3C1].>
Connector & terminal : Is there poor contact in TCM connec-
(B54) No. 1 (+) — Chassis ground (−): tor?
: Repair poor contact in TCM connector.
: Replace TCM. <Ref. to 3-2 [W22A0].>
B2M2581A
B2M2581A
564
ON-BOARD DIAGNOSTICS II SYSTEM [T11AY1] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
B2M2219
565
2-7 [T11AZ0] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
H2M3049
566
ON-BOARD DIAGNOSTICS II SYSTEM [T11BA1] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
H2M3050
567
2-7 [T11BB0] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
B2M2095
568
ON-BOARD DIAGNOSTICS II SYSTEM [T11BF0] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
569
2-7 [T11BF1] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
I WIRING DIAGRAM:
H2M3051
11BF1 : CHECK ANY OTHER DTC ON DIS- 11BF2 : CHECK THROTTLE POSITION
PLAY. SENSOR CIRCUIT.
: Is there any other DTC on display? Check throttle position sensor circuit. <Ref. to 3-2
: Inspect relevant DTC using “11. Diag- [T8F0].>
nostics Chart with Trouble Code for : Is there any trouble in throttle posi-
Except 2200 cc California Spec. tion sensor circuit?
Vehicles”. <Ref. to 2-7 [T11A0].> : Repair or replace throttle position sen-
: Go to step 11BF2. sor circuit.
: Go to step 11BF3.
570
ON-BOARD DIAGNOSTICS II SYSTEM [T11BF6] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
571
2-7 [T11BF6] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
MEMO:
572
ON-BOARD DIAGNOSTICS II SYSTEM [T11BG0] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
H2M3052
573
2-7 [T11BG1] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11BG1 : CHECK ANY OTHER DTC ON DIS- 11BG5 : CHECK INHIBITOR SWITCH CIR-
PLAY. CUIT.
: Is there any other DTC on display? Check inhibitor switch circuit. <Ref. to 2-7
: Inspect the relevant DTC using “11. [T11AX0].>
Diagnostics Chart with Trouble Code for : Is there any trouble in inhibitor
Except 2200 cc California Spec. switch circuit?
Vehicles”. <Ref. to 2-7 [T11A0].> : Repair or replace inhibitor switch circuit.
: Go to step 11BG2. : Go to step 11BG6.
11BG2 : CHECK DUTY SOLENOID B CIR- 11BG6 : CHECK BRAKE LIGHT SWITCH
CUIT. CIRCUIT.
Check duty solenoid B circuit. <Ref. to 3-2 Check brake light switch circuit. <Ref. to 2-7
[T8Q0].> [T11AW0].>
: Is there any trouble in duty solenoid : Is there any trouble in brake light
B circuit? switch circuit?
: Repair or replace duty solenoid B circuit. : Repair or replace brake light switch cir-
: Go to step 11BG3. cuit.
: Go to step 11BG7.
11BG3 : CHECK THROTTLE POSITION
SENSOR CIRCUIT. 11BG7 : CHECK ATF TEMPERATURE SEN-
SOR CIRCUIT.
Check throttle position sensor circuit. <Ref. to 3-2
[T8F0].> Check ATF temperature sensor circuit. <Ref. to 3-2
: Is there any trouble in throttle posi- [T8E0].>
tion sensor circuit? : Is there any trouble in ATF tempera-
: Repair or replace throttle position sen- ture sensor circuit?
sor circuit. : Repair or replace ATF temperature sen-
: Go to step 11BG4. sor circuit.
: Go to step 11BG8.
11BG4 : CHECK TORQUE CONVERTER
TURBINE SPEED SENSOR CIR- 11BG8 : CHECK POOR CONTACT.
CUIT.
574
ON-BOARD DIAGNOSTICS II SYSTEM [T11BG9] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
575
2-7 [T11BH0] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
H2M3053
576
ON-BOARD DIAGNOSTICS II SYSTEM [T11BI1] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
H2M3054
577
2-7 [T11BJ0] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
H2M3055
578
ON-BOARD DIAGNOSTICS II SYSTEM [T11BK1] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
B2M2098
579
2-7 [T11BL0] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
H2M3056
NOTE:
I On AT vehicles, place the inhibitor switch in the
“P” or “N” position.
I On MT vehicles, depress the clutch pedal.
: Does starter motor operate when
ignition switch to “ST”?
: Repair harness and connector.
NOTE:
In this case, repair the following:
I Open or ground short circuit in harness between
ECM and starter motor connector.
I Poor contact in ECM connector.
: Check starter motor circuit. <Ref. to 2-7
[T8B0].>
580
ON-BOARD DIAGNOSTICS II SYSTEM [T11BM0] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
BM: DTC P1101 — NEUTRAL POSITION SWITCH CIRCUIT LOW INPUT [MT
VEHICLES] —
I DTC DETECTING CONDITION:
I Two consecutive driving cycles with fault
I TROUBLE SYMPTOM:
I Erroneous idling
CAUTION:
After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].>
and INSPECTION MODE <Ref. to 2-7 [T3E0].>.
I WIRING DIAGRAM:
B2M2105
581
2-7 [T11BM1] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11BM1 : CHECK INPUT SIGNAL FOR ECM. 11BM3 : CHECK POOR CONTACT.
1) Turn ignition switch to ON. Check poor contact in ECM connector. <Ref. to
2) Measure voltage between ECM and chassis FOREWORD [T3C1].>
ground. : Is there poor contact in ECM connec-
Connector & terminal tor?
(B135) No. 26 (+) — Chassis ground (−): : Repair poor contact in ECM connector.
: Contact with SOA service.
NOTE:
Inspection by DTM is required, because probable
cause is deterioration of multiple parts.
OBD0469A
582
ON-BOARD DIAGNOSTICS II SYSTEM [T11BM6] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
B2M2092A
583
2-7 [T11BM6] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
MEMO:
584
ON-BOARD DIAGNOSTICS II SYSTEM [T11BN1] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
BN: DTC P1101 — NEUTRAL POSITION SWITCH CIRCUIT HIGH INPUT [AT
VEHICLES] —
I DTC DETECTING CONDITION:
I Two consecutive driving cycles with fault
I TROUBLE SYMPTOM:
I Erroneous idling
CAUTION:
After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].>
and INSPECTION MODE <Ref. to 2-7 [T3E0].>.
I WIRING DIAGRAM:
H2M3057
585
2-7 [T11BN2] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11BN2 : CHECK INPUT SIGNAL FOR ECM. 11BN4 : CHECK POOR CONTACT.
1) Turn ignition switch to ON. Check poor contact in ECM connector. <Ref. to
2) Measure voltage between ECM and chassis FOREWORD [T3C1].>
ground in selector lever “N” and “P” positions. : Is there poor contact in ECM connec-
Connector & terminal tor?
(B135) No. 26 (+) — Chassis ground (−): : Repair poor contact in ECM connector.
: Contact with SOA service.
NOTE:
Inspection by DTM is required, because probable
cause is deterioration of multiple parts.
B2M2091A
586
ON-BOARD DIAGNOSTICS II SYSTEM [T11BN8] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
H2M3169A
B2M1119
587
2-7 [T11BN9] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
588
ON-BOARD DIAGNOSTICS II SYSTEM [T11BO0] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
H2M3025
589
2-7 [T11BO1] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11BO1 : CHECK OUTPUT SIGNAL FROM 11BO3 : CHECK HARNESS BETWEEN ECM
ECM. AND PRESSURE SOURCES
SWITCHING SOLENOID VALVE
CONNECTOR.
1) Turn ignition switch to ON.
2) Measure voltage between ECM and chassis
ground. 1) Turn ignition switch to OFF.
2) Disconnect connector from pressure sources
Connector & terminal
switching solenoid valve and ECM.
(B134) No. 9 (+) — Chassis ground (−):
3) Measure resistance of harness between pres-
sure sources switching solenoid valve connector
and engine ground.
Connector & terminal
(E27) No. 1 — Engine ground:
B2M2712A
590
ON-BOARD DIAGNOSTICS II SYSTEM [T11BO7] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
B2M2713A OBD0676C
B2M1120
591
2-7 [T11BO7] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
MEMO:
592
ON-BOARD DIAGNOSTICS II SYSTEM [T11BP2] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
B2M2107
11BP1 : CHECK INPUT SIGNAL FOR ECM. 11BP2 : CHECK INPUT SIGNAL FOR ECM.
1) Turn ignition switch to ON. Measure voltage between ECM and chassis
2) Measure voltage between ECM and chassis ground.
ground. Connector & terminal
Connector & terminal (B135) No. 16 (+) — Chassis ground (−):
(B135) No. 16 (+) — Chassis ground (−):
B2M2094A
B2M2094A
: Is the voltage more than 10 V?
: Is the voltage more than 4.5 V? : Repair battery short circuit in harness
: Go to step 11BP2. between ECM and TCM connector.
: Go to step 11BP4. : Go to step 11BP3.
593
2-7 [T11BP3] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
594
ON-BOARD DIAGNOSTICS II SYSTEM [T11BQ2] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
B2M2404
11BQ1 : CHECK INPUT SIGNAL FOR ECM. 11BQ2 : CHECK INPUT SIGNAL FOR ECM.
1) Turn ignition switch to ON. Measure voltage between ECM and chassis
2) Measure voltage between ECM and chassis ground.
ground. Connector & terminal
Connector & terminal (B135) No. 17 (+) — Chassis ground (−):
(B135) No. 17 (+) — Chassis ground (−):
B2M2501A
B2M2501A
: Is the voltage more than 10 V?
: Is the voltage more than 4.5 V? : Repair battery short circuit in harness
: Go to step 11BQ2. between ECM and TCM connector.
: Go to step 11BQ4. : Go to step 11BQ3.
595
2-7 [T11BQ3] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
596
ON-BOARD DIAGNOSTICS II SYSTEM [T11BR0] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
BR: DTC P1115 — ENGINE TORQUE CONTROL CUT SIGNAL CIRCUIT HIGH
INPUT —
I DTC DETECTING CONDITION:
I Two consecutive driving cycles with fault
CAUTION:
After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].>
and INSPECTION MODE <Ref. to 2-7 [T3E0].>.
I WIRING DIAGRAM:
B2M2667
597
2-7 [T11BR1] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11BR1 : CHECK OUTPUT SIGNAL FROM 11BR2 : CHECK HARNESS BETWEEN ECM
ECM. AND TCM CONNECTOR.
1) Start engine, and warm-up the engine. 1) Turn ignition switch to OFF.
2) Turn ignition swtich to OFF. 2) Measure voltage between ECM and chassis
3) Disconnect connector from TCM. ground.
4) Turn ignition switch to ON. Connector & terminal
5) Measure voltage between ECM and chassis (B134) No. 31 (+) — Chassis ground (−):
ground.
Connector & terminal
(B134) No. 31 (+) — Chassis ground (−):
B2M2668A
598
ON-BOARD DIAGNOSTICS II SYSTEM [T11BS2] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
BS: DTC P1116 — ENGINE TORQUE CONTROL CUT SIGNAL CIRCUIT LOW
INPUT —
I DTC DETECTING CONDITION:
I Two consecutive driving cycles with fault
CAUTION:
After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].>
and INSPECTION MODE <Ref. to 2-7 [T3E0].>.
I WIRING DIAGRAM:
B2M2667
11BS1 : CHECK OUTPUT SIGNAL FROM 11BS2 : CHECK HARNESS BETWEEN ECM
ECM. AND TCM CONNECTOR.
1) Start engine, and warm-up the engine. 1) Turn ignition switch to OFF.
2) Turn ignition switch to OFF. 2) Disconnect connectors from ECM and TCM.
3) Turn ignition switch to ON. 3) Measure resistance of harness between ECM
4) Measure voltage between ECM and chassis and chassis ground.
ground. Connector & terminal
Connector & terminal (B134) No. 31 — Chassis ground:
(B134) No. 31 (+) — Chassis ground (−):
B2M2670A
B2M2668A
: Is the resistance less than 10 Ω?
: Is the voltage more than 3 V? : Repair ground short circuit in harness
: Repair poor contact in ECM connector. between ECM and TCM connector.
: Go to step 11BS2. : Go to step 11BS3.
599
2-7 [T11BS3] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
B2M2714A
600
ON-BOARD DIAGNOSTICS II SYSTEM [T11BT1] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
H2M3056
NOTE:
I On AT vehicles, place the inhibitor switch in each
position.
I On MT vehicles, depress or release the clutch
pedal.
: Does starter motor operate when
ignition switch to “ON”?
: Repair battery short circuit in starter
motor circuit. After repair, replace ECM.
<Ref. to 2-7 [W15A0].>
: Check starter motor circuit. <Ref. to 2-7
[T8B0].>
601
2-7 [T11BT1] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
MEMO:
602
ON-BOARD DIAGNOSTICS II SYSTEM [T11BU0] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
BU: DTC P1121 — NEUTRAL POSITION SWITCH CIRCUIT HIGH INPUT [MT
VEHICLES] —
I DTC DETECTING CONDITION:
I Two consecutive driving cycles with fault
I TROUBLE SYMPTOM:
I Erroneous idling
CAUTION:
After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].>
and INSPECTION MODE <Ref. to 2-7 [T3E0].>.
I WIRING DIAGRAM:
B2M2105
603
2-7 [T11BU1] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11BU1 : CHECK INPUT SIGNAL FOR ECM. 11BU3 : CHECK POOR CONTACT.
1) Turn ignition switch to ON. Check poor contact in ECM connector. <Ref. to
2) Measure voltage between ECM and chassis FOREWORD [T3C1].>
ground. : Is there poor contact in ECM connec-
Connector & terminal tor?
(B135) No. 26 (+) — Chassis ground (−): : Repair poor contact in ECM connector.
: Contact with SOA service.
NOTE:
Inspection by DTM is required, because probable
cause is deterioration of multiple parts.
B2M2091A
604
ON-BOARD DIAGNOSTICS II SYSTEM [T11BU7] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11BU5 : CHECK HARNESS BETWEEN ECM 11BU7 : CHECK HARNESS BETWEEN ECM
AND TCM CONNECTOR. AND NEUTRAL POSITION SWITCH
CONNECTOR.
1) Turn ignition switch to ON.
2) Measure voltage between ECM and chassis 1) Disconnect connector from ECM.
ground. 2) Measure resistance of harness between ECM
and transmission harness connector.
Connector & terminal
(B135) No. 26 (+) — Chassis ground (–): Connector & terminal
(B135) No. 26 — (B25) No. 1:
B2M2091A
B2M2671A
: Is the voltage more than 10 V?
: Repair battery short circuit in harness : Is the resistance less than 1 Ω?
between ECM and transmission har- : Go to step 11BU8.
ness connector. : Repair open circuit in harness between
: Go to step 11BU6. ECM and transmission harness connec-
tor.
11BU6 : CHECK NEUTRAL POSITION
SWITCH.
OBD0469A
605
2-7 [T11BU8] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
OBD0472A
606
ON-BOARD DIAGNOSTICS II SYSTEM [T11BV1] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
BV: DTC P1121 — NEUTRAL POSITION SWITCH CIRCUIT LOW INPUT [AT
VEHICLES] —
I DTC DETECTING CONDITION:
I Two consecutive driving cycles with fault
I TROUBLE SYMPTOM:
I Erroneous idling
CAUTION:
After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].>
and INSPECTION MODE <Ref. to 2-7 [T3E0].>.
I WIRING DIAGRAM:
H2M3057
607
2-7 [T11BV2] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11BV2 : CHECK INPUT SIGNAL FOR ECM. 11BV3 : CHECK HARNESS BETWEEN ECM
AND TRANSMISSION HARNESS
1) Turn ignition switch to ON. CONNECTOR.
2) Measure voltage between ECM and chassis
ground. 1) Turn ignition switch to OFF.
2) Disconnect connectors from ECM and trans-
Connector & terminal
mission harness connector.
(B135) No. 26 (+) — Chassis ground (−):
3) Measure resistance of harness between ECM
connector and chassis ground.
Connector & terminal
(B135) No. 26 — Chassis ground:
B2M2091A
608
ON-BOARD DIAGNOSTICS II SYSTEM [T11BV6] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
1) Disconnect connector from inhibitor switch. : Is there any fault in selector cable
2) Measure resistance of harness between trans- connection to inhibitor switch?
mission harness connector and engine ground. : Repair selector cable connection. <Ref.
Connector & terminal to 3-2 [W2A0].>
(T3) No. 12 — Engine ground: : Contact with SOA service.
NOTE:
Inspection by DTM is required, because probable
cause is deterioration of multiple parts.
S2M0458A
B2M1119
609
2-7 [T11BV6] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
MEMO:
610
ON-BOARD DIAGNOSTICS II SYSTEM [T11BW0] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
H2M3025
611
2-7 [T11BW1] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
B2M2712A
612
ON-BOARD DIAGNOSTICS II SYSTEM [T11BW5] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
B2M1120
613
2-7 [T11BW5] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
MEMO:
614
ON-BOARD DIAGNOSTICS II SYSTEM [T11BX0] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
H2M3024
615
2-7 [T11BX1] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11BX1 : CHECK ANY OTHER DTC ON DIS- 11BX3 : CHECK THROTTLE POSITION
PLAY. SENSOR.
: Does the Subaru Select Monitor or Measure voltage between ECM and chassis
OBD-II general scan tool indicate ground while throttle valve is fully opened.
DTC P0102, P0103 or P0122?
Connector & terminal
: Inspect DTC P0102, P0103 or P0122 (B136) No. 15 (+) — Chassis ground (−):
using “11. Diagnostics Chart with
Trouble Code for Except 2200 cc Cali-
fornia Spec. Vehicles”. <Ref. to 2-7
[T11A0].>
NOTE:
In this case, it is not necessary to inspect DTC
P1141.
: Go to step 11BX2.
Measure voltage between ECM and chassis : Is the voltage more than 4.5 V?
ground while throttle valve is fully closed. : Replace mass air flow sensor. <Ref. to
Connector & terminal 2-7 [W2A1].>
(B136) No. 15 (+) — Chassis ground (−): : Check throttle position sensor circuit.
<Ref. to 2-7 [T11K0].>
B2M2443A
616
ON-BOARD DIAGNOSTICS II SYSTEM [T11BY0] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
H2M3027
617
2-7 [T11BY1] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
618
ON-BOARD DIAGNOSTICS II SYSTEM [T11BZ0] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
H2M3025
619
2-7 [T11BZ1] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11BZ1 : CHECK IDLE SWITCH SIGNAL. 11BZ2 : CHECK DATA FOR CONTROL.
S2M0258B S2M0258B
3) Turn ignition switch to ON and Subaru Select 3) Turn ignition switch ON and Subaru Select
Monitor switch to ON. Monitor or the OBD-II general scan tool switch ON.
4) Operate the LED operation mode for engine 4) Start engine.
using Subaru Select Monitor. 5) Read data of atmospheric absolute pressure
NOTE: signal using Subaru Select Monitor or OBD-II gen-
I Subaru Select Monitor eral scan tool.
For detailed operation procedure, refer to the “LED NOTE:
OPERATION MODE FOR ENGINE”. <Ref. to 2-7 I Subaru Select Monitor
[T3C8].> For detailed operation procedure, refer to the
: Does the LED of {Idle Switch Signal} “READ CURRENT DATA SHOWN ON DISPLAY
come on? FOR ENGINE”. <Ref. to 2-7 [T3C4].>
I OBD-II general scan tool
: Go to step 11BZ2. For detailed operation procedures, refer to the
: Check throttle position sensor circuit. OBD-II General Scan Tool Instruction Manual.
<Ref. to 2-7 [T11K0].>
: Is the value less than 32 kPa (240
NOTE: mmHg, 9.45 inHg)?
In this case, it is not necessary to inspect DTC : Go to step 11BZ4.
P1143.
: Go to step 11BZ3.
620
ON-BOARD DIAGNOSTICS II SYSTEM [T11BZ5] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
B2M1162F
621
2-7 [T11BZ5] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
MEMO:
622
ON-BOARD DIAGNOSTICS II SYSTEM [T11CA0] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
H2M3025
623
2-7 [T11CA1] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11CA1 : CHECK IDLE SWITCH SIGNAL. 11CA2 : CHECK DATA FOR CONTROL.
S2M0258B S2M0258B
3) Turn ignition switch to ON and Subaru Select 3) Turn ignition switch ON and Subaru Select
Monitor switch to ON. Monitor or the OBD-II general scan tool switch ON.
4) Operate the LED operation mode for engine 4) Start engine.
using Subaru Select Monitor. 5) Read data of atmospheric absolute pressure
NOTE: signal using Subaru Select Monitor or OBD-II gen-
I Subaru Select Monitor eral scan tool.
For detailed operation procedure, refer to the “LED NOTE:
OPERATION MODE FOR ENGINE”. <Ref. to 2-7 I Subaru Select Monitor
[T3C8].> For detailed operation procedure, refer to the
: Does the LED of {Idle Switch Signal} “READ CURRENT DATA SHOWN ON DISPLAY
come on? FOR ENGINE”. <Ref. to 2-7 [T3C4].>
I OBD-II general scan tool
: Go to step 11CA2. For detailed operation procedures, refer to the
: Check throttle position sensor circuit. OBD-II General Scan Tool Instruction Manual.
<Ref. to 2-7 [T11K0].>
: Is the value more than 133 kPa (998
NOTE: mmHg, 39.29 inHg)?
In this case, it is not necessary to inspect DTC : Replace pressure sensor. <Ref. to 2-7
P1144. [W11A0].>
: Even if MIL lights up, the circuit has
returned to a normal condition at this
time. Contact with SOA service.
NOTE:
Inspection by DTM is required, because probable
cause is deterioration of multiple parts.
624
ON-BOARD DIAGNOSTICS II SYSTEM [T11CB0] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
CB: DTC P1150 — FRONT OXYGEN SENSOR HEATER CIRCUIT HIGH INPUT
—
I DTC DETECTING CONDITION:
I Two consecutive driving cycles with fault
CAUTION:
After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].>
and INSPECTION MODE <Ref. to 2-7 [T3E0].>.
I WIRING DIAGRAM:
H2M3029
625
2-7 [T11CB1] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11CB1 : CHECK OUTPUT SIGNAL FROM 11CB3 : CHECK FRONT OXYGEN SENSOR
ECM. HEATER CURRENT.
S2M0258B
B2M2715A
B2M2468A
626
ON-BOARD DIAGNOSTICS II SYSTEM [T11CB5] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11CB4 : CHECK OUTPUT SIGNAL FROM 11CB5 : CHECK OUTPUT SIGNAL FROM
ECM. ECM.
Measure voltage between ECM connector and Measure voltage between ECM connector and
chassis ground. chassis ground.
Connector & terminal Connector & terminal
(B134) No. 23 (+) — Chassis ground (−): (B134) No. 22 (+) — Chassis ground (−):
B2M2715A B2M2468A
: Does the voltage change more than 8 : Does the voltage change more than 8
V by shaking harness and connector V by shaking harness and connector
of ECM while monitoring the value of ECM while monitoring the value
with voltage meter?
with voltage meter?
: Repair battery short circuit in harness
: Repair battery short circuit in harness
between ECM and front oxygen sensor
between ECM and front oxygen sensor connector.
connector.
: END
: Go to step 11CB5.
627
2-7 [T11CB5] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
MEMO:
628
ON-BOARD DIAGNOSTICS II SYSTEM [T11CC0] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
CC: DTC P1151 — REAR OXYGEN SENSOR HEATER CIRCUIT HIGH INPUT
—
I DTC DETECTING CONDITION:
I Two consecutive driving cycles with fault
CAUTION:
After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to 2-7 [T3D0].>
and INSPECTION MODE <Ref. to 2-7 [T3E0].>.
I WIRING DIAGRAM:
H2M3031
629
2-7 [T11CC1] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11CC1 : CHECK INPUT SIGNAL FOR ECM. 11CC2 : CHECK FRONT OXYGEN SENSOR
HEATER CURRENT.
Measure voltage between ECM connector and
chassis ground. 1) Turn ignition switch to OFF.
2) Repair battery short circuit in harness between
Connector & terminal ECM and front oxygen sensor connector.
(B134) No. 21 (+) — Chassis ground (−): 3) Connect Subaru Select Monitor or the OBD-II
general scan tool to data link connector.
B2M2483A
S2M0258B
: Is the voltage more than 8 V?
4) Turn ignition switch to ON and Subaru Select
: Go to step 11CC2.
Monitor or OBD-II general scan tool switch to ON.
: Go to step 11CC3. 5) Read data of rear oxygen sensor heater current
using Subaru Select Monitor or the OBD-II general
scan tool.
NOTE:
I Subaru Select Monitor
For detailed operation procedure, refer to the
“READ CURRENT DATA SHOWN ON DISPLAY
FOR ENGINE”. <Ref. to 2-7 [T3C4].>
I OBD-II general scan tool
For detailed operation procedure, refer to the
OBD-II General Scan Tool Instruction Manual.
: Is the value more than 7 A?
: Replace ECM. <Ref. to 2-7 [W15A0].>
: END
630
ON-BOARD DIAGNOSTICS II SYSTEM [T11CD0] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
H2M3034
631
2-7 [T11CD1] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
B2M1090
B2M2487A
632
ON-BOARD DIAGNOSTICS II SYSTEM [T11CD6] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11CD5 : CHECK KNOCK SENSOR. 11CD6 : CHECK INPUT SIGNAL FOR ECM.
1) Disconnect connector from knock sensor. 1) Connect connectors to ECM and knock sensor.
2) Measure resistance between knock sensor 2) Turn ignition switch to ON.
connector terminal and engine ground. 3) Measure voltage between ECM and chassis
ground.
Terminal
No. 2 — Engine ground: Connector & terminal
(B136) No. 4 (+) — Chassis ground (−):
B2M1090
B2M2488A
633
2-7 [T11CD6] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
MEMO:
634
ON-BOARD DIAGNOSTICS II SYSTEM [T11CE0] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
H2M3058
635
2-7 [T11CE1] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
B2M2673A
636
ON-BOARD DIAGNOSTICS II SYSTEM [T11CE5] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
H2M3172
637
2-7 [T11CE6] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
H2M3236A
638
ON-BOARD DIAGNOSTICS II SYSTEM [T11CF0] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
H2M3058
639
2-7 [T11CF1] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11CF1 : CHECK OUTPUT SIGNAL FROM 11CF2 : CHECK OUTPUT SIGNAL FROM
ECM. ECM.
S2M0259B
B2M2673A
640
ON-BOARD DIAGNOSTICS II SYSTEM [T11CF6] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
H2M3172
641
2-7 [T11CF6] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
MEMO:
642
ON-BOARD DIAGNOSTICS II SYSTEM [T11CG0] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
H2M3039
643
2-7 [T11CG1] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11CG1 : CHECK OUTPUT SIGNAL FROM 11CG2 : CHECK OUTPUT SIGNAL FROM
ECM. ECM.
S2M0259B
B2M2493A
644
ON-BOARD DIAGNOSTICS II SYSTEM [T11CG6] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
S2M0424
645
2-7 [T11CG6] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
MEMO:
646
ON-BOARD DIAGNOSTICS II SYSTEM [T11CH0] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
H2M3040
647
2-7 [T11CH1] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11CH1 : CHECK OUTPUT SIGNAL FROM 11CH2 : CHECK OUTPUT SIGNAL FROM
ECM. ECM.
S2M0259B
B2M2495A
648
ON-BOARD DIAGNOSTICS II SYSTEM [T11CH6] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
S2M0465
649
2-7 [T11CI0] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
H2M3042
650
ON-BOARD DIAGNOSTICS II SYSTEM [T11CJ1] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
H2M3040
651
2-7 [T11CJ2] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11CJ2 : CHECK VENT LINE HOSES. 11CJ3 : CHECK DRAIN VALVE OPERA-
TION.
Check the following items.
I Clogging of vent hoses between canister and 1) Turn ignition switch to OFF.
drain valve 2) Connect test mode connector at the lower por-
I Clogging of vent hose between drain valve and tion of instrument panel (on the driver’s side), to
air filter the side of the center console box.
I Clogging of vent hose between air filter and
junction pipe
I Clogging of junction pipe
I Clogging of air filter
S2M0259B
652
ON-BOARD DIAGNOSTICS II SYSTEM [T11CK2] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
H2M3046
11CK1 : CHECK ANY OTHER DTC ON DIS- 11CK2 : CHECK AIR INTAKE SYSTEM.
PLAY.
1) Turn ignition switch to ON.
: Does the Subaru Select Monitor or 2) Start engine, and idle it.
OBD-II general scan tool indicate 3) Check the following items.
DTC P0116 or P0117 or P0505 or I Loose installation of intake manifold, idle air
P1505? control solenoid valve and throttle body
: Inspect DTC P0116 or P0117 or P0505 I Cracks of intake manifold gasket, idle air control
solenoid valve gasket and throttle body gasket
or P1505 using “11. Diagnostics Chart
I Disconnections of vacuum hoses
with Trouble Code for Except 2200 cc
California Spec. Vehicles”. <Ref. to 2-7 : Is there a fault in air intake system?
[T11A0].> : Repair air suction and leaks.
NOTE: : Replace idle air control solenoid valve.
In this case, it is not necessary to inspect DTC <Ref. to 2-7 [W12A2].>
P1507.
: Go to step 11CK2.
653
2-7 [T11CK2] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
MEMO:
654
ON-BOARD DIAGNOSTICS II SYSTEM [T11CQ0] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
655
2-7 [T11CR0] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
H2M3046
656
ON-BOARD DIAGNOSTICS II SYSTEM [T11CR2] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11CR1 : CHECK POWER SUPPLY TO IDLE 11CR2 : CHECK POWER SUPPLY TO IDLE
AIR CONTROL SOLENOID VALVE. AIR CONTROL SOLENOID VALVE.
1) Turn ignition switch to OFF. Measure voltage between idle air control solenoid
2) Disconnect connector from idle air control sole- valve connector and engine ground.
noid valve. Connector & terminal
3) Turn ignition switch to ON. (E7) No. 5 (+) — Engine ground (−):
4) Measure voltage between idle air control sole-
noid valve connector and engine ground.
Connector & terminal
(E7) No. 2 (+) — Engine ground (−):
B2M2717A
657
2-7 [T11CR3] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11CR3 : CHECK HARNESS BETWEEN ECM 11CR4 : CHECK HARNESS BETWEEN ECM
AND IDLE AIR CONTROL SOLE- AND IDLE AIR CONTROL SOLE-
NOID VALVE CONNECTOR. NOID VALVE CONNECTOR.
B2M2718A B2M2719A
658
ON-BOARD DIAGNOSTICS II SYSTEM [T11CR5] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
659
2-7 [T11CR5] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
MEMO:
660
ON-BOARD DIAGNOSTICS II SYSTEM [T11CS1] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
H2M3046
661
2-7 [T11CS2] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11CS2 : CHECK GROUND CIRCUIT FOR 11CS3 : CHECK HARNESS BETWEEN ECM
ECM. AND IDLE AIR CONTROL SOLE-
NOID VALVE CONNECTOR.
1) Turn ignition switch to OFF.
2) Measure resistance between ECM connector 1) Turn ignition switch to OFF.
and chassis ground. 2) Disconnect connector from idle air control sole-
noid valve.
Connector & terminal 3) Turn ignition switch to ON.
(B134) No. 7 — Chassis ground: 4) Measure voltage between ECM connector and
chassis ground.
Connector & terminal
#1; (B134) No. 5 (+) — Chassis ground
(–):
#2; (B134) No. 6 (+) — Chassis ground
(–):
#3; (B134) No. 19 (+) — Chassis ground
(–):
#4; (B134) No. 20 (+) — Chassis ground
(–):
B2M2720A
662
ON-BOARD DIAGNOSTICS II SYSTEM [T11CT0] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
H2M3043
663
2-7 [T11CT1] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
S2M0259B
B2M2654A
664
ON-BOARD DIAGNOSTICS II SYSTEM [T11CT6] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
1) Turn ignition switch to OFF. Check poor contact in ECM connector. <Ref. to
2) Remove main fan relay 1. FOREWORD [T3C1].>
3) Measure resistance between main fan relay 1 : Is there poor contact in ECM connec-
terminals. tor?
Terminal : Repair poor contact in ECM connector.
No. 27 — No. 28: : Replace ECM. <Ref. to 2-7 [W15A0].>
S2M0434
OBD0536
665
2-7 [T11CT6] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
MEMO:
666
ON-BOARD DIAGNOSTICS II SYSTEM [T11CU3] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
H2M3045
667
2-7 [T11CU4] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11CU4 : CHECK HARNESS BETWEEN ECM 11CU5 : CHECK HARNESS BETWEEN ECM
AND COMBINATION METER CON- AND COMBINATION METER CON-
NECTOR. NECTOR.
B2M2659A
B2M2658A
: Is the resistance less than 10 Ω?
: Is the voltage more than 2 V? : Repair ground short circuit in harness
between ECM and combination meter
: Repair harness and connector.
connector.
NOTE: : Repair poor contact in ECM connector.
In this case, repair the following:
I Open circuit in harness between ECM and com-
bination meter connector
I Poor contact in ECM connector
I Poor contact in combination meter connector
: Go to step 11CU5.
668
ON-BOARD DIAGNOSTICS II SYSTEM [T11CV0] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
H2M3047
669
2-7 [T11CV1] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11CV1 : CHECK INPUT SIGNAL FOR ECM. 11CV3 : CHECK FUSE SBF-2.
B2M2679A
670
ON-BOARD DIAGNOSTICS II SYSTEM [T11CW1] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
B2M2533
671
2-7 [T11CW1] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
MEMO:
672
ON-BOARD DIAGNOSTICS II SYSTEM [T11CX2] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
H2M3059
11CX1 : CHECK HARNESS BETWEEN TCM 11CX2 : CHECK HARNESS BETWEEN TCM
AND CCM CONNECTOR. AND CCM CONNECTOR.
1) Turn ignition switch to OFF. Measure resistance of harness between TCM and
2) Disconnect connectors from TCM and CCM. chassis ground.
3) Measure resistance of harness between TCM Connector & terminal
and CCM connector. (B54) No. 11 — Chassis ground:
Connector & terminal
(B54) No. 11 — (B94) No. 12:
B2M2682A
673
2-7 [T11CX3] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
B2M2683A
674
ON-BOARD DIAGNOSTICS II SYSTEM [T11CY1] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
B2M2111
675
2-7 [T11CY2] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11CY2 : CHECK HARNESS BETWEEN ECM 11CY3 : CHECK HARNESS BETWEEN ECM
AND TCM CONNECTOR. AND TCM CONNECTOR.
B2M2684A
B2M2685A
B2M2684A
676
ON-BOARD DIAGNOSTICS II SYSTEM [T11CZ1] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
B2M2401
677
2-7 [T11DA0] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
B2M2403
678
ON-BOARD DIAGNOSTICS II SYSTEM [T11DB1] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
H2M3060
679
2-7 [T11DB1] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
MEMO:
680
ON-BOARD DIAGNOSTICS II SYSTEM [T11DC1] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
B2M2111
681
2-7 [T11DC2] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11DC2 : CHECK HARNESS BETWEEN ECM 11DC4 : CHECK HARNESS BETWEEN ECM
AND TCM CONNECTOR. AND TCM CONNECTOR.
1) Turn ignition switch to ON. Measure voltage between ECM connector and
2) Measure voltage between ECM and chassis chassis ground.
ground. Connector & terminal
Connector & terminal (B135) No. 4 (+) — Chassis ground (−):
(B135) No. 4 (+) — Chassis ground (−):
B2M2684A
B2M2684A
: Is the voltage less than 1 V?
: Is the voltage more than 10 V? : Repair poor contact in ECM connector.
: Repair battery short circuit in harness : Go to step 11DC5.
between ECM and TCM connector.
After repair, replace ECM. <Ref. to 2-7
[W15A0].>
: Go to step 11DC3.
B2M2684A
682
ON-BOARD DIAGNOSTICS II SYSTEM [T11DC7] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
11DC5 : CHECK OUTPUT SIGNAL FROM 11DC6 : CHECK HARNESS BETWEEN ECM
ECM. AND TCM CONNECTOR.
Measure voltage between ECM and chassis Measure voltage between TCM and chassis
ground. ground.
Connector & terminal Connector & terminal
(B135) No. 4 (+) — Chassis ground (−): (B54) No. 4 (+) — Chassis ground (−):
B2M2684A B2M2686A
683
2-7 [T11DD0] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
B2M2111
684
ON-BOARD DIAGNOSTICS II SYSTEM [T11DE0] 2-7
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
B2M2112
685
2-7 [T11DE1] ON-BOARD DIAGNOSTICS II SYSTEM
11. Diagnostics Chart with Trouble Code for Except 2200 cc California Spec. Vehicles
B2M2722A
686
FUEL SYSTEM 2-8
Page
S SPECIFICATIONS AND SERVICE DATA..........................................................2
1. Fuel System ................................................................................................2
C COMPONENT PARTS .......................................................................................4
1. Fuel Tank.....................................................................................................4
2. Fuel Line......................................................................................................6
W SERVICE PROCEDURE ...................................................................................8
1. On-car Services...........................................................................................8
2. Fuel Tank ...................................................................................................11
3. Fuel Filler Pipe ..........................................................................................16
4. Fuel Filter ..................................................................................................21
5. Fuel Pump .................................................................................................22
6. Fuel Meter Unit..........................................................................................24
7. Fuel Delivery, Return and Evaporation Lines ...........................................26
8. Roll Over Valve .........................................................................................28
9. Fuel Cut Valve...........................................................................................29
10. Fuel Sub Meter Unit ..................................................................................29
K DIAGNOSTICS.................................................................................................31
1. Fuel System Trouble in General ...............................................................31
2-8 [S100] SPECIFICATIONS AND SERVICE DATA
1. Fuel System
1. Fuel System
Capacity 60 (15.9 US gal, 13.2 Imp gal)
Fuel tank
Location Under rear seat
Type Impeller
Discharge pressure 299.1 kPa (3.05 kg/cm2, 43.4 psi)
Fuel pump
More than 65 (17.2 US gal, 14.3 Imp gal)/h [12 V at 300
Discharge flow
kPa (3.06 kg/cm2, 43.5 psi)]
Fuel filter Cartridge type
2
SPECIFICATIONS AND SERVICE DATA [S100] 2-8
1. Fuel System
MEMO:
3
2-8 [C100] COMPONENT PARTS
1. Fuel Tank
1. Fuel Tank
S2M0877A
4
COMPONENT PARTS [C100] 2-8
1. Fuel Tank
(1) Heat sealed cover (15) Evaporation hose C (29) Jet pump filter
(2) Fuel tank band (16) Evaporation hose B (30) Fuel sub meter unit
(3) Protector LH (17) Evaporation hose D (31) Protector cover
(4) Protector RH (18) Evaporation hose E (32) Vent valve hose
(5) Fuel tank (19) Evaporation pipe ASSY (33) Vent valve
(6) Canister hose A (20) Retainer (34) Fuel tank pressure sensor
(7) Clamp (21) Quick connector (35) Fuel tank pressure sensor hose
(8) Fuel pump gasket (22) Jet pump hose A (36) Vent valve gasket
(9) Fuel pump ASSY (23) Fuel return hose A
(10) Fuel cut valve gasket (24) Fuel pipe ASSY Tightening torque: N·m (kg-m, ft-lb)
(11) Fuel cut valve (25) Jet pump hose B T1: 4.4±1.5 (0.45±0.15, 3.3±1.1)
(12) Fuel delivery hose A (26) Fuel return hose B T2: 7.4±2.0 (0.75±0.2, 5.4±1.4)
(13) Clip (27) Evaporation hose F T3: 33±10 (3.4±1.0, 25±7)
(14) Joint pipe (28) Fuel sub meter gasket
5
2-8 [C200] COMPONENT PARTS
2. Fuel Line
2. Fuel Line
S2M1114A
6
COMPONENT PARTS [C200] 2-8
2. Fuel Line
7
2-8 [W1A0] SERVICE PROCEDURE
1. On-car Services
A: PRECAUTIONS
WARNING:
I Place “No fire” signs near the working area.
I Disconnect ground terminal from battery.
I Be careful not to spill fuel on the floor.
B: RELEASING OF FUEL
PRESSURE
1) Disconnect connector from fuel pump relay. S2M0246
S2M0093A
S2M0060A
S2M0061
G6M0095
8
SERVICE PROCEDURE [W1D0] 2-8
1. On-car Services
9) Take off fuel pump from fuel tank. 12) Drain fuel from there.
WARNING:
Do not use a motor pump when draining fuel.
G2M0344
WARNING: 13) After draining fuel, reinstall fuel pump and fuel
Do not use a motor pump when draining fuel. sub meter unit.
Tighten nuts of fuel pump in numerical sequence
shown in figure to specified torque.
Tightening torque:
4.4±1.5 N·m (0.45±0.15 kg-m, 3.3±1.1 ft-lb)
G2M0345
S2M0153
S2M0152A
D: MEASUREMENT OF FUEL
PRESSURE
WARNING:
Before removing fuel pressure gauge, release
fuel pressure.
NOTE:
If out of specification, check or replace pressure
regulator and pressure regulator vacuum hose.
1) Release fuel pressure. <Ref. to 2-8 [W1B0].>
9
2-8 [W1D0] SERVICE PROCEDURE
1. On-car Services
2) Open fuel flap lid, and remove fuel filler cap. 6) Measure fuel pressure while disconnecting
pressure regulator vacuum hose from collector
chamber.
Fuel pressure:
235 — 265 kPa (2.4 — 2.7 kg/cm2, 34 —
38 psi)
H2M2535
S2M0248
S2M0195
S2M0248
S2M0093A
10
SERVICE PROCEDURE [W2A0] 2-8
2. Fuel Tank
H2M2536
H2M2535
B2M1737
B2M1738
B2M1739A
11
2-8 [W2A0] SERVICE PROCEDURE
2. Fuel Tank
(1) Separate rear exhaust pipe from center 14) Move clamp, and disconnect evaporation
exhaust pipe. hose from canister.
(2) Separate rear exhaust pipe from muffler.
(3) Remove bracket from rubber cushion, and
remove exhaust pipe.
NOTE:
To facilitate the removal of parts, apply a coat of
SUBARU CRC5-56 (Part No. 004301003).
S2M0949
S2M0158
G2M0384
B2M1743
S2M0166
H2M2538
12
SERVICE PROCEDURE [W2A0] 2-8
2. Fuel Tank
19) Remove bolts which hold parking brake cable 22) Loosen clamp, and disconnect fuel filler hose
holding bracket. (A) and air vent hose (B) from fuel filler pipe and
air vent pipe.
S2M0191
S2M0193A
20) Remove rear differential assembly.
(1) Remove rear axle shafts from rear differen- 23) Move clips, and disconnect fuel return hose
tial assembly. (B) and evaporation hose (C).
(2) Remove rear differential front cover. 24) Disconnect quick connector, and then discon-
(3) Remove propeller shaft. nect fuel delivery hose (A).
(4) Remove lower differential bracket.
(5) Set transmission jack under rear differential.
(6) Remove bolts which install rear differential
onto rear crossmember.
<Ref. to 3-4 [W2B0].> and <Ref. to 3-4
[W3B0].>
S2M0168A
S2M0169A
G4M0545
13
2-8 [W2B0] SERVICE PROCEDURE
2. Fuel Tank
G4M0545
G3M0059
B2M1743
S2M0169A
S2M0880
14
SERVICE PROCEDURE [W2B0] 2-8
2. Fuel Tank
11) Connect evaporation hose to canister, and 15) Install muffler assembly. <Ref. to 2-9 [W3A0].>
hold them with clamp.
G2M0384
S2M0949
16) Install rear exhaust pipe. <Ref. to 2-9
12) Connect hoses to roll over valve. [W2B0].>
H2M2538 S2M0158
13) Install bolts which hold parking brake holding 17) Lower the vehicle.
bracket. 18) Connect connectors to fuel tank harness, and
plug access hole with grommet.
S2M0191
B2M1738
14) Install heat sealed cover.
19) Install rear seat cushion. (Sedan model) <Ref.
to 5-3 [W2B0].>
S2M0166
B2M1736
15
2-8 [W3A0] SERVICE PROCEDURE
3. Fuel Filler Pipe
20) Set rear seat cushion. (Wagon model) 3. Fuel Filler Pipe
A: REMOVAL
1) Set the vehicle on the lift.
2) Release fuel pressure. <Ref. to 2-8 [W1B0].>
3) Open fuel flap lid, and remove fuel filler cap.
B2M1737
H2M2535
S2M0093A
G2M0345
G6M0095
G6M0095
16
SERVICE PROCEDURE [W3A0] 2-8
3. Fuel Filler Pipe
6) Remove screws which install fuel filler pipe on 12) Disconnect evaporation hoses from pipes.
filler lid open.
B2M1751
H2M2534
13) Remove bolts which hold fuel filler pipe
7) Remove wheel nuts of rear right side. bracket.
8) Lift-up the vehicle.
9) Remove rear right side wheel.
B2M1752
B2M1748
14) Lift-up the vehicle more.
15) Remove two evaporation hoses from clip.
10) Remove bolts which install protector cover on
body.
B2M1753
B2M1749
16) Disconnect evaporation hose from joint pipe.
B2M1754
B2M1750A
17
2-8 [W3B0] SERVICE PROCEDURE
3. Fuel Filler Pipe
17) Loosen clamp, and disconnect fuel filler hose 3) Lower the vehicle.
from fuel filler pipe. 4) Temporarily tighten screws which install fuel
filler pipe on filler lid open.
B2M1745
H2M2534
18) Remove fuel filler pipe to under side of
vehicle. 5) Tighten bolt which holds fuel filler pipe on body.
B2M1756 B2M1752
B2M1751
B2M1745
B2M1757
18
SERVICE PROCEDURE [W3B0] 2-8
3. Fuel Filler Pipe
9) Install two evaporation hoses to clip. 14) Tighten screws which install fuel filler pipe on
filler lid open.
B2M1753
H2M2534
10) Connect evaporation hose to joint pipe.
15) Install rear right wheel.
B2M1754
B2M1748
11) Lower the vehicle.
12) While holding the under side of protector 16) Install fuel filler cap.
cover on bracket, install it. 17) Connect connector to fuel pump relay.
B2M1750A S2M0093A
13) Tighten bolts which install protector cover on 18) Connect battery ground terminal.
body.
G6M0095
B2M1749
19
2-8 [W3C0] SERVICE PROCEDURE
3. Fuel Filler Pipe
B2M1762
B2M1758 D: ASSEMBLY
2) Remove bolt which installs joint pipe on fuel 1) Install shut valve on fuel filler pipe.
filler pipe. Tightening torque:
4.4±1.5 N·m (0.45±0.15 kg-m, 3.3±1.1 ft-lb)
B2M1759
B2M1762
3) Disconnect evaporation hose from fuel filler
pipe. 2) Connect evaporation hoses to shut valve.
B2M1760 B2M1761
4) Disconnect evaporation hoses from shut valve. 3) Connect evaporation hose to fuel filler pipe.
B2M1761 B2M1760
20
SERVICE PROCEDURE [W4B0] 2-8
4. Fuel Filter
B2M1758
G6M0095
B2M1759
S2M0195
B: 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.
21
2-8 [W4C0] SERVICE PROCEDURE
5. Fuel Pump
H2M2535
S2M0195
G6M0095
S2M0172
22
SERVICE PROCEDURE [W5C0] 2-8
5. Fuel Pump
6) Disconnect quick connector, and then discon- (1) Always use new gaskets.
nect fuel delivery hose (A). <Ref. to 2-8 [W7A0].> (2) Ensure sealing portion is free from fuel or for-
eign particles before installation.
(3) Tighten nuts in numerical sequence shown in
Figure to specified torque.
Tightening torque:
4.4±1.5 N·m (0.45±0.15 kg-m, 3.3±1.1 ft-lb)
S2M0060A
S2M0061
B: INSPECTION
Connect lead harness to connector terminal of fuel
pump, and apply battery power supply to check
whether the pump operate.
WARNING:
I Wipe off the fuel completely.
I Be sure to turn the battery supply ON and
OFF on the battery side.
I Do not run fuel pump for a long time under
non-load condition.
G2M0366
C: INSTALLATION
Installation is in the reverse order of removal. Do
the following:
23
2-8 [W6A0] SERVICE PROCEDURE
6. Fuel Meter Unit
6. Fuel Meter Unit 5) Move clips, and then disconnect fuel return
hose (B) and jet pump hose (C).
A: REMOVAL 6) Disconnect quick connector, and then discon-
nect fuel delivery hose (A). <Ref. to 2-8 [W7A0].>
NOTE:
Fuel meter unit is built in fuel pump assembly.
1) Release fuel pressure. <Ref. to 2-8 [W1B0].>
2) Open fuel flap lid, and remove fuel filler cap.
S2M0060A
S2M0145
G6M0095
10) Remove bolt which installs fuel meter unit on
4) Disconnect connector from fuel pump. mounting bracket.
S2M0172 H2M3206
24
SERVICE PROCEDURE [W6B0] 2-8
6. Fuel Meter Unit
B: INSTALLATION
Installation is in the reverse order of removal. Do
the following:
(1) Install the fuel meter unit on mounting bracket.
H2M3206
S2M0063A
25
2-8 [W7A0] SERVICE PROCEDURE
7. Fuel Delivery, Return and Evaporation Lines
7. Fuel Delivery, Return and 2) Open fuel flap lid, and remove fuel filler cap.
3) Remove inner trim, insulator and rear seat.
Evaporation Lines 4) emove fuel delivery pipes and hoses, fuel
A: REMOVAL return pipes and hoses, and evaporation pipes and
hoses.
1) Release fuel pressure. <Ref. to 2-8 [W1B0].>
H2M2431H
S2M0228A
(A) Connector
S2M0500 (B) Retainer
(C) Pipe
6) Separate quick connector on fuel deliverly line.
(1) Clean pipe and connector, if they are cov- B: INSTALLATION
ered with dust.
(2) Hold connector (A) and push retainer (B) Installation is in the reverse order of removal.
down. 1) Connect quick connector on fuel delivery line.
(3) Pull out connector (A) from retainer (B). CAUTION:
CAUTION: I Always use a new retainer.
Replace retainer with new ones. I Make sure that the connected portion is not
damaged or has dust. If necessary, clean sea
26
SERVICE PROCEDURE [W7B0] 2-8
7. Fuel Delivery, Return and Evaporation Lines
S2M0229A
(1) Fitting
(2) Clamp
(3) Hose
CAUTION:
I Pull the connector to ensure it is connected
securely.
I Ensure the two retainer pawls are engaged in
their mating positions in the connector.
I Be sure to inspect hoses and their connec-
tions for any leakage of fuel.
B2M1195A
(1) Hose
(2) Clip
(3) Pipe
S2M0231A
(A) Connector
(B) Retainer
(C) Pipe
27
2-8 [W8A0] SERVICE PROCEDURE
8. Roll Over Valve
G2M0374
S2M0174
2) While blowing through open end of hose, tilt
valve at least 90° left and right from normal posi-
3) Disconnect hoses from roll over valve, and tion.
remove it from bracket. 3) Ensure that there is no air flow when hose is
tilted greater than 90°.
S2M0175
S2M0174
28
SERVICE PROCEDURE [W10A0] 2-8
10. Fuel Sub Meter Unit
S2M0169A G6M0095
2) Disconnect evaporation hose from fuel cut 2) Remove fuel filler cap.
valve. 3) Remove service hole cover.
3) Remove fuel cut valve.
G2M0863
G2M0867
4) Installation is in the reverse order of removal 4) Disconnect connector from fuel sub meter, and
procedure. disconnect jet pump hose.
Tightening torque:
4.4±1.5 N·m (0.45±0.15 kg-m, 3.3±1.1 ft-lb)
S2M0151
29
2-8 [W10A0] SERVICE PROCEDURE
10. Fuel Sub Meter Unit
5) Remove bolts which install fuel sub meter unit 7) Installation is in the reverse order of removal.
on fuel tank. Tightening torque:
T: 4.4±1.5 N·m (0.45±0.15 kg-m, 3.3±1.1
ft-lb)
S2M0152
S2M0153
30
DIAGNOSTICS [K100] 2-8
1. Fuel System Trouble in General
31
2-8 DIAGNOSTICS
MEMO:
32
EXHAUST SYSTEM 2-9
Page
C COMPONENT PARTS .......................................................................................2
1. Exhaust System ..........................................................................................2
W SERVICE PROCEDURE ...................................................................................5
1. Front Exhaust Pipe and Center Exhaust Pipe............................................5
2. Rear Exhaust Pipe ......................................................................................7
3. Muffler..........................................................................................................8
2-9 [C1A0] COMPONENT PARTS
1. Exhaust System
1. Exhaust System
A: 2200 cc MODEL
H2M2936A
2
COMPONENT PARTS [C1A0] 2-9
1. Exhaust System
(1) Upper front exhaust pipe cover (12) Rear exhaust pipe (24) Front oxygen (A/F) sensor (Cali-
CTR (13) Self-locking nut fornia spec. vehicle)
(2) Lower front exhaust pipe cover (14) Gasket Front oxygen sensor (Except
CTR (15) Muffler California spec. vehicle)
(3) Band RH (16) Cushion rubber (25) Rear oxygen sensor
(4) Band LH (17) Clamp (26) Front catalytic converter
(5) Upper front exhaust pipe cover (18) Upper center exhaust pipe cover (27) Lower front catalytic converter
LH (19) Center exhaust pipe cover
(6) Lower front exhaust pipe cover (20) Clamp B (28) Upper front catalytic converter
LH (21) Upper rear catalytic converter cover
(7) Front exhaust pipe cover (29) Rear catalytic converter
(8) Lower front exhaust pipe cover (22) Lower rear catalytic converter (39) Gasket
RH cover
(9) Upper front exhaust pipe cover (23) Rear oxygen sensor Tightening torque: N·m (kg-m, ft-lb)
RH T1: 13±3 (1.3±0.3, 9.4±2.2)
(10) Gasket T2: 18±5 (1.8±0.5, 13.0±3.6)
(11) Spring T3: 30±5 (3.1±0.5, 22.4±3.6)
T4: 35±5 (3.6±0.5, 26.0±3.6)
T5: 48±5 (4.9±0.5, 35.4±3.6)
3
2-9 [C1B0] COMPONENT PARTS
1. Exhaust System
B: 2500 cc MODEL
S2M0921A
(1) Upper front exhaust pipe cover (11) Spring (25) Front catalytic converter
CTR (12) Rear exhaust pipe (26) Lower front catalytic converter
(2) Lower front exhaust pipe cover (13) Self-locking nut cover
CTR (14) Gasket (27) Upper front catalytic converter
(3) Band RH (15) Muffler cover
(4) Band LH (16) Cushion rubber (28) Gasket
(5) Upper front exhaust pipe cover (17) Clamp (29) Rear catalytic converter
LH (18) Upper center exhaust pipe cover (30) Gasket
(6) Lower front exhaust pipe cover (19) Center exhaust pipe
LH (20) Clamp B Tightening torque: N·m (kg-m, ft-lb)
(7) Front exhaust pipe (21) Upper rear catalytic converter T1: 13±3 (1.3±0.3, 9.4±2.2)
(8) Lower front exhaust pipe cover cover T2: 18±5 (1.8±0.5, 13.0±3.6)
RH (22) Lower rear catalytic converter T3: 30±5 (3.1±0.5, 22.4±3.6)
(9) Upper front exhaust pipe cover cover T4: 35±5 (3.6±0.5, 26.0±3.6)
RH (23) Front oxygen sensor
T5: 48±5 (4.9±0.5, 35.4±3.6)
(10) Gasket (24) Rear oxygen sensor
4
SERVICE PROCEDURE [W1A0] 2-9
1. Front Exhaust Pipe and Center Exhaust Pipe
1. Front Exhaust Pipe and 5) Separate front and center exhaust pipe assem-
bly from rear exhaust pipe.
Center Exhaust Pipe
WARNING:
A: REMOVAL Be careful, exhaust pipe is hot.
1) Disconnect battery ground cable.
B2M0055
S2M0922
B2M0312
B2M0313
5
2-9 [W1B0] SERVICE PROCEDURE
1. Front Exhaust Pipe and Center Exhaust Pipe
9) Separate front exhaust pipe from front catalytic 4) Tighten bolts which hold front exhaust pipe onto
converter and center exhaust pipe assembly. cylinder heads.
Tightening torque:
30±5 N·m (3.1±0.5 kg-m, 22.4±3.6 ft-lb)
S2M0923
B: INSTALLATION B2M0054
1) Install front exhaust pipe to front catalytic con- 5) Tighten bolts which install front and center
verter and center exhaust pipe assembly. exhaust pipe assembly to rear exhaust pipe.
CAUTION: Tightening torque:
Replace gaskets with new ones. 18±5 N·m (1.8±0.5 kg-m, 13.0±3.6 ft-lb)
Tightening torque:
30±5 N·m (3.1±0.5 kg-m, 22.4±3.6 ft-lb)
B2M0055
B2M0313
B2M0313
6
SERVICE PROCEDURE [W2A0] 2-9
2. Rear Exhaust Pipe
B2M0312
G2M0291
S2M0922
G2M0382
G2M0315
7
2-9 [W2B0] SERVICE PROCEDURE
3. Muffler
B: INSTALLATION 3. Muffler
CAUTION: A: REMOVAL AND INSTALLATION
Replace gaskets with new ones.
1) Separate muffler from rear exhaust pipe.
1) Install rear exhaust pipe bracket to rubber cush-
ion.
NOTE:
To facilitate installation, apply a coat of SUBARU
CRC to mating area of rubber cushion in advance.
SUBARU CRC (Part No. 004301003)
G2M0382
G2M0382
G2M0384
3) Install rear exhaust pipe to front catalytic con-
verter. 3) Remove front rubber cushion, and detach muf-
fler assembly.
Tightening torque:
18±5 N·m (1.8±0.5 kg-m, 13.0±3.6 ft-lb) NOTE:
To facilitate removal, apply a coat of SUBARU
CRC to mating area of rubber cushion in advance.
SUBARU CRC (Part No. 004301003)
G2M0291
G2M0385
8
SERVICE PROCEDURE [W3A0] 2-9
3. Muffler
G2M0382
9
2-9 SERVICE PROCEDURE
MEMO:
10
CLUTCH 2-10
Page
S SPECIFICATIONS AND SERVICE DATA..........................................................2
1. Specifications ..............................................................................................2
C COMPONENT PARTS .......................................................................................3
1. Clutch System .............................................................................................3
2. Master Cylinder and Reservoir Tank...........................................................5
W SERVICE PROCEDURE ...................................................................................6
1. General........................................................................................................6
2. On-car Service ............................................................................................7
3. Release Bearing and Lever ........................................................................8
4. Clutch Disc and Cover ..............................................................................11
5. Operating Cylinder ....................................................................................14
6. Master Cylinder and Reservoir Tank.........................................................15
7. Brake Fluid ................................................................................................17
K DIAGNOSTICS.................................................................................................18
1. Clutch Trouble in General .........................................................................18
2-10 [S100] SPECIFICATIONS AND SERVICE DATA
1. Specifications
1. Specifications
2200 cc 2500 cc
Clutch cover Diaphragm set load kg (lb) 450 (992) 580 (1,279)
Facing material Woven
O.D. × I.D. × thickness mm (in) 225 × 150 × 3.5 (8.86 × 5.91 × 0.138)
Spline O.D. 25.2 (0.992)
mm (in)
(No. of teeth) (24)
Clutch disc
1.3 — 1.9 1.65 — 2.25
Depth of rivet head mm Standard
(0.051 — 0.075) (0.0650 — 0.0886)
(in)
Limit of sinking 0.3 (0.012)
Limit for runout mm (in) 1.0 (0.039) at R = 107 (4.21)
Clutch release lever ratio 3.0 1.6
24 — 26 12 — 13.6
Stroke mm (in)
(0.94 — 1.02) (0.472 — 0.535)
Release lever
Play at release lever
mm (in) 3 — 4 (0.12 — 0.16) —
center
Release bearing Grease-packed self-aligning
140 — 145 130 — 135
Clutch pedal Full stroke mm (in)
(5.51 — 5.71) (5.12 — 5.31)
O.D.; Outer Diameter I.D.; Inner Diameter
2
COMPONENT PARTS [C1A0] 2-10
1. Clutch System
1. Clutch System
A: MECHANICAL APPLICATION TYPE
H2M2429B
3
2-10 [C1B0] COMPONENT PARTS
1. Clutch System
S2M0910A
4
COMPONENT PARTS [C200] 2-10
2. Master Cylinder and Reservoir Tank
S2M0911A
5
2-10 [W1A1] SERVICE PROCEDURE
1. General
S2M0351A
6
SERVICE PROCEDURE [W2A2] 2-10
2. On-car Service
G2M0234
B2M1179F
B2M1178A
7
2-10 [W3A1] SERVICE PROCEDURE
3. Release Bearing and Lever
B2M1179A
H2M2430A
B2M0174B
8
SERVICE PROCEDURE [W3B2] 2-10
3. Release Bearing and Lever
B2M0173A
B2M1257G
G2M0241
B2M1258A
9
2-10 [W3C1] SERVICE PROCEDURE
3. Release Bearing and Lever
10
SERVICE PROCEDURE [W4A0] 2-10
4. Clutch Disc and Cover
G2M0242
11
2-10 [W4B1] SERVICE PROCEDURE
4. Clutch Disc and Cover
B2M0328 B2M0333A
2) Hardened facing
Correct by using emery paper or replace. 2. CLUTCH COVER
3) Oil soakage on facing Visually check for the following items without
Replace clutch disc and inspect transmission front disassembling, and replace or repair if defective.
oil seal, transmission case mating surface, engine 1) Loose thrust rivet.
rear oil seal and other points for oil leakage. 2) Damaged or worn bearing contact area at cen-
ter of diaphragm spring.
B2M0329A
G2M0248
12
SERVICE PROCEDURE [W4C0] 2-10
4. Clutch Disc and Cover
3) Damaged or worn disc contact surface of pres- 2) Tighten the flywheel attaching bolts to the
sure plate. specified torque.
4) Loose strap plate setting bolt.
NOTE:
5) Worn diaphragm sliding surface.
Tighten flywheel installing bolts gradually. Each
bolt should be tightened to the specified torque in
a crisscross fashion.
Tightening torque:
72±3 N·m (7.3±0.3 kg-m, 52.8±2.2 ft-lb)
G2M0249
3. FLYWHEEL
CAUTION:
Since this bearing is grease sealed and is of a B2M0331B
non-lubrication type, do not wash with gaso-
line or any solvent. 3) Insert ST into the clutch disc and install them on
1) Damage of facing and ring gear the flywheel by inserting the ST end into the pilot
If defective, replace flywheel. bearing.
ST 499747100 CLUTCH DISC GUIDE
G2M0250
G2M0253
2) Smoothness of rotation
Rotate ball bearing applying pressure in thrust
direction.
3) If noise or excessive play is noted, replace fly-
wheel.
C: INSTALLATION
1) Install flywheel and ST.
ST 498497100 CRANKSHAFT STOPPER
B2M0332A
13
2-10 [W5A0] SERVICE PROCEDURE
5. Operating Cylinder
B2M1179B
B2M1011A
B2M1263
14
SERVICE PROCEDURE [W6B0] 2-10
6. Master Cylinder and Reservoir Tank
B2M1179C
B4M1189A
S2M0352A
B: DISASSEMBLY
1) Remove straight pin and reservoir tank.
S2M0915
15
2-10 [W6C0] SERVICE PROCEDURE
6. Master Cylinder and Reservoir Tank
S2M0917A
S2M0918A
B4M1189C
(A) Master cylinder body
(B) Return spring (A) Clevis pin
(C) Piston (B) Snap pin
(D) Snap ring (C) Push rod
(E) Rod ASSY
3) After bleeding air from system, ensure that
clutch operates properly.
<Ref. to 2-10 [W2A2].>
16
SERVICE PROCEDURE [W7A0] 2-10
7. Brake Fluid
17
2-10 [K100] DIAGNOSTICS
1. Clutch Trouble in General
18
DIAGNOSTICS [K100] 2-10
1. Clutch Trouble in General
19
2-10 [K1A0] DIAGNOSTICS
1. Clutch Trouble in General
B2M1012A
20
ENGINE AND TRANSMISSION
MOUNTING SYSTEM 2-11
Page
C COMPONENT PARTS .......................................................................................2
1. Engine Mounting .........................................................................................2
2. Transmission Mounting ...............................................................................3
W SERVICE PROCEDURE ...................................................................................5
1. Engine .........................................................................................................5
2. Transmission .............................................................................................18
2-11 [C100] COMPONENT PARTS
1. Engine Mounting
1. Engine Mounting
B2M1024A
2
COMPONENT PARTS [C2A0] 2-11
2. Transmission Mounting
2. Transmission Mounting
A: MT MODEL
H2M2432A
(1) Pitching stopper (8) Center crossmember Tightening torque: N·m (kg-m, ft-lb)
(2) Spacer (9) Rear plate
T1: 33±5 (3.4±0.5, 24.6±3.6)
(3) Cushion C (10) Front crossmember
T2: 37±10 (3.8±1.0, 27±7)
(4) Front plate
T3: 49±5 (5.0±0.5, 36.2±3.6)
(5) Rear cushion rubber
(6) Rear crossmember T4: 57±10 (5.8±1.0, 42±7)
(7) Cushion D T5: 69±15 (7.0±1.5, 51±11)
T6: 137±20 (14±2, 101±14)
3
2-11 [C2B0] COMPONENT PARTS
2. Transmission Mounting
B: AT MODEL
H2M2437A
4
SERVICE PROCEDURE [W1B0] 2-11
1. Engine
B: REMOVAL
1) Set the vehicle on lift arms.
2) Open front hood fully and support with stay.
3) Release fuel pressure.
(1) Disconnect fuel pump connector.
S2M0893
G2M0261
G6M0095
S2M0895
5
2-11 [W1B0] SERVICE PROCEDURE
1. Engine
(4) Remove ATF cooler pipe from cylinder (2) Collect refrigerant from A/C system.
head. (3) Disconnect A/C flexible hoses from A/C
compressor.
S2M0744
G2M0270
(5) Remove V-belt cover.
8) Remove air intake system.
(1) Disconnect connector from mass air flow
sensor. (Except 2200 cc California spec.
vehicles)
S2M0896
S2M0898
G2M0220
6
SERVICE PROCEDURE [W1B0] 2-11
1. Engine
S2M0900
I AT vehicles
S2M0901
7
2-11 [W1B0] SERVICE PROCEDURE
1. Engine
10) Disconnect connectors, cables and hoses. (1) Disconnect the following connectors.
S2M0887G
(1) Front oxygen sensor connector (4) Alternator connector and termi- (5) A/C compressor connectors
(2) Engine harness connectors nal (With A/C)
(3) Engine ground terminal stay
8
SERVICE PROCEDURE [W1B0] 2-11
1. Engine
B2M1979B
B2M0019F
S2M0201B B2M1291F
9
2-11 [W1B0] SERVICE PROCEDURE
1. Engine
H2M2768A
(1) Clutch release spring (2200 cc (2) Clutch cable (2200 cc MT (3) Accelerator cable
MT vehicle) vehicle)
H2M2434A
B2M1302C
10
SERVICE PROCEDURE [W1B0] 2-11
1. Engine
H2M2768B
(1) Brake booster vacuum hose (2) Heater inlet and outlet hoses
B2M2776A S2M0902A
11
2-11 [W1B0] SERVICE PROCEDURE
1. Engine
(1) Loosen lock bolt and slider bolt, and remove (1) Lift-up the vehicle.
front side V-belt. (2) Disconnect connector from rear oxygen
sensor.
G2M0286
B2M0335
(2) Remove pipe with bracket from intake mani-
fold. (3) Remove nuts which install front exhaust
pipe onto engine.
H4M1074
G2M0290
(3) Remove bolts which install power steering
pump from bracket. (4) Separate center exhaust pipe from rear
exhaust pipe.
S2M0086
G2M0291
(4) Place power steering pump on the right side
wheel apron. (5) Remove bolt which installs center exhaust
pipe on hunger bracket.
S2M0087
B2M0313
12) Remove front exhaust pipe and center
exhaust pipe. (6) Take off front and center exhaust pipes.
12
SERVICE PROCEDURE [W1B0] 2-11
1. Engine
G2M0295
B2M0336
G2M0293
18) Support engine with a lifting device and wire
15) Separate torque converter from drive plate. ropes.
(AT model)
(1) Lower the vehicle.
(2) Remove service hole plug.
(3) Remove bolts which hold torque converter
to drive plate.
(4) Remove other bolts while rotating the
engine using ST.
2200 cc vehicles:
ST 499977300 CRANK PULLEY WRENCH
2500 cc vehicles:
ST 499977100 CRANK PULLEY WRENCH G2M0297
S2M0207
13
2-11 [W1C0] SERVICE PROCEDURE
1. Engine
G2M0298
G2M0301
B2M2794
(2) Apply a small amount of grease to splines
21) Remove engine from vehicle. of mainshaft.
(1) Slightly raise engine. 2) Tighten bolts which hold upper side of transmis-
(2) Raise transmission with garage jack. sion to engine.
(3) Move engine horizontally until mainshaft is
Tightening torque:
withdrawn from clutch cover.
50±4 N·m (5.1±0.4 kg-m, 36.9±2.9 ft-lb)
(4) Slowly move engine away from engine
compartment.
CAUTION:
Be careful not to damage adjacent parts or
body panels with crank pulley, oil pressure
gauge, etc.
B2M2794
G2M0300
14
SERVICE PROCEDURE [W1C0] 2-11
1. Engine
3) Remove lifting device and wire ropes. 6) Install torque converter onto drive plate. (AT
model)
(1) Tighten bolts which hold torque converter to
drive plate.
(2) Tighten other bolts while rotating the engine
by using ST.
2200 cc vehicles:
ST 499977300 CRANK PULLEY WRENCH
2500 cc vehicles:
ST 499977100 CRANK PULLEY WRENCH
CAUTION:
G2M0297
Be careful not to drop bolts into torque con-
4) Remove garage jack. verter housing.
5) Install pitching stopper. Tightening torque:
Tightening torque: 25±2 N·m (2.5±0.2 kg-m, 18.1±1.4 ft-lb)
T1: 57±10 N·m (5.8±1.0 kg-m, 42±7 ft-lb)
T2: 49±5 N·m (5.0±0.5 kg-m, 36.2±3.6 ft-lb)
S2M0207
S2M0086
15
2-11 [W1C0] SERVICE PROCEDURE
1. Engine
(2) Install power steering pipe bracket on right 9) Tighten nuts which install front cushion rubber
side intake manifold, and install spark plug onto crossmember.
codes. Tightening torque:
69±15 N·m (7.0±1.5 kg-m, 51±11 ft-lb)
CAUTION:
Be sure to tighten front cushion rubber mount-
ing bolts in the innermost elliptical hole in the
front crossmember.
H4M1074
G2M0303
16
SERVICE PROCEDURE [W1C0] 2-11
1. Engine
(4) Connect connector to mass air flow sensor. (2) Fit cushions on lower side of radiator, into
holes on body side and install radiator.
B2M2018
G2M0220
(5) Install air intake duct with air cleaner case.
(2200 cc California spec. vehicles) <Ref. to 2-7 (3) Install radiator brackets and tighten bolts.
[W1A0].> Tightening torque:
16) Install A/C flexible hoses. (With A/C) 13.7±1.5 N·m (1.4±0.15 kg-m, 10.1±1.1
<Ref. to 4-7 [W16A0].> ft-lb)
CAUTION:
Use new O-rings.
Tightening torque:
25±7 N·m (2.5±0.7 kg-m, 18.1±5.1 ft-lb)
G2M0218
G2M0270
S2M0897
G2M0221
S2M0893
17
2-11 [W2A0] SERVICE PROCEDURE
2. Transmission
B: REMOVAL
1) Open front hood fully, and support with stay.
2) Disconnect battery ground terminal.
3) Remove air intake duct and chamber. (Except
2200 cc California spec. vehicles) <Ref. to 2-7
[W1A0].> and <Ref. to 2-7 [W18A0].>
4) Install air intake duct with air cleaner case.
S2M0896
(2200 cc California spec. vehicles) <Ref. to 2-7
18) Install battery in the vehicle, and connect [W1A0].>
cables. 5) Remove chamber stay.
19) Fill coolant. I MT vehicles
<Ref. to 2-5 [W1B0].>
Engine coolant capacity:
5.8 (6.1 US qt, 5.1 Imp qt)
20) Check ATF level and correct if necessary. (AT
model)
<Ref. to 3-2 [W1B1].>
21) Charge A/C system with refrigerant.
<Ref. to 4-7 [W700].>
22) Remove front hood stay, and close front hood.
23) Remove the vehicle from lift arms.
S2M0900
I AT vehicles
S2M0901
18
SERVICE PROCEDURE [W2B0] 2-11
2. Transmission
(1) Front oxygen sensor connector 7) Disconnect the following cable. (2200 cc MT
vehicle)
B2M1979
G2M0545
(2) Transmission harness connector (AT
vehicles) 8) Remove starter.
(1) Disconnect connectors and terminal from
starter.
(2) Remove bolt which installs upper side of
starter.
(3) Remove nut which installs lower side of
starter, and remove starter from transmission.
S2M0212A
B2M0337
S2M0907
19
2-11 [W2B0] SERVICE PROCEDURE
2. Transmission
(2) Remove bolts which hold torque converter 13) Set ST.
to drive plate. ST 41099AA020 ENGINE SUPPORT ASSY
NOTE:
Also is available Part No. 927670000.
S2M0207
2200 cc vehicles: 14) Remove bolt which holds right upper side of
ST 499977300 CRANK PULLEY WRENCH transmission to engine.
2500 cc vehicles:
ST 499977100 CRANK PULLEY WRENCH
CAUTION:
Be careful not to drop bolts into torque con-
verter housing.
11) Remove ATF level gauge. (AT vehicles)
CAUTION:
Plug opening to prevent entry of foreign par-
ticles into transmission fluid.
B2M2791
S2M0908A
B2M0335
B2M1179B
20
SERVICE PROCEDURE [W2B0] 2-11
2. Transmission
(3) Remove nuts which install front exhaust (7) Remove rear exhaust pipe.
pipe onto engine. CAUTION:
When removing exhaust pipes, be careful each
exhaust pipe does not drop out.
S2M0205
B2M0055
S2M0206
21
2-11 [W2B0] SERVICE PROCEDURE
2. Transmission
16) Drain ATF to remove ATF drain plug. (AT (3) Remove bolts which hold center bearing
vehicles) onto body.
CAUTION:
Be careful not to drop propeller shaft.
B3M1036A
S2M0909A
S2M0220
S2M0218
G3M0697
22
SERVICE PROCEDURE [W2B0] 2-11
2. Transmission
(2) Remove cable bracket from body. (3) Remove spring pins and separate front
drive shafts from each side of the transmission.
CAUTION:
Discard removing spring pin. Replace with a
new one.
S3M0013A
G2M0323
G2M0326
23
2-11 [W2C0] SERVICE PROCEDURE
2. Transmission
G2M0831
I AT vehicles
H2M1961A
S2M0221
B2M0035
24
SERVICE PROCEDURE [W2C0] 2-11
2. Transmission
3) Install transmission rear crossmember. 6) Tighten bolt which holds right upper side of
I MT vehicles transmission to engine.
Tightening torque: Tightening torque:
T1: 69±15 N·m (7.0±1.5 kg-m, 51±11 ft-lb) 50±4 N·m (5.1±0.4 kg-m, 36.9±2.9 ft-lb)
T2: 137±20 N·m (14±2 kg-m, 101±14 ft-lb)
B2M2791
G2M0832
7) Install torque converter to drive plate. (AT
I AT vehicles vehicles)
Tightening torque: (1) Tighten bolts which hold torque converter to
T1: 37±10 N·m (3.8±1.0 kg-m, 27±7 ft-lb) drive plate.
T2: 69±15 N·m (7.0±1.5 kg-m, 51±11 ft-lb) (2) Tighten other bolts while rotating the engine
by using ST.
2200 cc vehicles:
ST 499977300 CRANK PULLEY WRENCH
2500 cc vehicles:
ST 499977100 CRANK PULLEY WRENCH
CAUTION:
Be careful not to drop bolts into torque con-
verter housing.
Tightening torque:
25±2 N·m (2.5±0.2 kg-m, 18.1±1.4 ft-lb)
S2M0221A
S2M0207
B2M2790
25
2-11 [W2C0] SERVICE PROCEDURE
2. Transmission
8) Install operating cylinder. (2500 cc MT vehicle) 11) Install front drive shafts into transmission.
Tightening torque: (1) Lift-up the vehicle.
37±3 N·m (3.8±0.3 kg-m, 27.5±2.2 ft-lb) (2) Install front drive shaft into transmission.
(3) Drive spring pin into chamfered hole of drive
shaft.
CAUTION:
Always use a new spring pin.
B2M1179B
G2M0325
G2M0313
G2M0324
G2M0302
G2M0323
26
SERVICE PROCEDURE [W2C0] 2-11
2. Transmission
(1) Install gear shift rod onto transmission. (2) Tighten bolts which install propeller shaft
onto companion flange of rear differential.
Tightening torque:
T: 31±8 N·m (3.2±0.8 kg-m, 23.1±5.8 ft-lb)
G3M0697
S2M0219A
G2M0830
S2M0909A
27
2-11 [W2C0] SERVICE PROCEDURE
2. Transmission
(2) Install rear exhaust pipe to muffler. (5) Install center exhaust pipe to rear exhaust
Tightening torque: pipe.
48±9 N·m (4.9±0.9 kg-m, 35.4±6.5 ft-lb) Tightening torque:
18±5 N·m (1.8±0.5 kg-m, 13.0±3.6 ft-lb)
S2M0157
B2M0055
(3) Install hanger bracket on right side of trans-
mission. (6) Tighten bolt which installs center exhaust
pipe to hanger bracket.
Tightening torque:
30±5 N·m (3.1±0.5 kg-m, 22.4±3.6 ft-lb)
B2M0032
S2M0205
B2M0335
28
SERVICE PROCEDURE [W2C0] 2-11
2. Transmission
18) Install ATF level gauge. (AT vehicles) (5) Neutral position and back-up light switch
connector (MT vehicles)
S2M0908A
B2M0337
19) Connect the following connectors.
(1) Transmission harness connectors 20) Install starter.
(1) Install starter onto transmission case, and
connect connectors and terminals.
(2) Tighten bolt and nut which install starter
onto transmission.
Tightening torque:
50±4 N·m (5.1±0.4 kg-m, 36.9±2.9 ft-lb)
B2M0019
G2M0309
B2M1979
S2M0907
29
2-11 [W2C0] SERVICE PROCEDURE
2. Transmission
21) Install chamber stay. 22) Install air intake duct and chamber. (Except
I MT vehicles 2200 cc California spec. vehicles) <Ref. to 2-7
[W1A0].> and <Ref. to 2-7 [W18A0].>
23) Install air intake duct with air cleaner case.
(2200 cc California spec. vehicles) <Ref. to 2-7
[W1A0].>
24) Connect battery ground cable.
25) Fill ATF and differential gear oil. (AT vehicles)
<Ref. to 3-2 [S1A0].>
26) Check selector lever operation. (AT vehicles)
<Ref. to 3-2 [T2C0].>
27) Take off vehicle from lift arms.
S2M0900 28) Check the vehicle on road tester. (AT vehicles)
<Ref. to 3-2 [W6A0].>
I AT vehicles
S2M0901
30
MANUAL TRANSMISSION AND
DIFFERENTIAL 3-1
Page
S SPECIFICATIONS AND SERVICE DATA..........................................................2
1. Manual Transmission and Differential.........................................................2
2. Transmission Gear Oil ................................................................................2
3. Transmission Case Assembly .....................................................................2
4. Drive Pinion Assembly ................................................................................3
5. Reverse Idler Gear......................................................................................3
6. Shifter Fork and Rod...................................................................................4
7. Transfer Case..............................................................................................4
8. Extension Assembly ....................................................................................5
9. Front Differential..........................................................................................5
C COMPONENT PARTS .......................................................................................6
1. Transmission Case......................................................................................6
2. Drive Pinion Assembly ................................................................................7
3. Main Shaft Assembly...................................................................................9
4. Shifter Fork and Shifter Rod .....................................................................11
5. Transfer Case and Extension ...................................................................12
6. Front Differential........................................................................................13
W SERVICE PROCEDURE .................................................................................14
1. General......................................................................................................14
2. Transmission Case....................................................................................16
3. Drive Pinion Assembly ..............................................................................30
4. Main Shaft Assembly.................................................................................38
5. Transfer Case and Extension ...................................................................44
6. Front Differential........................................................................................51
7. Center Differential .....................................................................................54
K DIAGNOSTICS.................................................................................................55
1. Manual Transmission ................................................................................55
2. Differential .................................................................................................55
3-1 [S100] SPECIFICATIONS AND SERVICE DATA
1. Manual Transmission and Differential
2
SPECIFICATIONS AND SERVICE DATA [S500] 3-1
5. Reverse Idler Gear
3
3-1 [S600] SPECIFICATIONS AND SERVICE DATA
6. Shifter Fork and Rod
4
SPECIFICATIONS AND SERVICE DATA [S900] 3-1
9. Front Differential
5
3-1 [C100] COMPONENT PARTS
1. Transmission Case
1. Transmission Case
B3M1356A
6
COMPONENT PARTS [C2A0] 3-1
2. Drive Pinion Assembly
H3M1778A
(1) Drive pinion shaft (14) 1st driven gear (27) Lock nut
(2) Roller bearing (15) Baulk ring (28) Washer
(3) Washer (16) 1st-2nd synchronizer hub (29) Thrust bearing
(4) Thrust bearing (17) Insert key (30) Differential bevel gear sleeve
(5) Needle bearing (18) Reverse driven gear (31) Washer
(6) Driven shaft (19) Baulk ring (32) Lock washer
(7) Key (20) 2nd driven gear (33) Lock nut
(8) Woodruff key (21) 2nd driven gear bush
(9) Drive pinion collar (22) 3rd-4th driven gear Tightening torque: N·m (kg-m, ft-lb)
(10) Needle bearing (23) Driven pinion shim T1: 29±3 (3.0±0.3, 21.7±2.2)
(11) Snap ring (Outer) (24) Roller bearing T2: 118±8 (12.0±0.8, 86.8±5.8)
(12) Washer (25) 5th driven gear T3: 265±10 (27±1, 195±7)
(13) Sub gear (26) Lock washer
7
3-1 [C2B0] COMPONENT PARTS
2. Drive Pinion Assembly
B: 2500 cc MODEL
S3M0423A
(1) Drive pinion shaft (15) Baulk ring (29) Lock nut
(2) Roller bearing (16) 1st-2nd synchronizer hub (30) Washer
(3) Washer (17) Insert key (31) Thrust bearing
(4) Thrust bearing (18) Reverse driven gear (32) Differential bevel gear sleeve
(5) Needle bearing (19) Outer baulk ring (33) Washer
(6) Driven shaft (20) Synchro cone (34) Lock washer
(7) Key (21) Inner baulk ring (35) Lock nut
(8) Woodruff key (22) 2nd driven gear
(9) Drive pinion collar (23) 2nd driven gear bush Tightening torque: N·m (kg-m, ft-lb)
(10) Needle bearing (24) 3rd-4th driven gear T1: 29±3 (3.0±0.3, 21.7±2.2)
(11) Snap ring (Outer) (25) Driven pinion shim T2: 118±8 (12.0±0.8, 86.8±5.8)
(12) Washer (26) Roller bearing T3: 265±10 (27±1, 195±7)
(13) Sub gear (27) 5th driven gear
(14) 1st driven gear (28) Lock washer
8
COMPONENT PARTS [C3A0] 3-1
3. Main Shaft Assembly
H3M1776A
(1) Oil seal (12) 4th needle bearing race (23) Lock washer
(2) Needle bearing (13) Needle bearing (24) Lock nut
(3) Transmission main shaft (14) 4th gear thrust washer (25) Straight pin
(4) Needle bearing (15) Ball bearing (26) Reverse idler gear shaft
(5) 3rd drive gear (16) Needle bearing (27) Reverse idler gear
(6) Baulk ring (17) 5th drive gear (28) Washer
(7) Coupling sleeve (3rd-4th) (18) Baulk ring (5th)
(8) Synchronizer hub (3rd-4th) (19) Shifting insert key (5th-Rev) Tightening torque: N·m (kg-m, ft-lb)
(9) Shifting insert key (3rd-4th) (20) Synchronizer hub (5th-Rev) T: 118±6 (12.0±0.6, 86.8±4.3)
(10) Baulk ring (4th) (21) Coupling sleeve (5th-Rev)
(11) 4th drive gear (22) Insert stopper plate
9
3-1 [C3B0] COMPONENT PARTS
3. Main Shaft Assembly
B: 2500 cc MODEL
B3M1357A
10
COMPONENT PARTS [C400] 3-1
4. Shifter Fork and Shifter Rod
S3M0427A
11
3-1 [C500] COMPONENT PARTS
5. Transfer Case and Extension
B3M1358A
12
COMPONENT PARTS [C600] 3-1
6. Front Differential
6. Front Differential
B3M0521A
(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 (kg-m, ft-lb)
(4) Straight pin (11) Oil seal T1: 25±5 (2.5±0.5, 18.1±3.6)
(5) Washer (12) Differential side retainer T2: 62±5 (6.3±0.5, 45.6±3.6)
(6) Differential bevel gear (13) O-ring
(7) Differential bevel pinion (14) Axle drive shaft
13
3-1 [W1A0] SERVICE PROCEDURE
1. General
1. General B: INSPECTION
A: PRECAUTIONS Disassembled parts should be washed clean first
and then inspected carefully.
1) The following job should be followed before dis- 1) Bearings
assembly: Replace bearings in the following cases:
(1) Clean oil, grease, dirt and dust from trans- I Bearings whose balls, outer races and inner
mission. races are broken or rusty.
(2) Remove drain plug to drain oil. After I Worn bearings
draining, retighten it as before. I Bearings that fail to turn smoothly or make
CAUTION: abnormal noise when turned after gear oil lubrica-
Replace gasket with a new one. tion.
I The ball bearing on the rear side of the drive
Tightening torque: pinion shaft should be checked for smooth rotation
44±3 N·m (4.5±0.3 kg-m, 32.5±2.2 ft-lb) before the drive pinion assembly is disassembled.
In this case, because a preload is working on the
bearing, its rotation feels like it is slightly dragging
unlike the other bearings.
B3M0037C
14
SERVICE PROCEDURE [W1B0] 3-1
1. General
I If the gap between the end faces of the ring and 9) Differential gear
the gear splined part is excessively small when the Repair or replace the differential gear in the follow-
ring is pressed against the cone. ing cases:
I The hypoid drive gear and drive pinion shaft
Clearance (A): tooth surface are damaged, excessively worn, or
0.5 — 1.0 mm (0.020 — 0.040 in) seized.
I The roller bearing on the drive pinion shaft has
a worn or damaged roller path.
I There is damage, wear, or seizure of the differ-
ential bevel pinion, differential bevel gear, washer,
pinion shaft, and straight pin.
I The differential case has worn or damaged slid-
ing surfaces.
S3M0188A
S3M0189A
B3M0558B
6) Oil seal
Replace the oil seal if the lip is deformed, (A) Drive pinion shaft
hardened, damaged, worn, or defective in any way. (B) Hypoid driven gear
7) O-ring (C) Pinion shaft
Replace the O-ring if the sealing face is deformed, (D) Straight pin
hardened, damaged, worn, or defective in any way. (E) Washer
8) Gearshift mechanism (F) Differential bevel gear
Repair or replace the gearshift mechanism if (G) Differential bevel pinion
excessively worn, bent, or defective in any way. (H) Snap ring
(I) Roller bearing
(J) Differential case
15
3-1 [W2A1] SERVICE PROCEDURE
2. Transmission Case
2. Transmission Case
A: DISASSEMBLY
1. SEPARATION OF TRANSMISSION
B3M0614G
(1) Operating cylinder (2500 cc (4) Release bearing (8) Transmission case
model) (5) Release lever sealing (9) Drive pinion ASSY
(2) Release lever (2200 cc model) (6) Bolt (10) Main shaft ASSY
(3) Release lever (2500 cc model) (7) Main shaft rear plate (11) Front differential
1) Remove clutch release lever. <Ref. to 2-10 3) Remove bearing mounting bolts.
[W3A0].>
2) Remove transfer case assembly. <Ref. to 3-1
[W5A0].>
S3M0099
B3M0336I
16
SERVICE PROCEDURE [W2A1] 3-1
2. Transmission Case
4) Remove main shaft rear plate. 7) Remove drive pinion shaft assembly from left
side transmission case.
NOTE:
Use a hammer handle, etc. to remove if too tight.
S3M0100B
B3M1405A
G3M0557
B3M1359
17
3-1 [W2A2] SERVICE PROCEDURE
2. Transmission Case
2. TRANSMISSION CASE
S3M0432A
(1) Straight pin (7) 3rd-4th fork rod (13) Reverse idler gear
(2) 5th shifter fork (8) 3rd-4th shifter fork (14) Washer
(3) Checking ball plug (9) 1st-2nd fork rod (15) Snap ring
(4) Gasket (10) 1st-2nd shifter fork (16) Reverse fork rod arm
(5) Checking ball spring (11) Straight pin (17) Reverse fork rod
(6) Ball (12) Reverse idler gear shaft (18) Reverse shifter lever
B3M0333I
18
SERVICE PROCEDURE [W2A2] 3-1
2. Transmission Case
3) Drive out straight pin, and pull out 3-4 fork rod 6) Remove outer snap ring, and pull out reverse
and shifter fork. shifter rod arm from reverse fork rod. Then take out
NOTE: ball, spring and interlock plunger from rod.
When removing rod, keep other rods in neutral. And then remove rod.
Also, when pulling out straight pin, remove it NOTE:
toward inside of case so that it may not hit against When pulling out reverse shifter rod arm, be care-
case. ful not to let ball pop out of arm.
7) Remove reverse shifter lever.
8) Remove differential side retainers using ST.
ST 499787000 WRENCH ASSY
B3M0523C
4) Drive out straight pin, and pull out 1-2 fork rod 9) Remove outer snap ring and pull out speedom-
and shifter fork. eter driven gear. Next, remove vehicle speed sen-
5) Pull out straight pin, and remove idler gear sor 2, oil seal, speedometer shaft and washer.
shaft, reverse idler gear and washer.
B3M0525C
B3M0524C
(A) Outer snap ring
(A) Straight pin (B) Speedometer driven gear
(B) Idler gear shaft
(C) Idler gear
(D) Washer
19
3-1 [W2B1] SERVICE PROCEDURE
2. Transmission Case
B: ASSEMBLY
1. TRANSMISSION CASE
S3M0432B
(1) Reverse shifter lever (9) Checking ball spring (17) 3rd-4th shifter fork
(2) Reverse idler gear (10) Washer (18) 5th shifter fork
(3) Reverse idler gear shaft (11) Checking ball plug
(4) Straight pin (12) Washer Tightening torque: N·m (kg-m, ft-lb)
(5) Reverse fork rod arm (13) 1st-2nd fork rod T: 19.6±0.1 (2.00±0.015,
(6) Reverse fork rod (14) 1st-2nd shifter fork 14.5±0.1)
(7) Snap ring (15) Straight pin
(8) Ball (16) 3rd-4th fork rod
B3M0062D
20
SERVICE PROCEDURE [W2B1] 3-1
2. Transmission Case
2) Install reverse shifter lever, reverse idler gear 5) Move reverse shifter rod toward REV side.
and reverse idler gear shaft, and secure with Adjust clearance between reverse idler gear and
straight pin. transmission case wall, using reverse shifter lever.
NOTE: Clearance A:
Be sure to install reverse idler shaft from the rear 6.0 — 7.5 mm (0.236 — 0.295 in)
side.
G3M0796
B3M0526C
B3M0063
Washer (20.5 × 26 × t)
Part No. Thickness mm (in)
803020151 0.4 (0.016)
803020152 1.1 (0.043)
803020153 1.5 (0.059)
803020154 1.9 (0.075)
803020155 2.3 (0.091)
7) Install 1-2 fork rod into 1-2 shifter fork via the
hole on the rear of transmission case.
8) Align the holes in rod and fork, and drive
straight pin (6 × 22) into these holes using ST.
ST 398791700 STRAIGHT PIN REMOVER
21
3-1 [W2B1] SERVICE PROCEDURE
2. Transmission Case
B3M0333J
22
SERVICE PROCEDURE [W2B2] 3-1
2. Transmission Case
B3M0614E
(1) Differential ASSY (8) Differential side retainer (15) Operating cylinder (2500 cc
(2) Drive pinion shim (9) O-ring model)
(3) Drive pinion ASSY (10) Oil seal
(4) Main shaft ASSY (11) Retainer lock plate Tightening torque: N·m (kg-m, ft-lb)
(5) Main shaft rear plate (12) Release lever (2200 cc model) T1: 25 (2.5, 18)
(6) Transmission case (LH) (13) Release lever (2500 cc model) T2: 29±3 (3.0±0.3, 21.7±2.2)
(7) Transmission case (RH) (14) Release bearing
1) Alignment marks/numbers on hypoid gear set 2) Place drive pinion shaft assembly on right hand
The upper number on driven pinion is the match transmission main case without shim and tighten
number for combining it with hypoid driven gear. bearing mounting bolts.
The lower number is for shim adjustment. If no
lower number is shown, the value is zero. The
number on hypoid driven gear indicates a number
for combination with drive pinion.
G3M0554
23
3-1 [W2B2] SERVICE PROCEDURE
2. Transmission Case
B3M0528A
24
SERVICE PROCEDURE [W2B2] 3-1
2. Transmission Case
I Be careful not to drop oil seal when installing 1st driven gear to reverse driven gear
right side transmission main case. Clearance (a): 9.5 mm (0.374 in)
I Make sure straight pin is positioned in hole in Reverse driven gear to 2nd driven gear
needle bearing’s outer race. Clearance (b): 9.5 mm (0.374 in)
10) Install drive pinion shaft assembly with shims
selected before into transmission case.
NOTE:
Ensure that the knock pin of the case is fitted into
the hole in the bearing outer race.
S3M0430A
B3M1411A
(A) 3rd-4th
(B) Coupling sleeve
(C) 4th driven gear
25
3-1 [W2B2] SERVICE PROCEDURE
2. Transmission Case
5th driven gear to coupling sleeve 14) Tighten 17 bolts with bracket, clip, etc. as
Clearance (a): 9.3 mm (0.366 in) shown in the figure.
NOTE:
I Insert bolts from the bottom and tighten nuts at
the top.
I Put cases together so that drive pinion shim and
input shaft holder shim are not caught up in
between.
I Confirm that speedometer gear is meshed.
Tightening torque:
8 mm bolt
B3M1403A 25±2 N·m (2.5±0.2 kg-m, 18.1±1.4 ft-lb)
★ 10 mm bolt
(A) 5th driven gear 39±3 N·m (4.0±0.3 kg-m, 28.9±2.2 ft-lb)
(B) Coupling sleeve
B3M0530A S3M0099
26
SERVICE PROCEDURE [W2B2] 3-1
2. Transmission Case
16) Backlash adjustment of hypoid gear and pre- 19) Remove weight and screw in retainer without
load adjustment of roller bearing O-ring on the upper side and stop at the point
where slight resistance is felt.
NOTE:
Support drive pinion assembly with ST. NOTE:
At this point, the backlash between the hypoid gear
ST 498427100 STOPPER and drive pinion shaft is zero.
ST 499787000 WRENCH ASSY
B3M1362A
17) Place the transmission with case left side fac- B3M1360A
ing downward and put ST1 on bearing cup.
18) Screw retainer assembly into left case from 20) Fit lock plate. Loosen the retainer on the lower
side by 1-1/2 notches of lock plate and turn in the
the bottom with ST2. Fit ST3 on the transmission
retainer on the upper side by the same amount in
main shaft. Shift gear into 4th or 5th and turn the
order to obtain the backlash.
shaft several times. Screw in the retainer while
turning ST3 until a slight resistance is felt on ST2. NOTE:
This is the contact point of hypoid gear and drive The notch on the lock plate moves by 1/2 notch if
pinion shaft. Repeat the above sequence several the plate is turned upside down.
times to ensure the contact point. 21) Turn in the retainer on the upper side addition-
ST1 399780104 WEIGHT ally by 1 notch in order to apply preload on taper
ST2 499787000 WRENCH ASSY roller bearing.
ST3 499927100 HANDLE 22) Tighten temporarily both the upper and lower
lock plates and mark both holder and lock plate for
later readjustment.
23) Turn transmission main shaft several times
while tapping around retainer lightly with plastic
hammer.
24) Set ST1 and ST2. Insert the needle through
transmission oil drain plug hole so that the needle
comes in contact with the tooth surface at a right
angle and check the backlash.
ST1 498247001 MAGNET BASE
ST2 498247100 DIAL GAUGE
B3M1361A
ST3 498255400 PLATE
Backlash:
0.13 — 0.18 mm (0.0051 — 0.0071 in)
B3M1363A
27
3-1 [W2B2] SERVICE PROCEDURE
2. Transmission Case
B3M0071
H3M1203A
I Backlash is insufficient.
25) Check tooth contact of hypoid gear as follows: To increase backlash, loosen holder on the lower
Apply a uniform thin coat of red lead on both tooth side (case left side) and turn in the holder on the
surfaces of 3 or 4 teeth of the hypoid gear. Move upper side (case right side) by the same amount.
the hypoid gear back and forth by turning the trans-
mission main shaft until a definite contact pattern
is developed on hypoid gear, and judge whether
face contact is correct. If it is incorrect, make the
following correction.
I Tooth contact is correct.
B3M0072
B3M0070D
(A) Toe
(B) Coast side
(C) Heel
(D) Drive side
B3M0073
28
SERVICE PROCEDURE [W2B2] 3-1
2. Transmission Case
B3M0531A
S3M0014A
29
3-1 [W3A1] SERVICE PROCEDURE
3. Drive Pinion Assembly
G3M0607
B3M0536G
(C) Thrust bearing (25 × 37.5 × 3) 2) Remove 5th driven gear using ST.
(D) Washer No. 2 (25 × 37.5 × 4) ST 499857000 5TH DRIVEN GEAR
(E) Needle bearing (25 × 30 × 20) REMOVER
(F) Drive pinion collar
(G) Needle bearing (30 × 37 × 23)
(H) Thrust bearing (33 × 50 × 3)
G3M0609
30
SERVICE PROCEDURE [W3A3] 3-1
3. Drive Pinion Assembly
4) Remove roller bearing (42 × 74 × 40), 3rd and 1) Straighten lock nut at staked portion. Remove
4th driven gear using ST1 and ST2. the lock nut using ST1 and ST2.
ST1 499757002 SNAP RING PRESS ST1 499987300 SOCKET WRENCH (50)
ST2 899714110 REMOVER ST2 899884100 HOLDER
G3M0610 G3M0608
G3M0609
G3M0611
31
3-1 [W3B0] SERVICE PROCEDURE
3. Drive Pinion Assembly
B3M0537A
32
SERVICE PROCEDURE [W3B2] 3-1
3. Drive Pinion Assembly
CAUTION:
Attach a cloth to the end of driven shaft to pre-
vent damage.
ST1 499277200 INSTALLER
ST2 499587000 INSTALLER
G3M0617
G3M0618
NOTE:
I Stake lock nut at two points.
I Using spring balancer, check that starting load
of roller bearing is 1.7 to 30.6 N (0.17 to 3.12 kg,
0.37 to 6.88 lb).
G3M0615
B3M0079C
G3M0616
33
3-1 [W3B3] SERVICE PROCEDURE
3. Drive Pinion Assembly
3. DRIVEN GEAR ASSEMBLY (2500 cc 4) Install 2nd driven gear, inner baulk ring, syn-
MODEL) chro cone, outer baulk ring and insert onto driven
shaft.
Assemble a driven shaft and 1st driven gear that
select for adjustment the proper radial clearance.
Driven shaft 1st driven gear
Diameter A
Part No. Part No.
mm (in)
49.959 — 49.966
32229AA150 (1.9669 — 32231AA730
1.9672)
49.967 — 49.975
32229AA140 (1.9672 — 32231AA720
1.9675) S3M0445A
G3M0616
B3M0078D
34
SERVICE PROCEDURE [W3B4] 3-1
3. Drive Pinion Assembly
G3M0617
B3M0081D
G3M0618
(A) Roller bearing
NOTE: (B) Knock pin hole
I Stake lock nut at two points.
I Using spring balancer, check that starting load 2) Install thrust bearing (33 × 50 × 3) and needle
of roller bearing is 1.7 to 30.6 N (0.17 to 3.12 kg, bearing (30 × 37 × 23). Install driven shaft assem-
0.37 to 6.88 lb). bly.
B3M0082D
B3M0079D
35
3-1 [W3C1] SERVICE PROCEDURE
3. Drive Pinion Assembly
B3M0083D
B3M0538A
G3M0626
36
SERVICE PROCEDURE [W3C1] 3-1
3. Drive Pinion Assembly
3) After removing ST2, measure starting torque 5) If specified starting torque range cannot be
using torque driver. obtained when a No. 1 adjusting washer is used,
ST1 899884100 HOLDER then select a suitable No. 2 adjusting washer from
ST3 899988608 SOCKET WRENCH (27) those listed in the following table. Repeat steps 1)
through 4) to adjust starting torque.
Starting torque:
54±25 N·m (5.5±2.5 kg-m, 40±18 ft-lb)
B3M0536I
37
3-1 [W4A1] SERVICE PROCEDURE
4. Main Shaft Assembly
4. Main Shaft Assembly 4) Using ST1 and ST2, remove the rest of parts.
NOTE:
A: DISASSEMBLY Replace sleeve and hub with new ones. Do not
1. 2200 cc MODEL attempt to disassemble because they must engage
at a specified point. If they should be
1) Put vinyl tape around main shaft splines to pro-
disassembled, marking engagement point on
tect oil seal from damage. Then pull out oil seal
splines beforehand.
and needle bearing by hand.
2) Remove lock nut from transmission main shaft ST1 899864100 REMOVER
assembly. ST2 899714110 REMOVER
NOTE:
Remove caulking before taking off lock nut.
ST1 498937000 TRANSMISSION HOLDER
ST2 499987003 SOCKET WRENCH (35)
B3M0087A
B3M0834A
2. 2500 cc MODEL
1) Put vinyl tape around main shaft splines to pro-
tect oil seal from damage. Then pull out oil seal
and needle bearing by hand.
2) Remove lock nut from transmission main shaft
assembly.
B3M1364A
NOTE:
(A) Insert stopper plate Remove caulking before taking off lock nut.
(B) Sleeve and hub assembly No. 2 ST1 498937000 TRANSMISSION HOLDER
(C) Baulk ring ST2 499987003 SOCKET WRENCH (35)
(D) 5th drive gear
(E) Needle bearing (32 × 36 × 25.7)
B3M0439A
38
SERVICE PROCEDURE [W4A2] 3-1
4. Main Shaft Assembly
3) Remove 5th-Rev sleeve and hub assembly, 5) Using ST1, ST2 and a press, remove ball
baulk ring, 5th drive gear and needle bearing (32 bearing, synchro cone and baulk ring (Rev).
× 36 × 25.7). NOTE:
I Replace sleeve and hub with new ones. Do not
attempt to disassemble because they must engage
at a specified point. If they should be
disassembled, mark engagement point on splines
beforehand.
I Do not reuse ball bearing.
ST1 499757002 SNAP RING PRESS
ST2 498077400 SYNCHRO CONE
REMOVER
B3M0437B
B3M1365A
B3M0435B
39
3-1 [W4B0] SERVICE PROCEDURE
4. Main Shaft Assembly
6) Using ST1 and ST2, remove the rest of parts. 1. 2200 cc MODEL
NOTE: 1) Assemble sleeve and hub assembly for 3rd-4th
Replace sleeve and hub with new ones. Do not and, 5th synchronizing.
attempt to disassemble because they must engage
NOTE:
at a specified point. If they should be
Position open ends of spring 120° apart.
disassembled, marking engagement point on
splines beforehand.
ST1 899864100 REMOVER
ST2 899714110 REMOVER
B3M1366A
B3M0543C
40
SERVICE PROCEDURE [W4B1] 3-1
4. Main Shaft Assembly
4) Install baulk ring, needle bearing (32 × 30 × 7) Install the following parts to the rear section of
25.7), 4th drive gear and 4th gear thrust washer to transmission main shaft.
transmission main shaft. NOTE:
I Align groove in baulk ring with shifting insert.
I Be sure to fit pawl of insert stopper plate into 4
mm (0.16 in) dia. hole in the boss section of syn-
chronizer hub.
S3M0045A
(A) Groove
(B) 4th gear side
B3M0091D
41
3-1 [W4B2] SERVICE PROCEDURE
4. Main Shaft Assembly
B3M0543C
B3M1366A
B3M0837A
42
SERVICE PROCEDURE [W4B2] 3-1
4. Main Shaft Assembly
6) Using ST1 and ST2, install the 5th gear thrust 9) Install synchro cone stopper and snap ring to
washer and 5th needle bearing race onto the rear 5th-Rev sleeve and hub assembly.
section of transmission main shaft.
NOTE:
Face thrust washer in the correct direction.
ST1 899714110 REMOVER
ST2 499877000 RACE 4-5 INSTALLER
B3M0435B
B3M1371A
B3M1370A
11) Tighten lock nuts to the specified torque using
ST1 and ST2.
(A) Baulk ring NOTE:
(B) Synchro cone Secure lock nuts in two places after tightening.
(C) Ball bearing
ST1 499987000 SOCKET WRENCH
ST2 498937000 TRANSMISSION HOLDER
Tightening torque:
18±6 N·m (12.0±0.6 kg-m, 86.8±4.3 ft-lb)
43
3-1 [W5A0] SERVICE PROCEDURE
5. Transfer Case and Extension
5. Transfer Case and Extension 2) Remove transfer driven gear and center differ-
ential as a set.
A: REMOVAL
1) Remove back-up light switch and neutral
switch.
B3M1375A
B3M1376
B3M1373
B: DISASSEMBLY
1. SEPARATION OF TRANSFER CASE
AND EXTENSION ASSEMBLY
1) Separate transfer case and extension assem-
bly.
B3M1377
B3M1374A
B3M1378
44
SERVICE PROCEDURE [W5B4] 3-1
5. Transfer Case and Extension
B3M1380
B3M1383A
B3M1381
B3M1384A
45
3-1 [W5B5] SERVICE PROCEDURE
5. Transfer Case and Extension
B3M1385A
B3M1386A
46
SERVICE PROCEDURE [W5C2] 3-1
5. Transfer Case and Extension
B3M1387A
B3M1388A
2) Using ST, install oil seal to extension case. (A) Reverse check sleeve
CAUTION: (B) Return spring (1st-2nd)
Use new oil seal. (C) Return spring cap
(D) Reverse accent shaft
ST 498057300 INSTALLER (E) Return spring (5th-Rev)
3) Install shift bracket to extension case. (F) Reverse check cam
Tightening torque: (G) Reverse check spring
25±2 N·m (2.5±0.2 kg-m, 18.1±1.4 ft-lb)
2) Hook the bent section of reverse check spring
over reverse check plate.
3) Rotate cam so that the protrusion of reverse
check cam is at the opening in plate.
4) With cam held in that position, install plate onto
reverse check sleeve and hold with snap ring.
5) Position O-ring in groove in sleeve.
CAUTION:
I Make sure the cutout section of reverse
accent shaft is aligned with the opening in
B3M1381 reverse check sleeve.
I Spin cam by hand for smooth rotation.
4) Install transfer drive gear to extension case.
B3M1380
47
3-1 [W5C3] SERVICE PROCEDURE
5. Transfer Case and Extension
I Move cam and shaft all the way toward plate 2) Install reverse check sleeve assembly to trans-
and release. fer case.
If cam does not return properly, replace reverse Tightening torque:
check spring; if shaft does not, check for 6.4±0.5 N·m (0.65±0.05 kg-m, 4.7±0.4 ft-lb)
scratches on the inner surface of sleeve. If
sleeve is in good order, replace spring.
B3M1377
B3M1376
B3M1378
B3M1389A
48
SERVICE PROCEDURE [W5C5] 3-1
5. Transfer Case and Extension
2) Install ball bearing to transfer driven gear. 4) Calculate space “Y” using the following equa-
tion: Y = X − W + 0.24 mm (0.0094 in) [Thickness
of gasket]
5) Select suitable washer in the following table:
Standard clearance between thrust washer
and ball bearing:
0.05 — 0.30 mm (0.0020 — 0.0118 in)
Thrust washer
Space “Y” mm (in) Thickness
Part No.
mm (in)
B3M1390A 0.55 — 0.79
803052021 0.50 (0.0197)
(0.0217 — 0.0311)
5. COMBINATION OF TRANSFER CASE 0.80 — 1.04
803052022 0.75 (0.0295)
(0.0315 — 0.0409)
AND EXTENSION ASSEMBLY
1.05 — 1.30
803052023 1.00 (0.0394)
1) Install center differential and transfer driven (0.0413 — 0.0512)
gear into transfer case.
6) Fit thrust washers on transfer drive shaft.
7) Measure depth “T” between extension case
and transfer drive gear.
ST 398643600 GAUGE
B3M1375A
B3M1392A
B3M1395A
49
3-1 [W5D0] SERVICE PROCEDURE
5. Transfer Case and Extension
E: ADJUSTMENT
1. NEUTRAL POSITION ADJUSTMENT
1) Shift gear into 3rd gear position.
2) Shifter arm turns lightly toward the 1st/2nd gear
side but heavily toward the reverse gear side
because of the function of the return spring, until
arm contacts the stopper.
3) Make adjustment so that the heavy stroke
B3M1374A (reverse side) is a little more than the light stroke
(1st/2nd side).
4) To adjust, remove bolts holding reverse check
D: INSTALLATION sleeve assembly to the case, move sleeve assem-
1) Install shifter arm to transfer case. bly outward, and place adjustment shim (0 to 1 ea.)
between sleeve assembly and case to adjust the
clearance.
CAUTION:
Be careful not to break O-ring when placing
shim(s).
NOTE:
I When shim is removed, the neutral position will
move closer to reverse; when shim is added, the
neutral position will move closer to 1st gear.
I If shims alone cannot adjust the clearance,
B3M1396
replace reverse accent shaft and re-adjust.
2) Hang the shifter arm on the 3rd-4th fork rod.
Adjustment shim
Part No. Thickness mm (in)
32190AA000 0.15 (0.0059)
32190AA010 0.30 (0.0118)
50
SERVICE PROCEDURE [W6A0] 3-1
6. Front Differential
B3M0054B
B3M1372A
G3M0667
51
3-1 [W6B0] SERVICE PROCEDURE
6. Front Differential
4) Pull out pinion shaft, and remove differential 2) Measure backlash between bevel gear and pin-
bevel pinion and gear and washer. ion. If it is not within specifications, install a suitable
washer to adjust it.
NOTE:
Be sure the pinion gear tooth contacts adjacent
gear teeth during measurement.
ST1 498247001 MAGNET BASE
ST2 498247100 DIAL GAUGE
Standard backlash:
0.13 — 0.18 mm (0.0051 — 0.0071 in)
B3M0552B
G3M0670
Washer (38.1 × 50 × t)
Part No. Thickness mm (in)
0.925 — 0.95
803038021
(0.0364 — 0.0374)
0.975 — 1.000
803038022
(0.0384 — 0.0394)
1.025 — 1.050
G3M0668 803038023
(0.0404 — 0.0413)
B3M0099C B3M0609B
52
SERVICE PROCEDURE [W6B0] 3-1
6. Front Differential
4) Install roller bearing (40 × 80 × 19.75) to differ- 7) If it is not within specifications, replace snap
ential case. ring with a suitable one.
NOTE: Snap ring (Outer-28)
Be careful because roller bearing outer races are Part No. Thickness mm (in)
used as a set. 805028011 1.05 (0.0413)
ST1 499277100 BUSH 1-2 INSTALLER 805028012 1.20 (0.0472)
ST2 398497701 ADAPTER
G3M0671
B3M0554B
B3M0100
53
3-1 [W7A0] SERVICE PROCEDURE
7. Center Differential
B3M1399A
B3M1398A
54
DIAGNOSTICS [K200] 3-1
2. Differential
1. Manual Transmission
Symptom and possible cause Remedy
1. Gears are difficult to intermesh.
The cause for difficulty in shifting gears can be classified into two kinds: one is malfunction of the gear shift system and the
other is malfunction of the transmission. However, if the operation is heavy and engagement of the gears is difficult, defective
clutch disengagement may also be responsible. Check whether the clutch is correctly functioning, before checking the gear
shift system and transmission.
(a) Worn, damaged or burred chamfer of internal spline of Replace.
sleeve and reverse driven gear
(b) Worn, damaged or burred chamfer of spline of gears Replace.
(c) Worn or scratched bushings Replace.
(d) Incorrect contact between synchronizer ring and gear cone Correct or replace.
or wear
2. Gear slips out.
(1) Gear slips out when coasting on rough road.
(2) Gear slips out during acceleration.
(a) Defective pitching stopper adjustment Adjust.
(b) Loose engine mounting bolts Tighten or replace.
(c) Worn fork shifter, broken shifter fork rail spring Replace.
(d) Worn or damaged ball bearing Replace.
(e) Excessive clearance between splines of synchronizer hub Replace.
and synchronizer sleeve
(f) Worn tooth step of synchronizer hub (responsible for slip- Replace.
out of 3rd gear)
(g) Worn 1st driven gear, needle bearing and race Replace.
(h) Worn 2nd driven gear, needle bearing and race Replace.
(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 transmission.
If an unusual noise is heard when the vehicle is parked with its engine idling and if the noise ceases when the clutch is
disengaged, it may be considered that the noise comes from the transmission.
(a) Insufficient or improper lubrication Lubricate or replace with specified oil.
(b) Worn or damaged gears and bearings Replace.
NOTE: If the trouble is only wear of the tooth surfaces, merely
a high roaring noise will occur at high speeds, but if any part
is broken, rhythmical knocking sound will be heard even at
low speeds.
2. Differential
Symptom and possible cause Remedy
4. Broken differential (case, gear, bearing, etc.)
Abnormal noise will develop and finally it will become impossible to continue to run due to broken pieces obstructing the gear
revolution.
(a) Insufficient or improper oil Disassemble differential and replace broken components and
at the same time check other components for any trouble, and
replace if necessary.
(b) Use of vehicle under severe conditions such as excessive Readjust bearing preload and backlash and face contact of
load and improper use of clutch gears.
(c) Improper adjustment of taper roller bearing Adjust.
(d) Improper adjustment of drive pinion and hypoid driven Adjust.
gear
(e) Excessive backlash due to worn differential side gear, Add recommended oil to specified level. Do not use vehicle
washer or differential pinion under severe operating conditions.
55
3-1 [K200] DIAGNOSTICS
2. Differential
56
AUTOMATIC TRANSMISSION
AND DIFFERENTIAL 3-2
Page
S SPECIFICATIONS AND SERVICE DATA..........................................................2
1. Automatic Transmission and Differential ...................................................2
C COMPONENT PARTS .....................................................................................15
1. Torque Converter Clutch and Case ..........................................................15
2. Oil Pump....................................................................................................16
3. Transmission Case and Control Device....................................................18
4. Control Valve and Harness Routing..........................................................20
5. High Clutch and Reverse Clutch...............................................................21
6. Planetary Gear and 2-4 Brake ..................................................................22
7. Low Clutch and Low & Reverse Brake.....................................................23
8. Reduction Gear .........................................................................................24
9. Differential Case........................................................................................25
10. Transfer and Extension .............................................................................26
W SERVICE PROCEDURE .................................................................................27
1. General......................................................................................................27
2. Inhibitor Switch ..........................................................................................30
3. Sensor (in transmission) ...........................................................................33
4. Shift Solenoid, Duty Solenoid and Valve ..................................................34
5. Duty Solenoid C and Transfer Valve Body ...............................................37
6. Road Test ..................................................................................................42
7. Stall Test....................................................................................................43
8. Time Lag Test............................................................................................45
9. Line Pressure Test ....................................................................................45
10. Transfer Clutch Pressure Test...................................................................47
11. Overall Transmission.................................................................................48
12. Reduction Drive Gear Assembly ...............................................................76
13. Reduction Driven Gear..............................................................................77
14. Control Valve Body....................................................................................78
15. Oil Pump Assembly ...................................................................................82
16. Drive Pinion Shaft .....................................................................................84
17. High Clutch and Reverse Clutch...............................................................87
18. Low Clutch Drum and Planetary Gear......................................................93
19. Differential Case Assembly .....................................................................100
20. Transfer Clutch ........................................................................................101
21. Transfer Valve Body ................................................................................104
22. Transmission Control Module..................................................................105
23. Dropping Resistor....................................................................................106
3-2 [S1A0] SPECIFICATIONS AND SERVICE DATA
1. Automatic Transmission and Differential
2
SPECIFICATIONS AND SERVICE DATA [S1A0] 3-2
1. Automatic Transmission and Differential
Transmission in
neutral, output mem-
P (Park)
ber immovable, and
engine start possible
Transmission in
R (Reverse)
reverse for backing
Transmission in
N (Neutral) neutral, and engine
start possible
Automatic gear
change
D (Drive)
1st ←→ 2nd ← → 3rd
←
Transmis- Selector position → 4th
sion Automatic gear
change
3 (3rd)
1st ←→ 2nd ← → 3rd
← 4th
2nd gear locked
(Deceleration pos-
2 (2nd)
sible 4th → 3rd →
2nd)
1st gear locked
(Deceleration pos-
Automatic 1 (1st)
sible 4th → 3rd →
transmis- 2nd → 1st)
sion
Control method Hydraulic remote control
Type Prachoid constant-displacement pump
Driving method Driven by engine
Oil pump
Inner rotor 9
Number of teeth
Outer rotor 10
Electronic/hydraulic control [Four forward speed changes by electri-
Type
cal signals of vehicle speed and accelerator (throttle) opening]
Hydraulic Fluid Dexron IIE or Dexron III type Automatic transmission fluid
control
2200 cc 8.4 — 8.7 (8.9 — 9.2 US qt, 7.4 — 7.7 Imp qt)
Fluid capacity
2500 cc 9.3 — 9.6 (9.8 — 10.1 US qt, 8.2 — 8.4 Imp qt)
Lubrica- Lubrication system Forced feed lubrication with oil pump
tion Oil Automatic transmission fluid (above mentioned.)
Cooling Cooling system Liquid-cooled cooler incorporated in radiator
Inhibitor switch 12 poles
Harness
Transmission harness 17 poles
Transfer clutch Hydraulic multi-plate clutch
Plate number of transfer clutch Drive plate & driven plate 5
Control method Electronic, hydraulic type
Transfer
The same Automatic Transmission
Lubricant
Fluid used in automatic transmission.
1st reduction gear ratio 1.000 (53/53)
3
3-2 [S1A0] SPECIFICATIONS AND SERVICE DATA
1. Automatic Transmission and Differential
Final
Lubrication oil
reduction
H3M1235A
Oil capacity Front drive 1.2 (1.3 US qt, 1.1 Imp qt)
ATF cooling system Radiation capacity 4.630 kW (3,981 kcal/h, 15,797 BTU/h)
4
SPECIFICATIONS AND SERVICE DATA [S1A0] 3-2
1. Automatic Transmission and Differential
MEMO:
5
3-2 [S1B0] SPECIFICATIONS AND SERVICE DATA
1. Automatic Transmission and Differential
B: ADJUSTING PARTS
B3M1015A
6
SPECIFICATIONS AND SERVICE DATA [S1B0] 3-2
1. Automatic Transmission and Differential
7
3-2 [S1B0] SPECIFICATIONS AND SERVICE DATA
1. Automatic Transmission and Differential
8
SPECIFICATIONS AND SERVICE DATA [S1B0] 3-2
1. Automatic Transmission and Differential
MEMO:
9
3-2 [S1C0] SPECIFICATIONS AND SERVICE DATA
1. Automatic Transmission and Differential
S3M0220A
10
SPECIFICATIONS AND SERVICE DATA [S1D1] 3-2
1. Automatic Transmission and Differential
D: FLUID PASSAGES
1. TRANSMISSION CASE (FRONT SIDE)
B3M0987A
(1) Low clutch pressure (2) Oil cooler inlet pressure (3) Low & reverse brake pressure
11
3-2 [S1D2] SPECIFICATIONS AND SERVICE DATA
1. Automatic Transmission and Differential
B3M0988A
(1) Oil cooler outlet pressure (3) Oil cooler inlet pressure (5) 2-4 brake pressure
(2) Low & reverse brake pressure (4) Low clutch pressure
B3M0989A
12
SPECIFICATIONS AND SERVICE DATA [S1D5] 3-2
1. Automatic Transmission and Differential
B3M0990A
(1) High clutch pressure (3) Front lubricating hole (5) Reverse clutch pressure
(2) Lock-up release pressure (4) Lock-up apply pressure
B3M0991A
(1) Oil pump outlet pressure (4) High clutch pressure (7) Reverse clutch pressure
(2) Lock-up apply pressure (5) Drain
(3) Lock-up release pressure (6) Air breather
13
3-2 [S1D6] SPECIFICATIONS AND SERVICE DATA
1. Automatic Transmission and Differential
6. TRANSMISSION CASE
B3M0992A
(1) Oil pump inlet port (5) Lock-up release pressure (9) Pilot pressure
(2) Reverse clutch pressure (6) High clutch pressure (10) Low & reverse brake pressure
(3) Oil pump outlet port (7) Oil cooler outlet pressure (11) Low clutch pressure
(4) Lock-up apply pressure (8) Line pressure (12) 2-4 brake pressure
7. EXTENSION CASE
B3M0993A
14
COMPONENT PARTS [C100] 3-2
1. Torque Converter Clutch and Case
B3M0918A
(1) Pitching stopper bracket (9) Oil drain pipe Tightening torque: N·m (kg-m, ft-lb)
(2) O-ring (10) Input shaft
T1: 18±5 (1.8±0.5, 13.0±3.6)
(3) Differential oil level gauge (11) O-ring
T2: 41±3 (4.2±0.3, 30.4±2.2)
(4) Stay (12) Torque converter clutch
T3: 44±3 (4.5±0.3, 32.5±2.2)
(5) Seal pipe (13) Drain plug
(6) Seal ring (14) Gasket
(7) Oil pump shaft (15) Oil seal
(8) Clip (16) Torque converter clutch case
15
3-2 [C200] COMPONENT PARTS
2. Oil Pump
2. Oil Pump
B3M0876A
(1) Oil pump rotor (12) O-ring Tightening torque: N·m (kg-m, ft-lb)
(2) Oil pump cover (13) Test plug
T1: 7±1 (0.7±0.1, 5.1±0.7)
(3) Seal ring (14) Stud bolt
T2: 13±1 (1.3±0.1, 9.4±0.7)
(4) Thrust needle bearing (15) O-ring
T3: 18±5 (1.8±0.5, 13.0±3.6)
(5) Drive pinion shaft (16) O-ring
(6) Roller bearing (17) Oil seal retainer T4: 25±2 (2.5±0.2, 18.1±1.4)
(7) Shim (18) Oil seal T5: 39±3 (4.0±0.3, 28.9±2.2)
(8) Oil pump housing (19) O-ring T6: 41±3 (4.2±0.3, 30.4±2.2)
(9) Nipple (20) Drive pinion collar T7: 121±5 (12.3±0.5, 89.0±3.6)
(10) Air breather hose (21) Lock nut
(11) Gasket
16
COMPONENT PARTS [C200] 3-2
2. Oil Pump
MEMO:
17
3-2 [C300] COMPONENT PARTS
3. Transmission Case and Control Device
B3M0878A
18
COMPONENT PARTS [C300] 3-2
3. Transmission Case and Control Device
(1) Oil level gauge (20) Oil filter stud bolt (39) Nipple
(2) Oil charger pipe (21) Drain plug (40) Air breather hose
(3) O-ring (22) Gasket (41) Transmission case
(4) Transfer valve plate (23) Oil pan (42) Plate ASSY
(5) Transfer valve ASSY (24) Magnet (43) Washer
(6) Transfer clutch seal (25) Stud bolt (Short)
(7) Duty solenoid C (Transfer) (26) Stud bolt (Long) Tightening torque: N·m (kg-m, ft-lb)
(8) Straight pin (27) Parking rod T1: 3.4±0.5 (0.35±0.05, 2.5±0.4)
(9) Return spring (28) Manual plate T2: 4.9±0.5 (0.50±0.05, 3.6±0.4)
(10) Shaft (29) Spring pin T3: 5.9±1.0 (0.60±0.10, 4.3±0.7)
(11) Parking pawl (30) Detention spring T4: 7.8±1.0 (0.80±0.10, 5.8±0.7)
(12) Parking support (31) Ball
T5: 12.7±1.0 (1.30±0.10, 9.4±0.7)
(13) Inlet filter (32) Spring
T6: 13.7±2.0 (1.4±0.2, 10.1±1.4)
(14) Gasket (33) Gasket
T7: 17.7±2.9 (1.80±0.30, 13.0±2.2)
(15) Inlet pipe (34) Outlet pipe
T8: 24.5±2.0 (2.50±0.20, 18.1±1.4)
(16) Union screw (35) Union screw
(17) O-ring (36) Oil seal T9: 24.5±2.9 (2.5±0.3, 18.1±2.2)
(18) Test plug (37) Select lever T10: 34.3±2.9 (3.50±0.30, 25.3±2.2)
(19) Oil filter (38) Inhibitor switch ASSY
19
3-2 [C400] COMPONENT PARTS
4. Control Valve and Harness Routing
B3M0928A
20
COMPONENT PARTS [C500] 3-2
5. High Clutch and Reverse Clutch
S3M0221A
(1) High clutch drum (8) Spring retainer (15) Dish plate
(2) Lip seal (9) Cover (16) Driven plate
(3) Lathe cut seal ring (10) Snap ring (17) Drive plate
(4) Reverse clutch piston (11) Driven plate (18) Retaining plate
(5) Lathe cut seal ring (12) Drive plate (19) Snap ring
(6) Lathe cut seal ring (13) Retaining plate (20) Thrust needle bearing
(7) High clutch piston (14) Snap ring (21) High clutch hub
21
3-2 [C600] COMPONENT PARTS
6. Planetary Gear and 2-4 Brake
B3M1178A
22
COMPONENT PARTS [C700] 3-2
7. Low Clutch and Low & Reverse Brake
B3M1017A
23
3-2 [C800] COMPONENT PARTS
8. Reduction Gear
8. Reduction Gear
S3M0222A
(1) Seal ring (6) Snap ring Tightening torque: N·m (kg-m, ft-lb)
(2) Ball bearing (7) Ball bearing
T: 100±5 (10.2±0.5, 73.8±3.6)
(3) Reduction drive gear (8) Reduction driven gear
(4) Reduction drive shaft (9) Washer
(5) Drive pinion shaft (10) Lock nut
24
COMPONENT PARTS [C900] 3-2
9. Differential Case
9. Differential Case
B3M1019A
25
3-2 [C1000] COMPONENT PARTS
10. Transfer and Extension
H3M1811A
(1) Thrust needle bearing (11) Transfer clutch piston (21) Test plug
(2) Needle bearing (12) Rear drive shaft (22) O-ring
(3) Snap ring (13) Ball bearing (23) Clip
(4) Pressure plate (14) Seal ring
(5) Drive plate (15) Gasket Tightening torque: N·m (kg-m, ft-lb)
(6) Driven plate (16) Transfer clutch pipe T1: 13±1 (1.3±0.1, 9.4±0.7)
(7) Pressure plate (17) Extension case T2: 25±2 (2.5±0.2, 18.1±1.4)
(8) Snap ring (18) Transmission hanger
(9) Transfer piston seal (19) Oil seal
(10) Return spring (20) Dust cover
26
SERVICE PROCEDURE [W1B1] 3-2
1. General
27
3-2 [W1B2] SERVICE PROCEDURE
1. General
range (above the center between upper and lower 3. OIL LEAKAGE
marks). When the transmission is hot, the level
It is difficult to accurately determine the precise
should be above the center of upper and lower
position of a oil leak, since the surrounding area
marks, and when it is cold, the level should be
also becomes wet with oil. The places where oil
found below the center of these two marks.
seals and gaskets are used are as follows:
CAUTION: 1) Jointing portion of the case
I Use care not to exceed the upper limit level. I Transmission case and oil pump housing joint-
I ATF level varies with temperature. Remem- ing portion
ber that the addition of fluid to the upper limit I Torque converter clutch case and oil pump
mark when the transmission is cold will result housing jointing portion
in the overfilling of fluid. I Transmission case and extension case jointing
4) Fluid temperature rising speed portion
I By idling the engine
Time for temperature rise to 60°C (140°F) with
atmospheric temperature of 0°C (32°F): More than
25 minutes
<Reference>
Time for temperature rise to 30°C (86°F) with
atmospheric temperature of 0°C (32°F): Approx. 8
minutes
I By running the vehicle
Time for temperature rise to 60°C (140°F) with
atmospheric temperature of 0°C (32°F): More than B3M1021
B3M1022
G3M0283
28
SERVICE PROCEDURE [W1B3] 3-2
1. General
B3M1023
B3M1026
4) Automatic transmission case
I Transmission case (Defective casting)
I Mating surface of oil pan
I O-ring on the test plugs
I Oil supply pipe connector
I ATF cooler pipe connector and gasket
I Oil pan drain plug
I O-ring on the transmission harness holder
I Oil pump plugs
I ATF breather
I Shift lever oil seal
I O-ring on the vehicle speed sensor 2 (Front)
I O-ring on the turbine revolution sensor
I ATF filter oil seal
B3M1024
29
3-2 [W2A0] SERVICE PROCEDURE
2. Inhibitor Switch
G3M0293
S3M0013A
B3H0016B
30
SERVICE PROCEDURE [W2D0] 3-2
2. Inhibitor Switch
B3M1031A
B3M1028A
B3M1029A
D: INSTALLATION
1) Install inhibitor switch to transmission case.
B3M1030A
B3M1033A
31
3-2 [W2D0] SERVICE PROCEDURE
2. Inhibitor Switch
2) Move range select lever to neutral position. 7) Install front and center exhaust pipe. <Ref. to
3) Using ST, tighten bolts of inhibitor switch. <Ref. 2-9 [W1B0].>
to 3-2 [W2B0].> 8) Connect inhibitor switch connector.
ST 499267300 STOPPER PIN
B3M1028A
B3M1034A
9) Install air intake chamber and duct. (Except
4) Install select cable to range select lever. 2200 cc California spec. vehicles) <Ref. to 2-7
5) Install plate assembly to transmission. [W1A0].>
10) Install air cleaner case and duct. (2200 cc
Tightening torque: California spec. vehicles) <Ref. to 2-7 [W1A0].>
T: 24.5±2.0 N·m (2.50±0.20 kg-m, 18.1±1.4 and <Ref. to 2-7 [W18A0].>
ft-lb)
B3M1030B
B3M1029A
32
SERVICE PROCEDURE [W3A0] 3-2
3. Sensor (in transmission)
3. Sensor (in transmission) 3) Check each sensor, solenoid and ground sys-
tem for short circuits.
A: INSPECTION
1) Remove air intake chamber and duct.
2) Disconnect transmission connector.
S3M0039A
S2M0212A
B3M1035A
(A) Torque converter turbine speed (E) Duty solenoid A (Line pressure) (J) Shift solenoid 2
sensor (F) Duty solenoid B (Lock-up) (K) 2-4 brake timing solenoid
(B) Vehicle speed sensor 2 (Front) (G) Duty solenoid C (Transfer) (L) Low clutch timing solenoid
(C) Vehicle speed sensor 1 (Rear) (H) Duty solenoid D (2-4 brake) (M) Transmission connector
(D) ATF temperature sensor (I) Shift solenoid 1
33
3-2 [W3A1] SERVICE PROCEDURE
4. Shift Solenoid, Duty Solenoid and Valve
B2M2263C
34
SERVICE PROCEDURE [W4B0] 3-2
4. Shift Solenoid, Duty Solenoid and Valve
B3M1039B
B3M1038A
B3M1038B
B3M1039A
35
3-2 [W4B0] SERVICE PROCEDURE
4. Shift Solenoid, Duty Solenoid and Valve
B2M2263C
B3M1040A
S3M0223A
Tightening torque:
4.9±0.5 N·m (0.50±0.05 kg-m, 3.6±0.4 ft-lb)
(3) Tighten the valve body to the specified
torque.
Tightening torque:
8±1 N·m (0.8±0.1 kg-m, 5.8±0.7 ft-lb)
B3M1036A
36
SERVICE PROCEDURE [W5A0] 3-2
5. Duty Solenoid C and Transfer Valve Body
B3M1020A
S2M1000
B2M2320
B3M1042
37
3-2 [W5A0] SERVICE PROCEDURE
5. Duty Solenoid C and Transfer Valve Body
B3M1036A
B3M1043
G3M0305
9) Remove extension and gasket.
6) Remove propeller shaft. (1) Remove select cable nut.
<Ref. to 3-4 [W1B0].>
NOTE:
Before removing propeller shaft, scribe matching
marks on propeller shaft and rear differential cou-
pling.
G3M0308
38
SERVICE PROCEDURE [W5B0] 3-2
5. Duty Solenoid C and Transfer Valve Body
B3M1044
B3M1045A
B: INSTALLATION
1) Install duty solenoid C and transfer valve body.
(1) Install duty solenoid C and transfer valve B3M1043A
body.
4) Install rear crossmember.
Tightening torque: (1) Tighten bolts.
T: 8±1 N·m (0.8±0.1 kg-m, 5.8±0.7 ft-lb)
Tightening torque:
(2) Connect duty solenoid C (transfer) connec- T1: 37±10 N·m (3.8±1.0 kg-m, 27±7 ft-lb)
tor. T2: 69±15 N·m (7.0±1.5 kg-m, 51±11 ft-lb)
B3M1045B
S2M0221B
39
3-2 [W5B0] SERVICE PROCEDURE
5. Duty Solenoid C and Transfer Valve Body
B3M1042A
G3M0782
10) Replenish ATF and check oil level. Check for
6) Install front and center exhaust pipe assembly. leaks.
<Ref. to 2-9 [W1B0].>
B3M1020A
G3M0305
S2M0212A
40
SERVICE PROCEDURE [W5B0] 3-2
5. Duty Solenoid C and Transfer Valve Body
MEMO:
41
3-2 [W6A1] SERVICE PROCEDURE
6. Road Test
G3M0321
42
SERVICE PROCEDURE [W7A2] 3-2
7. Stall Test
G3M0322
43
3-2 [W7A3] SERVICE PROCEDURE
7. Stall Test
stall speed range on the tachometer scale. 9) If stall speed in 2 range is higher than
3) Place the wheel chocks at the front and rear of specifications, low clutch slipping and 2-4 brake
all wheels and engage the parking brake. slipping may occur. To identify it, conduct the same
4) Move the manual linkage to ensure it operates test as above in D range.
properly, and shift the select lever to the 2 range. 10) Perform the stall tests with the select lever in
5) While forcibly depressing the foot brake pedal, the R range.
gradually depress the accelerator pedal until the
engine operates at full throttle. NOTE:
I Do not continue the stall test for MORE THAN
FIVE SECONDS at a time (from closed throttle,
fully open throttle to stall speed reading). Failure to
follow this instruction causes the engine oil and
ATF to deteriorate and the clutch and brake to be
adversely affected.
Be sure to cool down the engine for at least one
minute after each stall test with the select lever set
in the P or N range and with the idle speed lower
than 1,200 rpm.
I If the stall speed is higher than the specified
B3M0286B range, attempt to finish the stall test in as short a
6) When the engine speed is stabilized, read that time as possible, in order to prevent the automatic
speed quickly and release the accelerator pedal. transmission from sustaining damage.
7) Shift the select lever to Neutral, and cool down Stall speed (at sea level):
the engine by idling it for more than one minute. 2200 cc 2,200 — 2,700 rpm
8) Record the stall speed. 2500 cc 2,100 — 2,600 rpm
3. EVALUATION
Stall speed (at sea level) Position Cause
I Throttle valve not fully open
2
Less than specifications I Erroneous engine operation
R
I Torque converter clutch’s one-way clutch slipping
I Low clutch slipping
D
I One-way clutch malfunctioning
I Line pressure too low
R I Reverse clutch slipping
Greater than specifications
I Low & reverse brake slipping
I Line pressure too low
2 I Low clutch slipping
I 2-4 brake slipping
44
SERVICE PROCEDURE [W9A1] 3-2
9. Line Pressure Test
45
3-2 [W9A2] SERVICE PROCEDURE
9. Line Pressure Test
S2M0286A
46
SERVICE PROCEDURE [W10A2] 3-2
10. Transfer Clutch Pressure Test
B3M1047A
47
3-2 [W11A0] SERVICE PROCEDURE
11. Overall Transmission
H3M1250A
B3M1036A
B3M1048A
48
SERVICE PROCEDURE [W11B1] 3-2
11. Overall Transmission
4) Extract the torque converter clutch assembly. 7) Remove harnesses from bracket.
NOTE:
I Extract the torque converter clutch horizontally.
Be careful not to scratch the bushing inside the oil
pump shaft.
I Note that oil pump shaft also comes out.
B3M1054A
B3M1051A
6) Remove the pitching stopper bracket. 9) Remove the oil charger pipe, and remove the
O-ring from the flange face. Attach the O-ring to the
pipe.
B3M0629
B3M1052A
49
3-2 [W11B2] SERVICE PROCEDURE
11. Overall Transmission
10) Remove the oil cooler inlet and outlet pipes. (2) Separation of transmission case and exten-
CAUTION: sion case sections
When removing outlet pipes, be careful not to
lose balls and springs used with retaining
screws.
B3M1057A
B3M1058A
B3M1055A
B3M0954A
B3M1056A
50
SERVICE PROCEDURE [W11B3] 3-2
11. Overall Transmission
(3) Using the ST, extract the reduction drive 3) Remove the parking pawl, return spring and
gear. shaft.
ST 499737100 PULLER SET
B3M1062A
B3M0953A
4) Loosen the taper roller bearing mounting bolts.
2) Remove transfer valve body and duty solenoid
C (Transfer).
(1) Disconnect connector from duty solenoid C
(Transfer).
(2) Remove transfer valve body and duty sole-
noid C (Transfer).
B3M1063
B3M1061A
B3M1064A
51
3-2 [W11B3] SERVICE PROCEDURE
11. Overall Transmission
6) Remove the oil pan. 9) Remove vehicle speed sensor 2 (front) and
NOTE: torque converter turbine speed sensor.
Use a scraper to remove oil pan.
B3M1066A
B3M1067A
B3M1037A B3M1069A
52
SERVICE PROCEDURE [W11B3] 3-2
11. Overall Transmission
13) Take out the high clutch and reverse clutch 16) Pull out leaf spring.
assembly. CAUTION:
CAUTION: Be careful not to bend leaf spring during
Be careful not to lose thrust needle bearing. removal.
NOTE:
Remove it while pressing down on lower leaf
spring.
B3M1070A
14) Take out the high clutch hub and the thrust
bearing.
B3M1073A
B3M1071A
15) Take out the front sun gear and the thrust
bearing. B3M1074A
B3M1072A
B3M1075
53
3-2 [W11B3] SERVICE PROCEDURE
11. Overall Transmission
19) Take out the thrust needle bearing, planetary 23) Separate 2-4 brake piston and piston retainer.
gear assembly and the low clutch assembly.
B3M1080A
B3M1076A
24) Pull out leaf spring.
20) Remove snap ring. CAUTION:
Be careful not to bend leaf spring during
removal.
B3M1077A
B3M1078B
B3M1082
B3M1079A
54
SERVICE PROCEDURE [W11B3] 3-2
11. Overall Transmission
27) Turning the case upside down, take out the 30) Pull off the straight pin of manual lever.
one-way clutch inner race, retainer and wave
spring.
NOTE:
After loosening all socket bolts, place the side of
the transmission case on the floor.
B3M1083A
B3M1085A
B3M0957
32) Remove the detention spring.
B3M1086A
B3M1084A
B3M1087A
55
3-2 [W11B4] SERVICE PROCEDURE
11. Overall Transmission
B3M1088A
5. EXTENSION SECTION
1) Take out the transfer clutch by lightly tapping
the end of the rear drive shaft.
CAUTION:
Be careful not to damage the oil seal in the
extension.
G3M0368
CAUTION:
2) Remove the transfer pipe.
Do not reuse the circlip.
CAUTION:
ST1 499095500 REMOVER
Be careful not to bend the pipe.
ST2 499247300 INSTALLER
B3M1090A
G3M0956
56
SERVICE PROCEDURE [W11C1] 3-2
11. Overall Transmission
ST 398437700 DRIFT
6) Install the oil seal and outer race (taper roller
bearing) to the differential side retainer. Then
screw in the retainer and the O-ring after coating
the threads with oil.
CAUTION:
I Pay attention not to damage the oil seal lips.
I Do not confuse the RH and LH oil seals.
I Keep the O-ring removed from the retainer.
7) Using the ST, screw in the retainer until light
contact is felt.
G3M0379
NOTE:
3) Install the differential assembly to the case, Screw in the RH side slightly deeper than the LH
paying special attention not to damage the inside side.
of the case (particularly, the differential side ST 499787000 WRENCH ASSY
retainer contact surface).
B3M0352A
G3M0380
8) Hypoid gear backlash adjustment and tooth
4) Install the circlip to the axle shaft, insert the contact check
shaft into the differential assembly, and tap it into (1) Assemble the drive pinion assembly to the
position with a plastic hammer. oil pump housing.
CAUTION: CAUTION:
I If no play is felt, check whether the shaft is I Be careful not to bend the shims.
fully inserted. If shaft insertion is correct, I Be careful not to force the pinion against the
replace the axle shaft. housing bore.
I Be sure to use a new circlip.
Thrust play:
0.3 — 0.5 mm (0.012 — 0.020 in)
57
3-2 [W11C1] SERVICE PROCEDURE
11. Overall Transmission
(2) Tighten four bolts to secure the roller bear- (5) Tighten the LH retainer until contact is felt
ing. while rotating the shaft. Then loosen the RH
Tightening torque: retainer. Keep tightening the LH retainer and
41±3 N·m (4.2±0.3 kg-m, 30.4±2.2 ft-lb) loosening the RH retainer until the pinion shaft
can no longer be turned. This is the “zero” state.
B3M1091
G3M0884
(3) Install the oil pump housing assembly to the
torque converter clutch case, and secure evenly (6) After the “zero” state is established, back off
by tightening four bolts. the LH retainer 3 notches and secure it with the
lock plate. Then back off the RH retainer and
CAUTION: retighten until it stops. Repeat this procedure
I Thoroughly remove the liquid gasket from several times. Tighten the RH retainer 1-3/4
the case mating surface beforehand. notches further. This sets the preload. Finally,
I Use an old gasket or an aluminum washer so secure the retainer with its lock plate.
as not to damage the mating surface of the
housing.
Tightening torque:
41±3 N·m (4.2±0.3 kg-m, 30.4±2.2 ft-lb)
G3M0885
NOTE:
Turning the retainer by one tooth changes the
B3M1092 backlash about 0.05 mm (0.0020 in).
H3M1256A
G3M0384
58
SERVICE PROCEDURE [W11C1] 3-2
11. Overall Transmission
(7) Turn the drive pinion several rotations with (8) Apply red lead evenly to the surfaces of
ST1 and check to see if the backlash is within three or four teeth of the crown gear. Rotate the
the standard value with ST2, ST3, ST4 and drive pinion in the forward and reverse direc-
ST5. tions several times. Then remove the oil pump
NOTE: housing, and check the tooth contact pattern.
After confirming that the backlash is correct, check If tooth contact is improper, readjust the back-
the tooth contact. lash or shim thickness.
ST1 499787100 WRENCH
ST2 498247001 MAGNET BASE
ST3 498247100 DIAL GAUGE
ST4 499787500 ADAPTER WRENCH
ST5 498255400 PLATE
Backlash:
0.13 — 0.18 mm (0.0051 — 0.0071 in)
B3M0570B
59
3-2 [W11C1] SERVICE PROCEDURE
11. Overall Transmission
B3M0317A
Face contact This may cause noise and chipping at Increase thickness of drive pinion height
Backlash is too large. tooth ends. adjusting shim in order to bring drive pin-
ion close to crown gear.
B3M0319
B3M0323
Flank contact Backlash is too small. This may cause noise and stepped wear Reduce thickness of drive pinion height
on surfaces. adjusting shim in order to move drive
pinion away from crown gear.
B3M0320
B3M0324
Toe contact This may cause chipping at toe. Adjust as for flank contact.
(Inside end contact)
Contact areas is small.
B3M0321 B3M0324
Heel contact (Outside end contact) This may cause chipping at heel ends. Adjust as for face contact.
Contact area is small.
B3M0322 B3M0323
60
SERVICE PROCEDURE [W11C1] 3-2
11. Overall Transmission
(9) If tooth contact is correct, mark the retainer 11) Attach the O-ring to the oil seal retainer with
position and loosen it. After fitting the O-ring, vaseline. Install the seal to the oil pump housing
screw in the retainer to the marked position. bore.
Then tighten the lock plate to the specified CAUTION:
torque. Always discard old O-rings and install new
Tightening torque: ones.
25±2 N·m (2.5±0.2 kg-m, 18.1±1.4 ft-lb)
B3M1093A
G3M0885
12) Install the oil seal retainer taking care not to
9) Install the seal pipe to the torque converter damage the oil seal lips. Then secure with three
clutch case. bolts.
CAUTION: NOTE:
Be sure to use a new seal pipe. Make sure the O-ring is fitted correctly in position.
Tightening torque:
7±1 N·m (0.7±0.1 kg-m, 5.1±0.7 ft-lb)
G3M0370
10) Install two oil seals to the oil seal retainer with
ST. B3M1094A
CAUTION:
I Always discard old oil seals, and install new
ones.
I Pay attention to the orientation of the oil
seals.
ST 499247300 INSTALLER
G3M0390
61
3-2 [W11C2] SERVICE PROCEDURE
11. Overall Transmission
13) Apply vaseline to the groove on the oil pump 2) Install parking support to transmission case.
cover, and install two (R) seal rings and two (H) Tightening torque:
seal rings. 25±2 N·m (2.5±0.2 kg-m, 18.1±1.4 ft-lb)
NOTE:
I Fit the seal ring after compressing, and rub
vaseline into the seal ring to avoid expansion.
I The “R” seal ring has a large diameter, while “H”
has small diameter.
B3M1088A
B3M1087A
G3M0394
B3M1086A
G3M0396
62
SERVICE PROCEDURE [W11C2] 3-2
11. Overall Transmission
5) Insert range select lever, and tighten bolt. 8) Install the low and reverse piston.
Tightening torque: CAUTION:
6±1 N·m (0.6±0.1 kg-m, 4.3±0.7 ft-lb) I Be careful not to tilt the piston when install-
ing.
I Be careful not to damage the lip seal.
B3M1096A
B3M1085A
B3M1083A
B3M1099B
63
3-2 [W11C2] SERVICE PROCEDURE
11. Overall Transmission
B3M1409A
B3M0957
B3M0958
B3M0977
(4) Install thrust needle bearing.
64
SERVICE PROCEDURE [W11C2] 3-2
11. Overall Transmission
Available retaining plates 16) Install 2-4 brake piston and retainer to trans-
Part No. Thickness mm (in)
mission case.
31667AA320 4.2 (0.165) CAUTION:
31667AA330 4.5 (0.177) Align the hole in the 2-4 brake seal of transmis-
31667AA340 4.8 (0.189) sion case with the hole in 2-4 brake piston
31667AA350 5.1 (0.201) retainer during installation.
31667AA360 5.4 (0.213)
31667AA370 5.7 (0.224)
31667AA380 6.0 (0.236)
B3M1079A
B3M0956A
B3M1080A
B3M1101A
65
3-2 [W11C2] SERVICE PROCEDURE
11. Overall Transmission
19) Install planetary gear and low clutch assembly (3) After all 2-4 brake component parts have
to transmission case. been installed, blow in air intermittently and con-
Install carefully while rotating the low clutch and firm the operation of the brake.
planetary gear assembly slowly paying special
attention not to damage the seal ring.
B3M1103
B3M1076A
(4) Measure the clearance between the retain-
ing plate and the snap ring.
20) Installation of the 2-4 brake: NOTE:
(1) Install pressure plate, drive plate, driven Select a retaining plate with a suitable value from
plate, retaining plate and snap ring. the following table, so that the clearance becomes
the standard value.
Standard value:
0.8 — 1.2 mm (0.031 — 0.047 in)
Allowable limit:
1.5 mm (0.059 in)
B3M1075
66
SERVICE PROCEDURE [W11C2] 3-2
11. Overall Transmission
21) Install leaf spring of 2-4 brake. 24) Install the high clutch hub and thrust needle
NOTE: bearing.
Attach the thrust needle bearing to the hub with
Be careful not to mistake the location of the leaf
vaseline and install the hub by correctly engaging
spring to be inserted.
the splines of the front planetary carrier.
CAUTION:
Install thrust needle bearing in the correct
direction. <Ref. to 3-2 [S1C0].>
B3M1104A
B3M1075
B3M1072A
B3M0982A
67
3-2 [W11C3] SERVICE PROCEDURE
11. Overall Transmission
(2) Using ST, measure the distance from the oil (2) After correctly installing the gasket to the
pump housing mating surface to the top surface case mating surface, carefully install the oil
of the oil pump cover with thrust needle bearing. pump housing assembly. Be careful to avoid hit-
ST 398643600 GAUGE ting the drive pinion against the inside of the
case.
CAUTION:
I Be careful not to damage the seal ring.
I Be sure to use a new gasket.
(3) Install both parts with dowel pins aligned.
Make sure no clearance exists at the mating
surface.
NOTE:
Any clearance suggests a damaged seal ring.
B3M0983A
(4) Secure the housing with two nuts.
(3) Calculation of total end play Tightening torque:
Select suitable bearing race from among those T: 41±3 N·m (4.2±0.3 kg-m, 30.4±2.2 ft-lb)
listed in this table so that clearance C is in the
0.25 — 0.55 mm (0.0098 — 0.0217 in) range.
C = (L + G) −
Clearance between concave portion of high clutch
C
and end of clutch drum support
Length from case mating surface to concave por-
L
tion of high clutch
G Gasket thickness (0.28 mm, 0.0110 in)
Height from housing mating surface to upper sur-
face of clutch drum support
B3M1068A
68
SERVICE PROCEDURE [W11C4] 3-2
11. Overall Transmission
2) Install the torque converter clutch case assem- (2) Temporarily tighten the valve body on the
bly to the transmission case assembly, and secure transmission case.
with six bolts and four nuts. CAUTION:
CAUTION: Be sure to engage the manual valve with the
When installing, be careful not to damage the manual plate during installation.
torque converter clutch case bushing and oil
seal.
Tightening torque:
41±3 N·m (4.2±0.3 kg-m, 30.4±2.2 ft-lb)
B3M1037A
S3M0223A
69
3-2 [W11C5] SERVICE PROCEDURE
11. Overall Transmission
3) Connect all connectors. (3) Install the oil pan to the transmission case
assembly, and secure with 20 bolts.
NOTE:
Tighten the bolts evenly.
Tightening torque:
4.9±0.5 N·m (0.50±0.05 kg-m, 3.6±0.4 ft-lb)
B2M2263C
B3M1105A B3M1066A
B3M1040A
B3M1090A
70
SERVICE PROCEDURE [W11C6] 3-2
11. Overall Transmission
2) Install the transfer clutch assembly to the case. 3) Install transfer valve plate, valve body and duty
CAUTION: solenoid C (transfer) to transmission case.
Be careful not to damage the seal rings. CAUTION:
NOTE: I Be sure to install transfer seal lip to transfer
Insert the clutch assembly fully into position until control valve body.
the bearing shoulder bottoms. I If transfer seal lip is damaged, replace seal
with new one.
Tightening torque:
8±1 N·m (0.8±0.1 kg-m, 5.8±0.7 ft-lb)
B3M1106A
B3M1062A
B3M1113A
B3M1061A
71
3-2 [W11C6] SERVICE PROCEDURE
11. Overall Transmission
Tightening torque: T = (L + G) − − H
98±5 N·m (10.0±0.5 kg-m, 72.3±3.6 ft-lb) T : Shim clearance
L : Distance from end of extension case to
end of rear drive shaft
G: Gasket thickness (0.45 mm, 0.0177 in)
: Height from end of transmission case to
end of reduction drive gear
H : Thrust needle bearing thickness
0.05 — 0.25 mm (0.0020 — 0.0098 in)
Thrust needle bearing
Part No. Thickness mm (in)
806536020 3.8 (0.150)
B3M1058A
806535030 4.0 (0.157)
7) Measurement and adjustment of extension end 806535040 4.2 (0.165)
806535050 4.4 (0.173)
play
806535060 4.6 (0.181)
(1) Measure distance L from end of extension 806535070 4.8 (0.189)
case and rear drive shaft with ST. 806535090 5.0 (0.197)
ST 398643600 GAUGE
L = Measured value − 15 mm 8) Installation of extension case and transmission
case
(1) Attach the selected thrust needle bearing to
the end surface of reduction drive gear with
vaseline.
CAUTION:
Install thrust needle bearing in the correct
direction. <Ref. to 3-2 [S1C0].>
(2) Install the extension case to the transmis-
sion case.
B3M0985A CAUTION:
(2) Measure the distance “” from the transmis- Be sure to use a new gasket.
sion case mating surface to the reduction drive (3) Tighten bolts to secure the case.
gear end surface with ST1 and ST2.
= Measured value − 50 mm Tightening torque:
ST1 398643600 GAUGE 25±2 N·m (2.5±0.2 kg-m, 18.1±1.4 ft-lb)
ST2 499577000 GAUGE
B3M1057A
B3M1114A
72
SERVICE PROCEDURE [W11C7] 3-2
11. Overall Transmission
9) Install the vehicle speed sensor 1 (rear). (1) With the select lever set to “N” adjust the
Tightening torque: inhibitor switch so that the hole of range select
7±1 N·m (0.7±0.1 kg-m, 5.1±0.7 ft-lb) lever is aligned with the inhibitor switch hole
with ST.
NOTE:
Ensure that gauge moves properly.
ST 499267300 STOPPER PIN
B3M1056A
7. EXTERNAL PARTS
1) Using ST, install ATF filter to transmission case.
B3M1115A
Calculate ATF filter torque specifications using the
following formula. (2) With hole aligned, tighten three bolts to
T2 = L2/(L1 + L2) × T1 secure the inhibitor switch.
T1: 14±2 N·m (1.4±0.2 kg-m, 10.1±1.4 ft-lb)
[Required torque setting] Tightening torque:
T2: Tightening torque 3.4±0.5 N·m (0.35±0.05 kg-m, 2.5±0.4 ft-lb)
L1: ST length 0.078 m (3.07 in) 3) Install air breather hose.
L2: Torque wrench length
CAUTION:
Align ST with torque wrench while tightening
AFT filter.
ST 498545400 OIL FILTER WRENCH
B3M1051A
B3M1054A
73
3-2 [W11C7] SERVICE PROCEDURE
11. Overall Transmission
5) Install the oil cooler outlet pipe. 9) Tighten the drain plugs.
CAUTION: Tightening torque:
Be sure to use a new aluminum washer. Diff.
Tightening torque: 44±3 N·m (4.5±0.3 kg-m, 32.5±2.2 ft-lb)
34±3 N·m (3.5±0.3 kg-m, 25.3±2.2 ft-lb) ATF
25±2 N·m (2.5±0.2 kg-m, 18.1±1.4 ft-lb)
6) Install the oil cooler inlet pipe.
CAUTION:
Be sure to use a new aluminum washer.
Tightening torque:
25±2 N·m (2.5±0.2 kg-m, 18.1±1.4 ft-lb)
B3M1036A
B3M1050B
B3M0629
74
SERVICE PROCEDURE [W11C7] 3-2
11. Overall Transmission
B3M1116A
75
3-2 [W12A0] SERVICE PROCEDURE
12. Reduction Drive Gear Assembly
B3M1121A
B3M1121A
B3M0962A
B3M0963A
B: INSPECTION
Make sure that each component is free of harmful
gouges, cuts, or dust.
C: ASSEMBLY
1) Press-fit the reduction drive gear to the shaft.
2) Press-fit the ball bearing to the reduction drive
gear.
76
SERVICE PROCEDURE [W13C0] 3-2
13. Reduction Driven Gear
13. Reduction Driven Gear 2) Install snap ring to reduction driven gear.
A: DISASSEMBLY
1) Remove snap ring from reduction driven gear.
B3M1125A
B3M1125A
B3M1127A
B: INSPECTION
Check ball bearing and gear for dents or damage.
C: ASSEMBLY
1) Using a press, install ball bearing to reduction
driven gear.
B3M1128A
77
3-2 [W14A0] SERVICE PROCEDURE
14. Control Valve Body
14. Control Valve Body be also handled carefully, as springs may jump out
of place when the parts are disassembled or
A: PRECAUTION removed. Extreme care should be taken so as not
The control valve is composed of parts which are to drop valves on the floor. Before assembling, the
accurately machined to a high degree and should parts and valves should be dipped in a container
be handled carefully during disassembly and filled with the ATF. Make sure that the valves are
assembly. As these parts are similar in shape, they clean and free from any foreign material before
should be arranged in neat order on a table after assembly. Torque specifications should also be
disassembly so that they can be easily installed to observed.
their original positions. Spring loaded parts should
B3M1129A
(1) 2-4 brake clutch accumulator (11) 2-4 brake timing plug (23) Shift valve A
piston B (12) 2-4 brake timing sleeve (24) Manual valve
(2) 2-4 brake clutch accumulator (13) 2-4 brake timing valve A (25) Throttle accumulator piston B
piston A (14) 2-4 brake timing valve B (26) 1st reducing valve
(3) Low clutch accumulator piston (15) Torque convertor regulator valve (27) Throttle accumulator piston A
(4) High clutch accumulator piston A (16) Pressure modifier valve (28) Lock-up control valve
(5) High clutch accumulator piston B (17) Accumulator control valve A (29) Lock-up control plug
(6) Pressure regulator sleeve (18) Low clutch timing valve A (30) Lock-up control sleeve
(7) Pressure regulator plug (19) Low clutch timing sleeve (31) Modifier accumulator piston
(8) Pressure regulator valve (20) Low clutch timing plug (32) Pilot valve
(9) Reverse inhibit valve (21) Low clutch timing valve B
(10) Accumulator control valve B (22) Shift valve B
78
SERVICE PROCEDURE [W14A0] 3-2
14. Control Valve Body
79
3-2 [W14B0] SERVICE PROCEDURE
14. Control Valve Body
B: DISASSEMBLY CAUTION:
I Do not lose the ten (10) steel balls contained
1) Remove oil strainer from lower control valve in the upper valve body and middle valve body.
body. I Do not lose strainers contained in the lower
valve body.
NOTE:
During ordinary servicing, clean the control valve
bodies in this condition, without further disassem-
bly. In the event of a seized clutch or other
problem, disassemble the control valve bodies
further, and clean the component parts.
5) Remove upper separator plate from middle
valve body.
B3M1038A
B3M1132A
C: INSPECTION
Make sure that each component is free of harmful
gouges, cuts, or dust.
B3M1130
80
SERVICE PROCEDURE [W14D0] 3-2
14. Control Valve Body
B3M1136A
B3M1132A
B3M1138
B3M1135A
81
3-2 [W15A0] SERVICE PROCEDURE
15. Oil Pump Assembly
B3M1130A
B3M1039B
B3M1095A
(A) Lock-up duty solenoid (Blue)
(B) Low clutch timing solenoid (Gray) 4) Remove the oil pump cover.
(C) Line pressure duty solenoid (Red)
NOTE:
(D) Shift solenoid 1 (Yellow)
Lightly tap the end of the stator shaft to remove the
(E) Shift solenoid 2 (Green)
(F) 2-4 brake timing solenoid (Black)
cover.
(G) 2-4 brake duty solenoid D (Red)
(H) ATF temperature sensor
B3M1139A
82
SERVICE PROCEDURE [W15C0] 3-2
15. Oil Pump Assembly
5) Remove the inner and outer rotor. Oil pump rotor assembly
Part No. Thickness mm (in)
15008AA060 11.37 — 11.38 (0.4476 — 0.4480)
15008AA070 11.38 — 11.39 (0.4480 — 0.4484)
15008AA080 11.39 — 11.40 (0.4484 — 0.4488)
C: ASSEMBLY
1) Install oil pump rotor assembly to oil pump
housing.
B3M1140A
B: INSPECTION
1) Check seal ring and O-ring oil seal for breaks or
damage.
2) Check other parts for dents or abnormalities.
3) Selection of oil pump rotor assembly
(1) Tip clearance B3M1140A
Install inner rotor and outer rotor to oil pump.
With rotor gears facing each other, measure 2) Install the oil pump cover.
crest-to-crest clearance. Tightening torque:
Tip clearance: 25±2 N·m (2.5±0.2 kg-m, 18.1±1.4 ft-lb)
0.02 — 0.15 mm (0.0008 — 0.0059 in) NOTE:
I Align both pivots with the pivot holes of the
cover, and install the cover being careful not to
apply undue force to the pivots.
I After assembling, turn the oil pump shaft to
check for smooth rotation of the rotor.
B3M0965A
B3M0966A
83
3-2 [W16A0] SERVICE PROCEDURE
16. Drive Pinion Shaft
I Install the oil seal retainer and seal rings. After 16. Drive Pinion Shaft
adjusting the drive pinion backlash and tooth con-
tact. A: DISASSEMBLY
1) Straighten the staked portion of the lock nut,
and remove the lock nut while locking the rear
spline portion of the shaft with ST1 and ST2. Then
pull off the drive pinion collar.
ST1 498937100 HOLDER
ST2 499787100 WRENCH
ST3 499787500 ADAPTER
B3M1095A
B3M0587A
G3M0459
G3M0460
B: INSPECTION
Make sure that all component parts are free of
harmful cuts, gouges, and other faults.
84
SERVICE PROCEDURE [W16C0] 3-2
16. Drive Pinion Shaft
C: ASSEMBLY 4) Tighten the lock washer and lock nut with ST1,
ST2 and ST3.
1) Measure dimension “A” of the drive pinion ST1 498937110 HOLDER
shaft. ST2 499787100 WRENCH
ST 398643600 GAUGE ST3 499787500 ADAPTER
Actual tightening torque:
116±5 N·m (11.8±0.5 kg-m, 85.3±3.6 ft-lb)
NOTE:
I Pay attention to the orientation of lock washer.
I Tightening torque using torque wrench is deter-
mined by the following equation.
T1 = L/L + 72.2 ×T
T: Actual tightening torque
B3M1176A
I Install ST2 to torque wrench as straight as pos-
2) Using a press, force-fit the roller bearing in sible.
position.
CAUTION:
Do not change the relative positions of the
outer race and bearing cone.
B3M1410A
B3M0589
85
3-2 [W16C0] SERVICE PROCEDURE
16. Drive Pinion Shaft
B3M0590D
86
SERVICE PROCEDURE [W17A0] 3-2
17. High Clutch and Reverse Clutch
S3M0221A
(1) Reverse clutch drum (8) Spring retainer (15) Dish plate
(2) Lip seal (9) Cover (16) Driven plate
(3) Lathe cut seal ring (10) Snap ring (17) Drive plate
(4) Reverse clutch piston (11) Driven plate (18) Retaining plate
(5) Lathe cut seal ring (12) Drive plate (19) Snap ring
(6) Lathe cut seal ring (13) Retaining plate (20) Thrust needle bearing
(7) High clutch piston (14) Snap ring (21) High clutch hub
87
3-2 [W17B0] SERVICE PROCEDURE
17. High Clutch and Reverse Clutch
1) Remove the snap ring, and take out the retain- 5) Remove seal rings and lip seal from high clutch
ing plate, drive plates, driven plates. piston and reverse clutch piston.
B3M1142A B3M1146A
B3M1143A
B3M1144A
B3M1145B
88
SERVICE PROCEDURE [W17C0] 3-2
17. High Clutch and Reverse Clutch
C: ASSEMBLY
S3M0221A
(1) Reverse clutch drum (8) Spring retainer (15) Dish plate
(2) Lip seal (9) Cover (16) Driven plate
(3) Lathe cut seal ring (10) Snap ring (17) Drive plate
(4) Reverse clutch piston (11) Driven plate (18) Retaining plate
(5) Lathe cut seal ring (12) Drive plate (19) Snap ring
(6) Lathe cut seal ring (13) Retaining plate (20) Thrust needle bearing
(7) High clutch piston (14) Snap ring (21) High clutch hub
89
3-2 [W17C0] SERVICE PROCEDURE
17. High Clutch and Reverse Clutch
1) Install seal rings and lip seal to high clutch pis- 5) Install ST to high clutch piston.
ton and reverse clutch piston. ST 498437000 HIGH CLUTCH PISTON
2) Install high clutch piston to reverse clutch pis- GAUGE
ton.
B3M1150A
B3M1146A
6) Install cover to high clutch piston.
3) Install reverse clutch to high clutch drum. CAUTION:
NOTE: Be careful not to fold over the high clutch pis-
Align the groove on the reverse clutch piston with ton seal during installation.
the groove on the high clutch drum during installa- 7) Using ST1 and ST2, install snap ring.
tion.
NOTE:
After installing snap ring, remove STs.
ST1 398673600 COMPRESSOR
ST2 498627100 SEAT
ST3 498437000 HIGH CLUTCH PISTON
GAUGE
B3M1148A
B3M0973A
B3M1151
90
SERVICE PROCEDURE [W17C0] 3-2
17. High Clutch and Reverse Clutch
10) Apply compressed air intermittently to check 12) If specified tolerance limits are exceeded,
for operation. select a suitable high clutch retaining plate.
High clutch retaining plate
Part No. Thickness mm (in)
31567AA710 4.7 (0.185)
31567AA720 4.8 (0.189)
31567AA730 4.9 (0.193)
31567AA740 5.0 (0.197)
31567AA670 5.1 (0.201)
31567AA680 5.2 (0.205)
31567AA690 5.3 (0.209)
31567AA700 5.4 (0.213)
B3M1168
13) Install driven plate, drive plate, retaining plate
11) Measure the clearance between the retaining and snap ring.
plate and snap ring.
CAUTION:
Do not press down retaining plate during clear-
ance measurements.
Standard value:
0.8 — 1.1 mm (0.031 — 0.043 in)
Allowable limit:
1.5 mm (0.059 in)
B3M1153
B3M1152A
B3M1169
91
3-2 [W17C0] SERVICE PROCEDURE
17. High Clutch and Reverse Clutch
15) Measure the clearance between the retaining 16) If specified tolerance limits are exceeded,
plate and snap ring. select a suitable high clutch retaining plate.
CAUTION: Reverse clutch retaining plates
Do not press down retaining plate during clear-
Part No. Thickness mm (in)
ance measurements.
31567AA750 3.8 (0.150)
Standard value: 31567AA760 4.0 (0.157)
0.5 — 0.8 mm (0.020 — 0.031 in) 31567AA770 4.2 (0.165)
31567AA780 4.4 (0.173)
Allowable limit: 31567AA790 4.6 (0.181)
1.2 mm (0.047 in) 31567AA800 4.8 (0.189)
31567AA810 5.0 (0.197)
31567AA820 5.2 (0.205)
B3M1154A
92
SERVICE PROCEDURE [W18A0] 3-2
18. Low Clutch Drum and Planetary Gear
B3M1155A
93
3-2 [W18A0] SERVICE PROCEDURE
18. Low Clutch Drum and Planetary Gear
1) Remove snap ring from the low clutch drum. 5) Take out rear internal gear.
B3M1156A B3M1160A
2) Take out front planetary carrier and thrust 6) Remove the snap ring from the low clutch drum.
needle bearing from low clutch drum.
B3M1161A
B3M1157A
7) Remove the retaining plate, drive plates, driven
3) Take out rear sun gear. plates and dish plate.
8) Compress the spring retainer, and remove the
snap ring from the low clutch drum, by using ST1
and ST2.
ST1 498627100 SEAT
ST2 398673600 COMPRESSOR
B3M1158A
B3M1162A
B3M1159A
94
SERVICE PROCEDURE [W18B0] 3-2
18. Low Clutch Drum and Planetary Gear
B3M0960A
B3M1163A
B3M1164A
B: INSPECTION
1) Drive plate facing for wear and damage
2) Snap ring for wear, return spring for setting and
breakage, and snap ring retainer for deformation
3) Lip seal and lathe cut ring for damage
4) Piston and drum check ball for operation
95
3-2 [W18C0] SERVICE PROCEDURE
18. Low Clutch Drum and Planetary Gear
C: ASSEMBLY
B3M1155A
1) Install lathe cut seal ring to low clutch piston. 3) Install spring retainer to low clutch piston.
2) Fit the low clutch piston to the low clutch drum.
B3M1166A
B3M1165A
96
SERVICE PROCEDURE [W18C0] 3-2
18. Low Clutch Drum and Planetary Gear
4) Install ST to low clutch drum. 7) Check the low clutch for operation.
ST 498437100 LOW CLUTCH PISTON Set the one-way clutch inner race, and apply com-
GUIDE pressed air for checking.
B3M1167A B3M0960A
5) Set the cover on the piston with a press using 8) Checking low clutch clearance
ST1 and ST2, and attach the snap ring. Measure the gap between the retaining plate and
CAUTION: the operation of the low clutch.
Be careful not to fold cover seal during instal- NOTE:
lation. Before measuring clearance, place the same thick-
NOTE: ness of shim on both sides to prevent retaining
After installing snap ring, remove ST1, ST2 and plate from tilting.
ST3. If the clearance is out of the specified range, select
a proper retaining plate so that the standard clear-
ST1 498627100 SEAT ance can be obtained.
ST2 398673600 COMPRESSOR
ST3 498437100 LOW CLUTCH PISTON Standard value:
GUIDE 0.7 — 1.1 mm (0.028 — 0.043 in)
Allowable limit:
1.6 mm (0.063 in)
B3M1168B
B3M1169A
97
3-2 [W18C0] SERVICE PROCEDURE
18. Low Clutch Drum and Planetary Gear
9) Install washer to rear internal gear. 12) Install washer to rear planetary carrier.
NOTE:
Make sure washer tooth is inserted into hole on
planetary carrier.
B3M1170A
B3M1160A
B3M1171A
B3M1173
98
SERVICE PROCEDURE [W18C0] 3-2
18. Low Clutch Drum and Planetary Gear
15) Install rear sun gear. 18) Install snap ring to low clutch drum.
NOTE:
Pay attention to the orientation of the rear sun
gear.
B3M1156A
B3M1164A
B3M1175A
B3M1157A
99
3-2 [W19A0] SERVICE PROCEDURE
19. Differential Case Assembly
G3M0488
G3M0490
2) Secure the case in a vise and remove the
crown gear tightening bolts, then separate the 2) Install the washer and differential bevel gear to
crown gear, case (RH) and case (LH). the differential case (LH). Then put the case over
the differential case (RH), and connect both cases.
3) Install the crown gear and secure by tightening
the bolt.
Standard tightening torque:
62±5 N·m (6.3±0.5 kg-m, 45.6±3.6 ft-lb)
G3M0489
G3M0490
B: INSPECTION
Check each component for harmful cuts, damage
and other faults.
100
SERVICE PROCEDURE [W20A0] 3-2
20. Transfer Clutch
NOTE: CAUTION:
Measure the backlash by applying a pinion tooth Be careful not to damage the seal ring.
between two bevel gear teeth.
Standard value:
0.13 — 0.18 mm (0.0051 — 0.0071 in)
G3M0493
G3M0494
G3M0492
G3M0495
101
3-2 [W20B0] SERVICE PROCEDURE
20. Transfer Clutch
4) Remove the snap ring with ST1, ST2 and ST3, 2) Install return spring to transfer piston.
and take out the return spring and transfer clutch
piston seal.
ST1 399893600 PLIERS
ST2 398673600 COMPRESSOR
ST3 398623600 SEAT
B3M1177A
B3M1415A
B3M1401A
G3M0497
B: INSPECTION
1) Check the drive plate facing for wear and dam-
age.
2) Check the snap ring for wear, return spring for
permanent set and breakage, and return spring for
B3M1402A
deformation.
3) Check the lathe cut ring for damage. 5) Install snap ring to ST.
ST 499257300 SNAP RING OUTER GUIDE
C: ASSEMBLY
1) Install the transfer clutch piston.
B3M1180A
B3M1400A
102
SERVICE PROCEDURE [W20C0] 3-2
20. Transfer Clutch
6) Using ST1 and ST2, install snap ring to rear 9) Check the clearance.
drive shaft. NOTE:
NOTE: Before measuring clearance, place the same thick-
After installing snap ring, remove ST1 and ST2. ness of shim on both sides to prevent pressure
ST1 499257300 SNAP RING OUTER GUIDE plate from tilting.
ST2 499247400 INSTALLER If the clearance is not within the specified range,
select a proper pressure plate.
Standard value:
0.2 — 0.6 mm (0.008 — 0.024 in)
Allowable limit:
1.6 mm (0.063 in)
B3M1181A
G3M0503
G3M0505
G3M0502
103
3-2 [W21A0] SERVICE PROCEDURE
21. Transfer Valve Body
11) Coat the seal ring with vaseline, and install it 21. Transfer Valve Body
in the seal ring groove of the shaft.
CAUTION: A: DISASSEMBLY
Do not expand the seal ring excessively when 1) Separate duty solenoid C (transfer) and trans-
installing. fer valve body.
ST 899580100 INSTALLER 2) Remove the stopper plate and pry out the plug
with a screwdriver. Then extract the spring and
transfer control valve together.
CAUTION:
Be careful not to damage the valve and valve
body.
G3M0493
B3M1183A
B: INSPECTION
Check each component for harmful cuts, damage,
or other faults.
C: ASSEMBLY
To assemble, reverse the removal sequence.
NOTE:
Make sure the valve slides smoothly after assem-
bling.
104
SERVICE PROCEDURE [W22B0] 3-2
22. Transmission Control Module
G6M0095 B3M0443L
2) Remove lower cover and then disconnect con- (A) Transmission control module
nector. (B) Pedal bracket
B3M0377A
B3M0443L
105
3-2 [W23A0] SERVICE PROCEDURE
23. Dropping Resistor
B3M1408A
G6M0095
B3M1408A
106
AUTOMATIC TRANSMISSION
AND DIFFERENTIAL 3-2
Page
T DIAGNOSTICS ...................................................................................................2
1. Precaution ...................................................................................................2
2. Pre-inspection..............................................................................................2
3. Electrical Components Location..................................................................4
4. Schematic....................................................................................................9
5. Transmission Control Module (TCM) I/O Signal .......................................10
6. Diagnostic Chart for On-board Diagnostics System .................................13
7. Diagnostics for On-board Diagnostics Failed ...........................................16
8. Diagnostic Chart with Trouble Code .........................................................23
9. Diagnostic Chart with Select Monitor ......................................................115
10. General Diagnostic Table ........................................................................155
3-2 [T1A0] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
1. Precaution
1. Precaution 2. Pre-inspection
A: SUPPLEMENTAL RESTRAINT A: ATF LEVEL
SYSTEM “AIRBAG” Make sure that ATF level is in the specification.
Airbag system wiring harness is routed near the
transmission control module (TCM).
CAUTION:
I All Airbag system wiring harness and con-
nectors are colored yellow. Do not use electri-
cal test equipment on these circuit.
I Be careful not to damage Airbag system wir-
ing harness when performing diagnostics and
servicing the TCM.
B: MEASUREMENT B3M0173A
When measuring voltage and resistance of the
ECM, TCM or each sensor, use a tapered pin with
a diameter of less than 0.64 mm (0.025 in) in order B: FRONT DIFFERENTIAL OIL
to avoid poor contact. Do not insert the pin more LEVEL
than 5 mm (0.20 in). Make sure that front differential oil level is in the
specification.
B3M0174A
2
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T2C0] 3-2
2. Pre-inspection
C: OPERATION OF SHIFT
SELECTOR LEVER
WARNING:
Stop the engine while checking operation of
selector lever.
1) Check that selector lever does not move from
“N” to “R” without pushing the button.
2) Check that selector lever does not move from
“R” to “P” without pushing the button.
3) Check that selector lever does not move from
“P” to “R” without pushing the button.
4) Check that selector lever does not move from
“3” to “2” without pushing the button.
G3M0717
3
3-2 [T3A0] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
3. Electrical Components Location
H3M1087O
(1) ECM (3) TCM (4) Data link connector (for Subaru
(2) AT OIL TEMP indicator light (AT select monitor and OBD-II gen-
diagnostic indicator light) eral scan tool)
4
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T3A0] 3-2
3. Electrical Components Location
B3M0183E H3M1675B
S3M0056D S2M0258C
5
3-2 [T3B0] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
3. Electrical Components Location
B: SENSOR
H3M1087P
(1) Throttle position sensor (4) Inhibitor switch (6) Torque converter turbine speed
(2) Dropping resistor (5) Vehicle speed sensor 1 (Rear) sensor
(3) Vehicle speed sensor 2 (Front) (7) ATF temperature sensor
6
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T3B0] 3-2
3. Electrical Components Location
S2M0262B B2M2262C
B2M2258C B2M2246D
B2M2260C B2M2261C
7
3-2 [T3C0] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
3. Electrical Components Location
C: SOLENOID
B3M1186A
(1) Solenoid 1 (4) Low clutch timing solenoid (7) 2-4 brake timing solenoid
(2) Solenoid 2 (5) Duty solenoid B (8) Duty solenoid C
(3) Duty solenoid A (6) Duty solenoid D
B2M2263D B2M2264E
8
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T400] 3-2
4. Schematic
4. Schematic
H3M1806A
(1) Transmission control module (15) “N” range switch (29) Torque converter turbine speed
(2) Data link connector (16) “D” range switch sensor
(3) Cruise set switch (17) “3” range switch (30) Vehicle speed sensor 2 (Front)
(4) ABS control module (18) “2” range switch (31) Vehicle speed sensor 1 (Rear)
(5) Ignition switch (19) “1” range switch (32) Shift solenoid 1
(6) Brake switch (20) Throttle position sensor (33) Shift solenoid 2
(7) Brake light (21) Engine speed signal (34) 2-4 brake timing solenoid
(8) Battery (22) Torque control cut signal (35) Duty solenoid A
(9) Combination meter (23) Torque control signal 2 (36) Line pressure dropping resistor
(10) AT OIL TEMP indicator light (24) Torque control signal 1 (37) Duty solenoid D
(11) FWD indicator light (25) AT load signal (38) 2-4 brake dropping resistor
(12) FWD switch (26) AT diagnostics signal (39) Duty solenoid B
(13) “P” range switch (27) Engine control module (40) Low clutch timing solenoid
(14) “R” range switch (28) ATF temperature sensor (41) Duty solenoid C
9
3-2 [T500] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
5. Transmission Control Module (TCM) I/O Signal
B2M2269A
10
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T500] 3-2
5. Transmission Control Module (TCM) I/O Signal
11
3-2 [T500] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
5. Transmission Control Module (TCM) I/O Signal
12
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T6A0] 3-2
6. Diagnostic Chart for On-board Diagnostics System
H3M1672G
13
3-2 [T6B0] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
6. Diagnostic Chart for On-board Diagnostics System
S3M0062A
14
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T6C0] 3-2
6. Diagnostic Chart for On-board Diagnostics System
C: ON-BOARD DIAGNOSTICS
S3M0063A
15
3-2 [T7A0] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
7. Diagnostics for On-board Diagnostics Failed
H3M1779
7A1 : CHECK AT OIL TEMP INDICATOR 7A2 : CHECK AT OIL TEMP INDICATOR
LIGHT. LIGHT.
Turn ignition switch to ON (engine OFF). Perform on-board diagnostics. <Ref. to 3-2
: Does AT OIL TEMP indicator light illu- [T6C0].>
minate? : Does AT OIL TEMP indicator light
: Go to step 7A2. blink?
: Go to step 7A3. : A temporary poor contact of the connec-
tor or harness may be the cause. Repair
harness or connector in TCM, inhibitor
switch and combination meter.
: Go to step 7A8.
16
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T7A6] 3-2
7. Diagnostics for On-board Diagnostics Failed
Remove fuse (No. 18). Measure voltage between combination meter con-
: Is the fuse (No. 18) blown out? nector and chassis ground.
: Replace fuse (No. 18). If replaced fuse Connector & terminal
(No. 18) is blown out easily, repair short (i10) No. 2 (+) — Chassis ground (−):
circuit in harness between fuse (No. 18)
and combination meter.
: Go to step 7A4.
H3M1784A
17
3-2 [T7A7] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
7. Diagnostics for On-board Diagnostics Failed
7A7 : CHECK INPUT SIGNAL FOR TCM. 7A9 : CHECK SHORT CIRCUIT OF HAR-
NESS.
1) Connect connector to TCM and combination
meter. 1) Disconnect connector from TCM.
2) Turn ignition switch to ON (engine OFF). 2) Remove combination meter.
3) Measure voltage between TCM connector and 3) Disconnect connector from combination meter.
chassis ground. 4) Measure resistance of harness connector
between TCM and combination meter.
Connector & terminal
(B54) No. 3 (+) — Chassis ground (−): Connector & terminal/specified resistance
(B54) No. 3 — Chassis ground:
B3M1190A
B3M1191A
18
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T7A9] 3-2
7. Diagnostics for On-board Diagnostics Failed
MEMO:
19
3-2 [T7B0] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
7. Diagnostics for On-board Diagnostics Failed
H3M1780
7B1 : CHECK BACK-UP POWER SUPPLY 7B2 : CHECK FUSE (NO. 4).
CIRCUIT.
Remove fuse (No. 4).
1) Turn ignition switch to ON.
: Is the fuse (No. 4) blown out?
2) Measure back-up power supply voltage
between TCM connector terminal. : Replace fuse (No. 4). If replaced fuse
(No. 4) has blown out easily, repair short
Connector & terminal circuit in harness between fuse (No. 4)
(B55) No. 6 (+) — No. 19 (−): and TCM.
: Repair open circuit in harness between
fuse (No. 4) and TCM, and poor contact
in coupling connector.
B3M1194A
20
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T7B6] 3-2
7. Diagnostics for On-board Diagnostics Failed
7B3 : CHECK IGNITION POWER SUPPLY 7B5 : CHECK FUSE (NO. 11).
CIRCUIT.
Remove fuse (No. 11).
1) Turn ignition switch to ON (engine OFF).
: Is the fuse (No. 11) blown out?
2) Measure ignition power supply voltage between
TCM connector terminal. : Replace fuse (No. 11). If replaced fuse
(No. 11) has blown out easily, repair
Connector & terminal short circuit in harness between fuse
(B54) No. 23 (+) — (B55) No. 19 (−): (No. 11) and TCM.
: Repair open circuit in harness between
fuse (No. 11) and TCM, and poor con-
tact in coupling connector.
B3M1197A
B3M1196A
21
3-2 [T7B7] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
7. Diagnostics for On-board Diagnostics Failed
B3M1349B
B3M1198A
22
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T8A1] 3-2
8. Diagnostic Chart with Trouble Code
23
3-2 [T8A2] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
8. Diagnostic Chart with Trouble Code
B3M1199A
B: CLEAR MEMORY
Current trouble codes shown on the display are
cleared by turning the ignition switch OFF after
conducting on-board diagnostics operation. Previ-
ous trouble codes, however, cannot be cleared
since they are stored in the TCM memory which is
operating on the back-up power supply. These
trouble codes can be cleared by removing the
specified fuse (located under the light or left lower
position of the instrument panel).
CLEAR MEMORY:
Removal of No. 4 fuse (for at least one
minute)
I The No. 4 fuse is located in the line to the
memory back-up power supply of the TCM.
Removal of this fuse clears the previous trouble
codes stored in the TCM memory.
I Be sure to remove the No. 4 fuse for at least the
specified length of time. Otherwise, trouble codes
may not be cleared.
24
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T8B0] 3-2
8. Diagnostic Chart with Trouble Code
MEMO:
25
3-2 [T8C0] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
8. Diagnostic Chart with Trouble Code
H3M1807
1) Turn ignition switch to OFF. Measure resistance of harness between TCM con-
2) Disconnect connectors from TCM and ECM. nector and chassis ground.
3) Measure resistance of harness between TCM Connector & terminal
and ECM connector. (B55) No. 4 — Chassis ground:
Connector & terminal
(B55) No. 4 — (B134) No. 30:
B3M1202A
26
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T8C7] 3-2
8. Diagnostic Chart with Trouble Code
8C3 : PREPARE SUBARU SELECT MONI- 8C5 : CHECK INPUT SIGNAL FOR TCM
TOR. USING SUBARU SELECT MONITOR.
: Do you have a Subaru Select Moni- 1) Connect connectors to TCM and ECM.
tor? 2) Connect Subaru Select Monitor to data link
: Go to step 8C5. connector.
: Go to step 8C4.
27
3-2 [T8C7] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
8. Diagnostic Chart with Trouble Code
MEMO:
28
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T8D2] 3-2
8. Diagnostic Chart with Trouble Code
H3M1795
1) Turn ignition switch to OFF. Measure resistance of harness between TCM con-
2) Disconnect connectors from TCM and ECM. nector and chassis ground.
3) Measure resistance of harness between TCM Connector & terminal
and ECM connector. (B55) No. 20 — Chassis ground:
Connector & terminal
(B55) No. 20 — (B136) No. 11:
B3M1243A
29
3-2 [T8D3] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
8. Diagnostic Chart with Trouble Code
8D3 : PREPARE SUBARU SELECT MONI- 8D5 : CHECK INPUT SIGNAL FOR TCM
TOR. USING SUBARU SELECT MONITOR.
: Do you have a Subaru Select Moni- 1) Connect connectors to TCM and ECM.
tor? 2) Turn ignition switch to OFF.
3) Connect Subaru Select Monitor to data link
: Go to step 8D5.
connector.
: Go to step 8D4.
30
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T8E2] 3-2
8. Diagnostic Chart with Trouble Code
B2M2219
1) Turn ignition switch to OFF. Measure resistance of harness between TCM and
2) Disconnect connector from transmission and transmission connector.
TCM. Connector & terminal
3) Measure resistance of harness between TCM (B55) No. 11 — (B11) No. 11:
and transmission connector.
Connector & terminal
(B55) No. 10 — (B11) No. 12:
B3M1314A
31
3-2 [T8E3] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
8. Diagnostic Chart with Trouble Code
Measure resistance of harness between TCM con- : Is the resistance between 275 and
nector and transmission ground. 375 Ω?
Connector & terminal : Go to step 8E6.
(B55) No. 11 — Chassis ground: : Go to step 8E13.
B3M1316A
32
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T8E8] 3-2
8. Diagnostic Chart with Trouble Code
8E6 : CHECK ATF TEMPERATURE SEN- 8E8 : CHECK INPUT SIGNAL FOR TCM.
SOR.
1) Warm-up the transmission until ATF tempera-
1) Turn ignition switch to ON (engine OFF). ture is about 80°C (176°F).
2) Measure resistance between transmission con-
NOTE:
nector terminals.
If ambient temperature is below 0°C (32°F), drive
Connector & terminal the vehicle until the ATF reaches its operating tem-
(T4) No. 11 — No. 12: perature.
2) Measure voltage between TCM connector ter-
minal.
Connector & terminal
(B55) No. 11 (+) — No. 10 (−):
H3M1824A
33
3-2 [T8E9] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
8. Diagnostic Chart with Trouble Code
8E9 : CHECK INPUT SIGNAL FOR TCM. 8E10 : CHECK INPUT SIGNAL FOR TCM
USING SUBARU SELECT MONITOR.
1) Turn ignition switch to ON (engine OFF).
2) Measure voltage between TCM connector ter- 1) Turn ignition switch to OFF.
minal. 2) Connect connectors to TCM and transmission.
3) Connect Subaru Select Monitor to data link
Connector & terminal
connector.
(B55) No. 11 (+) — No. 10 (−):
S2M0258
B3M1319A
34
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T8E15] 3-2
8. Diagnostic Chart with Trouble Code
B3M1320A
35
3-2 [T8E16] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
8. Diagnostic Chart with Trouble Code
B3M1323A
36
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T8F1] 3-2
8. Diagnostic Chart with Trouble Code
H3M1796
37
3-2 [T8F2] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
8. Diagnostic Chart with Trouble Code
B3M1208A
B3M1207
: Is the resistance less than 1 Ω?
: Is the resistance between 0.3 and 0.7 : Go to step 8F5.
kΩ? : Repair open circuit in harness between
: Go to step 8F3. TCM and throttle position sensor
: Replace throttle position sensor. <Ref. connector, and poor contact in coupling
to 2-7 [W9A0].> connector.
B3M1206
38
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T8F7] 3-2
8. Diagnostic Chart with Trouble Code
B3M1209A
: Go to step 8F10.
: Repair open circuit in harness between : Is the resistance between 0.3 and 0.7
TCM and throttle position sensor kΩ?
connector, and poor contact in coupling : Go to step 8F7.
connector. : Replace throttle position sensor. <Ref.
to 2-7 [W9A0].>
B3M1211
39
3-2 [T8F8] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
8. Diagnostic Chart with Trouble Code
1) Disconnect connector from TCM. Measure resistance of harness between TCM and
2) Measure resistance of harness between TCM throttle position sensor connector.
and throttle position sensor connector. Connector & terminal
Connector & terminal (B55) No. 1 — (E13) No. 1:
(B55) No. 2 — (E13) No. 3:
B3M1213A
B3M1212A
: Is the resistance less than 1 Ω?
: Is the resistance less than 1 Ω? : Go to step 8F10.
: Go to step 8F9. : Repair open circuit in harness between
: Repair open circuit in harness between TCM and throttle position sensor
TCM and throttle position sensor connector, and poor contact in coupling
connector, and poor contact in coupling connector.
connector.
8F10 : CHECK HARNESS CONNECTOR
BETWEEN TCM AND THROTTLE
POSITION SENSOR.
B3M1214A
40
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T8F14] 3-2
8. Diagnostic Chart with Trouble Code
B3M1217A
B3M1215A
: Is the resistance less than 1 Ω?
: Is the resistance more than 1 MΩ? : Go to step 8F14.
: Go to step 8F12. : Repair open circuit in harness between
: Repair short circuit in harness between TCM and ECM connector.
TCM and throttle position sensor con-
nector. 8F14 : PREPARE SUBARU SELECT MONI-
TOR.
8F12 : CHECK HARNESS CONNECTOR
BETWEEN TCM AND ECM. : Do you have a Subaru Select Moni-
tor?
1) Disconnect connector from ECM. : Go to step 8F17.
2) Measure resistance of harness between TCM
: Go to step 8F15.
and ECM connector.
Connector & terminal
(B55) No. 2 — (B136) No. 17:
B3M1216A
41
3-2 [T8F15] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
8. Diagnostic Chart with Trouble Code
8F15 : CHECK INPUT SIGNAL FOR TCM. 8F17 : CHECK INPUT SIGNAL FOR TCM
USING SUBARU SELECT MONITOR.
1) Connect connectors to TCM, throttle position
sensor and ECM. 1) Connect connectors to TCM, throttle position
2) Turn ignition switch to ON (engine OFF). sensor and ECM.
3) Measure voltage between TCM connector ter- 2) Connect Subaru Select Monitor to data link
minals. connector.
Connector & terminal
(B55) No. 2 (+) — No. 9 (−):
S2M0258
42
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T8F21] 3-2
8. Diagnostic Chart with Trouble Code
8F19 : CHECK INPUT SIGNAL FOR TCM 8F21 : CHECK POOR CONTACT.
(THROTTLE POSITION SENSOR
POWER SUPPLY). : Is there poor contact in throttle posi-
tion sensor circuit?
Measure voltage between TCM connector termi- : Repair poor contact.
nals. : Replace TCM. <Ref. to 3-2 [W22A0].>
Connector & terminal
(B55) No. 1 (+) — (B136) No. 15 (−):
H3M1785A
43
3-2 [T8F21] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
8. Diagnostic Chart with Trouble Code
MEMO:
44
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T8G1] 3-2
8. Diagnostic Chart with Trouble Code
H3M1797
45
3-2 [T8G2] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
8. Diagnostic Chart with Trouble Code
1) Disconnect connector from TCM. Measure resistance of harness between TCM and
2) Measure resistance of harness between TCM transmission connector.
and transmission connector. Connector & terminal
Connector & terminal (B55) No. 21 — Chassis ground:
(B55) No. 5 — (B11) No. 17:
B3M1249A
B3M1247A
: Is the resistance more than 1 MΩ?
: Is the resistance less than 1 Ω? : Go to step 8G5.
: Go to step 8G3. : Repair short circuit in harness between
: Repair open circuit in harness between TCM and transmission connector.
TCM and transmission connector.
8G5 : CHECK HARNESS CONNECTOR
8G3 : CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMIS-
BETWEEN TCM AND TRANSMIS- SION.
SION.
Measure resistance of harness between TCM and
Measure resistance of harness between TCM and transmission connector.
transmission connector. Connector & terminal
Connector & terminal (B55) No. 5 — Chassis ground:
(B55) No. 21 — (B11) No. 18:
B3M1250A
B3M1248A
: Is the resistance more than 1 MΩ?
: Is the resistance less than 1 Ω? : Go to step 8G6.
: Go to step 8G4. : Repair short circuit in harness between
: Repair open circuit in harness between TCM and transmission connector.
TCM and transmission connector, and
poor contact in coupling connector.
46
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T8G9] 3-2
8. Diagnostic Chart with Trouble Code
8G6 : CHECK VEHICLE SPEED SENSOR 2. 8G9 : CHECK INPUT SIGNAL FOR TCM.
47
3-2 [T8G10] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
8. Diagnostic Chart with Trouble Code
8G10 : CHECK VEHICLE SPEED SENSOR 2 8G11 : CHECK INPUT SIGNAL FOR TCM
USING OSCILLOSCOPE. USING SUBARU SELECT MONITOR.
S2M0258
48
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T8G15] 3-2
8. Diagnostic Chart with Trouble Code
H3M1786A
H3M1787A
49
3-2 [T8G16] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
8. Diagnostic Chart with Trouble Code
B3M1256A
50
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T8G19] 3-2
8. Diagnostic Chart with Trouble Code
8G18 : CHECK INPUT SIGNAL FOR TCM 8G19 : CHECK POOR CONTACT.
USING SUBARU SELECT MONITOR.
: Is there poor contact in vehicle speed
1) Connect all connectors. sensor 2 circuit?
2) Lift-up the vehicle and place safety stand. : Repair poor contact.
CAUTION: : Replace TCM. <Ref. to 3-2 [W22A0].>
On AWD models, raise all wheels off ground.
3) Connect Subaru Select Monitor to data link
connector.
S2M0258
51
3-2 [T8G19] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
8. Diagnostic Chart with Trouble Code
MEMO:
52
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T8H2] 3-2
8. Diagnostic Chart with Trouble Code
H3M1798
B3M1293A B3M1294A
53
3-2 [T8H3] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
8. Diagnostic Chart with Trouble Code
Measure resistance of harness between TCM and Measure resistance of harness between TCM and
transmission connector. transmission connector.
Connector & terminal Connector & terminal
(B55) No. 21 — (B11) No. 15: (B55) No. 12 — Chassis ground:
B3M1295A B3M1297A
B3M1296A
54
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T8H9] 3-2
8. Diagnostic Chart with Trouble Code
8H8 : CHECK INPUT SIGNAL FOR TCM. 8H9 : CHECK INPUT SIGNAL FOR TCM
USING SUBARU SELECT MONITOR.
1) Connect connectors to TCM and transmission.
2) Lift-up or raise the vehicle and place safety 1) Connect connectors to TCM and transmission.
stands. 2) Connect Subaru Select Monitor to data link
connector.
CAUTION:
Raise all wheels off floor.
3) Start the engine and set vehicle in 20 km/h (12
MPH) condition.
NOTE:
The speed difference between front and rear
wheels may light the ABS warning light, but this
indicates no malfunction. When AT control diagno-
sis is finished, perform the ABS memory clearance
procedure of on-board diagnostics system. <Ref.
to 4-4 [T6D2].> S2M0258
4) Measure voltage between TCM connector ter- 3) Lift-up or raise the vehicle and place safety
minals. stands.
Connector & terminal CAUTION:
(B55) No. 12 (+) — No. 21 (−): Raise all wheels off floor.
4) Turn ignition switch to ON and turn Subaru
Select Monitor switch to ON.
5) Start the engine.
6) Read data of vehicle speed using Subaru
Select Monitor.
I Compare speedometer with Subaru Select
Monitor indications.
I Vehicle speed is indicated in “km/h” or “MPH”.
7) Slowly increase vehicle speed to 20 km/h or 12
MPH.
B3M1299A
NOTE:
: Is the voltage more than AC 1 V? The speed difference between front and rear
wheels may light the ABS warning light, but this
: Even if “AT OIL TEMP” lights up, the
indicates no malfunction. When AT control diagno-
circuit has returned to a normal condi-
sis is finished, perform the ABS memory clearance
tion at this time. A temporary poor con-
procedure of on-board diagnostics system. <Ref.
tact of the connector or harness may be
to 4-4 [T6D2].>
the cause. Repair harness or connector
in the TCM and transmission. : Is the revolution value same as the
: Go to step 8H11. tachometer reading shown on the
combination meter?
: Even if “AT OIL TEMP” lights up, the
circuit has returned to a normal condi-
tion at this time. A temporary poor con-
tact of the connector or harness may be
the cause. Repair harness or connector
in the TCM and transmission.
: Go to step 8H11.
55
3-2 [T8H10] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
8. Diagnostic Chart with Trouble Code
8H10 : CHECK INPUT SIGNAL FOR TCM 5) Measure signal voltage indicated on oscillo-
USING OSCILLOSCOPE. scope.
56
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T8I2] 3-2
8. Diagnostic Chart with Trouble Code
H3M1799
1) Turn ignition switch to OFF. Measure resistance of harness between TCM and
2) Disconnect connectors from TCM and ECM. ECM connector.
3) Measure resistance of harness between TCM Connector & terminal
and ECM connector. (B54) No. 13 — (B135) No. 16:
Connector & terminal
(B54) No. 21 — (B135) No. 17:
H3M1789A
57
3-2 [T8I3] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
8. Diagnostic Chart with Trouble Code
Measure resistance of harness between TCM con- 1) Connect connectors to TCM and ECM.
nector and chassis ground. 2) Turn ignition switch to ON (engine OFF).
Connector & terminal 3) Measure voltage between TCM connector ter-
(B54) No. 21 — Chassis ground: minals.
Connector & terminal
(B54) No. 21 (+) — (B55) No. 19:
B3M1334A
: Go to step 8I4.
: Is the voltage more than 9 V?
: Repair short circuit in harness between
TCM and ECM connector. : Even if “AT OIL TEMP” lights up, the
circuit has returned to a normal condi-
tion at this time. A temporary poor con-
8I4 : CHECK HARNESS CONNECTOR tact of the connector or harness may be
BETWEEN TCM AND ECM. the cause. Repair harness or connector
in the TCM and ECM.
Measure resistance of harness between TCM con- : Go to step 8I6.
nector and chassis ground.
Connector & terminal
(B54) No. 13 — Chassis ground:
B3M1354A
58
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T8I8] 3-2
8. Diagnostic Chart with Trouble Code
B3M1355A
59
3-2 [T8I8] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
8. Diagnostic Chart with Trouble Code
MEMO:
60
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T8J2] 3-2
8. Diagnostic Chart with Trouble Code
B3M1244
1) Turn ignition switch to OFF. Measure resistance of harness between TCM con-
2) Disconnect connectors from TCM and ECM. nector and chassis ground.
3) Measure resistance of harness between TCM Connector & terminal
and ECM connector. (B55) No. 20 — Chassis ground:
Connector & terminal
(B55) No. 20 — (B136) No. 11:
B3M1243A
61
3-2 [T8J3] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
8. Diagnostic Chart with Trouble Code
8J3 : PREPARE SUBARU SELECT MONI- 8J5 : CHECK INPUT SIGNAL FOR TCM
TOR. USING SUBARU SELECT MONITOR.
: Do you have a Subaru Select Moni- 1) Connect connectors to TCM and ECM.
tor? 2) Turn ignition switch to OFF.
3) Connect Subaru Select Monitor to data link
: Go to step 8J5.
connector.
: Go to step 8J4.
62
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T8K2] 3-2
8. Diagnostic Chart with Trouble Code
B2M2226
B3M1226A
63
3-2 [T8K3] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
8. Diagnostic Chart with Trouble Code
1) Disconnect connector from TCM. Measure resistance of harness between TCM con-
2) Measure resistance of harness between TCM nector and transmission ground.
and shift solenoid 1 connector. Connector & terminal
Connector & terminal (B54) No. 7 — Chassis ground:
(B54) No. 7 — (B11) No. 1:
B3M1229A
B3M1227A
: Is the resistance more than 1 MΩ?
: Is the resistance less than 1 Ω? : Go to step 8K6.
: Go to step 8K4. : Repair short circuit in harness between
: Repair open circuit in harness between TCM and transmission connector.
TCM and transmission connector.
8K6 : CHECK HARNESS CONNECTOR
8K4 : CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMIS-
BETWEEN TCM AND TRANSMIS- SION.
SION.
Measure resistance of harness TCM connector
Measure resistance of harness between TCM and and transmission ground.
shift solenoid 1 connector. Connector & terminal
Connector & terminal (B55) No. 19 — Chassis ground:
(B55) No. 19 — (B11) No. 16:
H3M1791A
H3M1790A
: Is the resistance more than 1 MΩ?
: Is the resistance less than 1 Ω? : Go to step 8K7.
: Go to step 8K5. : Repair short circuit in harness between
: Repair open circuit in harness between TCM and transmission connector.
TCM and transmission connector.
64
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T8K9] 3-2
8. Diagnostic Chart with Trouble Code
B3M1232
B3M1231A
: Is the resistance between 10 and 16
Ω?
: Is the voltage 1 V → 9 V?
: Go to step 8K10.
: Even if “AT OIL TEMP” lights up, the
circuit has returned to a normal condi- : Replace shift solenoid 1. <Ref. to 3-2
tion at this time. A temporary poor con- [W4A0].>
tact of the connector or harness may be
the cause. Repair harness or connector
in the TCM.
: Go to step 8K8.
65
3-2 [T8K10] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
8. Diagnostic Chart with Trouble Code
Measure resistance of harness between shift sole- Measure resistance of harness between shift sole-
noid 1 and transmission connector. noid 1 connector and transmission ground.
Connector & terminal Connector & terminal
(AT5) No. 1 — (T4) No. 1: (T4) No. 1 — Transmission ground:
B3M1233A B3M1234A
66
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T8L2] 3-2
8. Diagnostic Chart with Trouble Code
B2M2098
B3M1235A
67
3-2 [T8L3] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
8. Diagnostic Chart with Trouble Code
1) Disconnect connector from TCM. Measure resistance of harness between TCM con-
2) Measure resistance of harness between TCM nector and transmission ground.
and shift solenoid 2 connector. Connector & terminal
Connector & terminal (B54) No. 6 — Chassis ground:
(B54) No. 6 — (B11) No. 2:
B3M1237A
B3M1236A
: Is the resistance more than 1 MΩ?
: Is the resistance less than 1 Ω? : Go to step 8L6.
: Go to step 8L4. : Repair short circuit in harness between
: Repair open circuit in harness between TCM and transmission connector.
TCM and transmission connector.
8L6 : CHECK HARNESS CONNECTOR
8L4 : CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMIS-
BETWEEN TCM AND TRANSMIS- SION.
SION.
Measure resistance of harness between TCM con-
Measure resistance of harness between TCM and nector and transmission ground.
shift solenoid 2 connector. Connector & terminal
Connector & terminal (B55) No. 19 — Chassis ground:
(B55) No. 19 — (B11) No. 16:
H3M1791A
H3M1790A
: Is the resistance more than 1 MΩ?
: Is the resistance less than 1 Ω? : Go to step 8L7.
: Go to step 8L5. : Repair short circuit in harness between
: Repair open circuit in harness between TCM and transmission connector.
TCM and transmission connector.
68
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T8L9] 3-2
8. Diagnostic Chart with Trouble Code
B3M1232
: Is the voltage 9 V → 1 V?
: Even if “AT OIL TEMP” lights up, the
circuit has returned to a normal condi-
tion at this time. A temporary poor con-
tact of the connector or harness may be
the cause. Repair harness or contact in
the TCM.
: Go to step 8L8.
69
3-2 [T8L10] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
8. Diagnostic Chart with Trouble Code
Measure resistance of harness between shift sole- Measure resistance of harness between shift sole-
noid 2 and transmission connector. noid 2 connector and transmission ground.
Connector & terminal Connector & terminal
(AT6) No. 1 — (T4) No. 2: (T4) No. 2 — Transmission ground:
B3M1239A B3M1240A
70
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T8M2] 3-2
8. Diagnostic Chart with Trouble Code
H3M1800
8M1 : CHECK LOW CLUTCH TIMING SOLE- 8M2 : CHECK LOW CLUTCH TIMING SOLE-
NOID GROUND LINE. NOID.
B3M1259A
71
3-2 [T8M3] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
8. Diagnostic Chart with Trouble Code
1) Disconnect connector from TCM. Measure resistance of harness between TCM con-
2) Measure resistance of harness between TCM nector and transmission ground.
and transmission connector. Connector & terminal
Connector & terminal (B54) No. 14 — Chassis ground:
(B54) No. 14 — (B11) No. 3:
B3M1261A
B3M1260A
: Is the resistance more than 1 MΩ?
: Is the resistance less than 1 Ω? : Go to step 8M6.
: Go to step 8M4. : Repair short circuit in harness between
: Repair open circuit in harness between TCM and transmission connector.
TCM and transmission connector.
8M6 : CHECK HARNESS CONNECTOR
8M4 : CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMIS-
BETWEEN TCM AND TRANSMIS- SION.
SION.
Measure resistance of harness between TCM con-
Measure resistance of harness between TCM and nector and transmission ground.
transmission connector. Connector & terminal
Connector & terminal (B55) No. 19 — Chassis ground:
(B55) No. 19 — (B11) No. 16:
H3M1791A
H3M1790A
: Is the resistance more than 1 MΩ?
: Is the resistance less than 1 Ω? : Go to step 8M7.
: Go to step 8M5. : Repair short circuit in harness between
: Repair open circuit in harness between TCM and transmission connector.
TCM and transmission connector.
72
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T8M9] 3-2
8. Diagnostic Chart with Trouble Code
8M7 : CHECK OUTPUT SIGNAL EMITTED 8M8 : CHECK OUTPUT SIGNAL EMITTED
FROM TCM. FROM TCM.
1) Connect connectors to TCM and transmission. 1) Move selector lever to “D”, and slowly increase
2) Lift-up or raise the vehicle and support with vehicle speed to 65 km/h (40 MPH).
safety stand. NOTE:
CAUTION: The speed difference between front and rear
On AWD models, raise all wheels off ground. wheels may light the ABS warning light, but this
3) Start the engine and warm-up the transmission indicates no malfunction. When AT control diagno-
until ATF temperature is above 80°C (176°F). sis is finished, perform the ABS memory clearance
procedure of on-board diagnostics system. <Ref.
NOTE: to 4-4 [T6D2].>
If ambient temperature is below 0°C (32°F), drive
the vehicle until the ATF reaches its operating tem- 2) Measure voltage between TCM connector ter-
perature. minals.
4) Move selector lever to “2”, and slowly increase Connector & terminal
vehicle speed to 35 km/h (22 MPH). (B54) No. 14 (+) — (B55) No. 19 (−):
NOTE:
The speed difference between front and rear
wheels may light the ABS warning light, but this
indicates no malfunction. When AT control diagno-
sis is finished, perform the ABS memory clearance
procedure of on-board diagnostics system. <Ref.
to 4-4 [T6D2].>
5) Measure voltage between TCM connector ter-
minals.
B3M1262A
Connector & terminal
(B54) No. 14 (+) — (B55) No. 19 (−):
: Is the voltage more than 9 V?
: Even if “AT OIL TEMP” lights up, the
circuit has returned to a normal condi-
tion at this time. A temporary poor con-
tact of the connector or harness may be
the cause. Repair harness or contact in
the TCM.
: Go to step 8M9.
73
3-2 [T8M10] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
8. Diagnostic Chart with Trouble Code
B3M1232
74
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T8M12] 3-2
8. Diagnostic Chart with Trouble Code
B3M1264A
75
3-2 [T8M12] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
8. Diagnostic Chart with Trouble Code
MEMO:
76
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T8N2] 3-2
8. Diagnostic Chart with Trouble Code
H3M1801
8N1 : CHECK 2-4 BRAKE TIMING SOLE- 8N2 : CHECK 2-4 BRAKE TIMING SOLE-
NOID GROUND LINE. NOID.
B3M1273A
77
3-2 [T8N3] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
8. Diagnostic Chart with Trouble Code
1) Disconnect connector from TCM. Measure resistance of harness between TCM con-
2) Measure resistance of harness between TCM nector and transmission ground.
and transmission connector. Connector & terminal
Connector & terminal (B54) No. 5 — Chassis ground:
(B54) No. 5 — (B11) No. 4:
B3M1275A
B3M1274A
: Is the resistance more than 1 MΩ?
: Is the resistance less than 1 Ω? : Go to step 8N6.
: Go to step 8N4. : Repair short circuit in harness between
: Repair open circuit in harness between TCM and transmission connector.
TCM and transmission connector.
8N6 : CHECK HARNESS CONNECTOR
8N4 : CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMIS-
BETWEEN TCM AND TRANSMIS- SION.
SION.
Measure resistance of harness between TCM con-
Measure resistance of harness between TCM and nector and transmission ground.
transmission connector. Connector & terminal
Connector & terminal (B55) No. 19 — Chassis ground:
(B55) No. 19 — (B11) No. 16:
H3M1791A
H3M1790A
: Is the resistance more than 1 MΩ?
: Is the resistance less than 1 Ω? : Go to step 8N7.
: Go to step 8N5. : Repair short circuit in harness between
: Repair open circuit in harness between TCM and transmission connector.
TCM and transmission connector.
78
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T8N9] 3-2
8. Diagnostic Chart with Trouble Code
8N7 : CHECK OUTPUT SIGNAL EMITTED 8N8 : CHECK OUTPUT SIGNAL EMITTED
FROM TCM. FROM TCM.
1) Connect connectors to TCM and transmission. 1) Move selector lever to “D”, and slowly increase
2) Lift-up or raise the vehicle and support with vehicle speed to 65 km/h (40 MPH).
safety stand. NOTE:
CAUTION: The speed difference between front and rear
On AWD models, raise all wheels off ground. wheels may light the ABS warning light, but this
3) Start the engine and warm-up the transmission indicates no malfunction. When AT control diagno-
until ATF temperature is above 80°C (176°F). sis is finished, perform the ABS memory clearance
procedure of on-board diagnostics system. <Ref.
NOTE: to 4-4 [T6D2].>
If ambient temperature is below 0°C (32°F), drive
the vehicle until the ATF reaches its operating tem- 2) Measure voltage between TCM connector ter-
perature. minals.
4) Move selector lever to “1”, and slowly increase Connector & terminal
vehicle speed to 10 km/h (6 MPH). (B54) No. 5 (+) — (B55) No. 19 (−):
NOTE:
The speed difference between front and rear
wheels may light the ABS warning light, but this
indicates no malfunction. When AT control diagno-
sis is finished, perform the ABS memory clearance
procedure of on-board diagnostics system. <Ref.
to 4-4 [T6D2].>
5) Measure voltage between TCM connector ter-
minals.
B3M1276A
Connector & terminal
(B54) No. 5 (+) — (B55) No. 19 (−):
: Is the voltage more than 9 V?
: Even if “AT OIL TEMP” lights up, the
circuit has returned to a normal condi-
tion at this time. A temporary poor con-
tact of the connector or harness may be
the cause. Repair harness or contact in
the TCM.
: Go to step 8N9.
: Is the voltage less than 1 V? : Is there poor contact in 2-4 brake tim-
ing solenoid circuit?
: Go to step 8N8.
: Repair poor contact.
: Go to step 8N9.
: Replace TCM. <Ref. to 3-2 [W22A0].>
79
3-2 [T8N10] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
8. Diagnostic Chart with Trouble Code
8N10 : CHECK 2-4 BRAKE TIMING SOLE- 8N11 : CHECK HARNESS CONNECTOR
NOID (IN TRANSMISSION). BETWEEN 2-4 BRAKE TIMING
SOLENOID AND TRANSMISSION.
1) Remove transmission connector from bracket.
2) Lift-up or raise the vehicle and support with Measure resistance of harness between 2-4 brake
safety stand. timing solenoid and transmission connector.
CAUTION: Connector & terminal
On AWD models, raise all wheels off ground. (AT8) No. 1 — (T4) No. 4:
3) Drain automatic transmission fluid.
CAUTION:
Do not drain the automatic transmission fluid
until it cools down.
4) Remove oil pan, and disconnect connector
from 2-4 brake timing solenoid.
5) Measure resistance between 2-4 brake timing
solenoid connector and transmission ground.
Terminal B3M1278A
No. 1 — Transmission ground:
: Is the resistance less than 1 Ω?
: Go to step 8N12.
: Repair open circuit in harness between
2-4 brake timing solenoid and transmis-
sion connector.
B3M1232
80
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T8N12] 3-2
8. Diagnostic Chart with Trouble Code
B3M1279A
81
3-2 [T8N12] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
8. Diagnostic Chart with Trouble Code
MEMO:
82
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T8O2] 3-2
8. Diagnostic Chart with Trouble Code
B2M2100
B3M1280
B3M1281A
83
3-2 [T8O3] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
8. Diagnostic Chart with Trouble Code
Measure resistance of harness between dropping Measure resistance of harness between dropping
resistor connector and chassis ground. resistor connector and chassis ground.
Connector & terminal Connector & terminal
(B4) No. 1 — Chassis ground: (B4) No. 2 — Chassis ground:
B3M1282A B3M1284A
: Is the resistance more than 1 MΩ? : Is the resistance more than 1 MΩ?
: Go to step 8O4. : Go to step 8O6.
: Repair short circuit in harness between : Repair short circuit in harness between
TCM and dropping resistor connector. dropping resistor and transmission con-
nector.
8O4 : CHECK HARNESS CONNECTOR
BETWEEN TRANSMISSION AND 8O6 : CHECK DUTY SOLENOID A GROUND
DROPPING RESISTOR. LINE.
B3M1198A
B3M1283A
: Is the resistance less than 1 Ω?
: Is the resistance less than 1 Ω? : Go to step 8O7.
: Go to step 8O5. : Repair open circuit in transmission har-
: Repair open circuit in harness between ness.
dropping resistor and transmission con-
nector.
84
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T8O10] 3-2
8. Diagnostic Chart with Trouble Code
B3M1285A
Ω?
: Go to step 8O8. : Is the resistance less than 1 Ω?
: Go to step 8O20. : Go to step 8O10.
: Repair open circuit in harness between
TCM and transmission connector.
8O8 : CHECK HARNESS CONNECTOR
BETWEEN TCM AND TRANSMIS-
SION. 8O10 : CHECK HARNESS CONNECTOR
BETWEEN TCM AND CHASSIS
Measure resistance of harness between TCM and GROUND.
transmission connector.
Measure resistance of harness between TCM and
Connector & terminal
chassis ground.
(B54) No. 9 — (B11) No. 5:
Connector & terminal
(B54) No. 9 — Chassis ground:
B3M1286A
: Go to step 8O9.
: Is the resistance more than 1 MΩ?
: Repair open circuit in harness between
TCM and transmission connector. : Go to step 8O11.
: Repair short circuit in harness between
TCM and transmission connector.
85
3-2 [T8O11] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
8. Diagnostic Chart with Trouble Code
8O11 : PREPARE SUBARU SELECT MONI- 8O13 : CHECK OUTPUT SIGNAL EMITTED
TOR. FROM TCM.
B3M1288A
H3M1791A
: Is the resistance more than 1 MΩ? : Is the voltage between 1.5 and 4.0 V
with throttle fully closed?
: Go to step 8O13.
: Go to step 8O14.
: Repair short circuit harness between
TCM and transmission connector. : Go to step 8O19.
86
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T8O16] 3-2
8. Diagnostic Chart with Trouble Code
8O14 : CHECK OUTPUT SIGNAL EMITTED 8O16 : CHECK OUTPUT SIGNAL EMITTED
FROM TCM. FROM TCM.
Measure voltage between TCM connector termi- Measure voltage between TCM connector termi-
nal. nal.
Connector & terminal Connector & terminal
(B54) No. 9 (+) — (B55) No. 19 (−): (B54) No. 18 (+) — (B55) No. 19:
B3M1288A B3M1289A
: Is the voltage less than 1 V with : Is the voltage less than 1 V with
throttle fully open? throttle fully open?
: Go to step 8O15. : Even if “AT OIL TEMP” lights up, the
: Go to step 8O19. circuit has returned to a normal condi-
tion at this time. A temporary poor con-
tact of the connector or harness may be
8O15 : CHECK OUTPUT SIGNAL EMITTED the cause. Repair harness or connector
FROM TCM. in TCM.
: Go to step 8O19.
Measure voltage between TCM connector termi-
nal.
Connector & terminal
(B54) No. 18 (+) — (B55) No. 19 (−):
B3M1289A
87
3-2 [T8O17] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
8. Diagnostic Chart with Trouble Code
88
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T8O22] 3-2
8. Diagnostic Chart with Trouble Code
Measure resistance of harness between duty sole- Measure resistance of harness between transmis-
noid A and transmission connector. sion connector and transmission ground.
Connector & terminal Connector & terminal
(T4) No. 5 — (AT2) No. 1: (T4) No. 5 — Transmission ground:
B3M1291A B3M1292A
89
3-2 [T8O22] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
8. Diagnostic Chart with Trouble Code
MEMO:
90
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T8P2] 3-2
8. Diagnostic Chart with Trouble Code
H3M1802
B3M1302
B3M1303A
91
3-2 [T8P3] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
8. Diagnostic Chart with Trouble Code
Measure resistance of harness between dropping Measure resistance of harness between dropping
resistor connector and chassis ground. resistor connector and chassis ground.
Connector & terminal Connector & terminal
(B4) No. 3 — Chassis ground: (B4) No. 4 — Chassis ground:
B3M1304A B3M1306A
: Is the resistance more than 1 MΩ? : Is the resistance more than 1 MΩ?
: Go to step 8P4. : Go to step 8P6.
: Repair short circuit in harness between : Repair short circuit in harness between
TCM and dropping resistor connector. dropping resistor and transmission con-
nector.
8P4 : CHECK HARNESS CONNECTOR
BETWEEN TRANSMISSION AND 8P6 : CHECK DUTY SOLENOID D GROUND
DROPPING RESISTOR. LINE.
B3M1198A
B3M1305A
: Is the resistance less than 1 Ω?
: Is the resistance less than 1 Ω? : Go to step 8P7.
: Go to step 8P5. : Repair open circuit in transmission har-
: Repair open circuit in harness between ness.
dropping resistor and transmission con-
nector.
92
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T8P10] 3-2
8. Diagnostic Chart with Trouble Code
B3M1307A
Ω?
: Go to step 8P8. : Is the resistance less than 1 Ω?
: Go to step 8P20. : Go to step 8P10.
: Repair open circuit in harness between
TCM and transmission connector.
8P8 : CHECK HARNESS CONNECTOR
BETWEEN TCM AND TRANSMIS-
SION. 8P10 : CHECK HARNESS CONNECTOR
BETWEEN TCM AND CHASSIS
Measure resistance of harness between TCM and GROUND.
transmission connector.
Measure resistance of harness between TCM and
Connector & terminal
chassis ground.
(B54) No. 8 — (B11) No. 9:
Connector & terminal
(B54) No. 8 — Chassis ground:
B3M1308A
: Go to step 8P9.
: Is the resistance more than 1 MΩ?
: Repair open circuit in harness between
TCM and transmission connector. : Go to step 8P11.
: Repair short circuit in harness between
TCM and transmission connector.
93
3-2 [T8P11] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
8. Diagnostic Chart with Trouble Code
8P11 : PREPARE SUBARU SELECT MONI- 8P13 : CHECK OUTPUT SIGNAL EMITTED
TOR. FROM TCM.
B3M1310A
H3M1791A
: Is the resistance more than 1 MΩ? : Is the voltage between 1.5 and 4.0 V
with throttle fully closed?
: Go to step 8P13.
: Go to step 8P14.
: Repair short circuit harness between
TCM and transmission connector. : Go to step 8P19.
94
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T8P16] 3-2
8. Diagnostic Chart with Trouble Code
8P14 : CHECK OUTPUT SIGNAL EMITTED 8P16 : CHECK OUTPUT SIGNAL EMITTED
FROM TCM. FROM TCM.
Measure voltage between TCM connector termi- Measure voltage between TCM connector termi-
nal. nal.
Connector & terminal Connector & terminal
(B54) No. 8 (+) — (B55) No. 19 (−): (B54) No. 17 (+) — (B55) No. 19 (−):
B3M1310A B3M1311A
: Is the voltage less than 1 V with : Is the voltage less than 1 V with
throttle fully open? throttle fully open?
: Go to step 8P15. : Even if “AT OIL TEMP” lights up, the
: Go to step 8P19. circuit has returned to a normal condi-
tion at this time. A temporary poor con-
tact of the connector or harness may be
8P15 : CHECK OUTPUT SIGNAL EMITTED the cause. Repair harness or connector
FROM TCM. in TCM.
: Go to step 8P19.
Measure voltage between TCM connector termi-
nal.
Connector & terminal
(B54) No. 17 (+) — (B55) No. 19 (−):
B3M1311A
95
3-2 [T8P17] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
8. Diagnostic Chart with Trouble Code
96
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T8P22] 3-2
8. Diagnostic Chart with Trouble Code
Measure resistance of harness between duty sole- Measure resistance of harness between transmis-
noid D and transmission connector. sion connector and transmission ground.
Connector & terminal Connector & terminal
(T4) No. 9 — (AT7) No. 1: (T4) No. 9 — Transmission ground:
B3M1298A B3M1312A
97
3-2 [T8P22] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
8. Diagnostic Chart with Trouble Code
MEMO:
98
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T8Q2] 3-2
8. Diagnostic Chart with Trouble Code
B2M2224
B3M1198A
99
3-2 [T8Q3] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
8. Diagnostic Chart with Trouble Code
H3M1793A
: Go to step 8Q4.
: Is the resistance less than 1 Ω?
: Go to step 8Q14.
: Go to step 8Q6.
: Repair open circuit in harness between
8Q4 : CHECK HARNESS CONNECTOR
BETWEEN TCM AND TRANSMIS- TCM and transmission connector.
SION.
8Q6 : CHECK HARNESS CONNECTOR
1) Disconnect connector from TCM. BETWEEN TCM AND TRANSMIS-
2) Measure resistance of harness between TCM SION.
and transmission connector.
Measure resistance of harness connector between
Connector & terminal
TCM and chassis ground.
(B55) No. 19 — (B11) No. 16:
Connector & terminal
(B54) No. 16 — Chassis ground:
H3M1790A
: Go to step 8Q5.
: Is the resistance more than 1 MΩ?
: Repair open circuit in harness between
TCM and transmission connector. : Go to step 8Q7.
: Repair short circuit in harness between
TCM and transmission connector.
100
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T8Q9] 3-2
8. Diagnostic Chart with Trouble Code
H3M1791A
NOTE:
The speed difference between front and rear
wheels may light the ABS warning light, but this
: Is the resistance more than 1 MΩ?
indicates no malfunction. When AT control diagno-
: Go to step 8Q8. sis is finished, perform the ABS memory clearance
: Repair short circuit in harness between procedure of on-board diagnostics system. <Ref.
TCM and transmission connector. to 4-4 [T6D2].>
5) Measure voltage between TCM connector ter-
8Q8 : PREPARE SUBARU SELECT MONI- minals.
TOR.
Connector & terminal
(B54) No. 16 (+) — (B55) No. 19 (−):
: Do you have a Subaru Select Moni-
tor?
: Go to step 8Q11.
: Go to step 8Q9.
B3M1327A
101
3-2 [T8Q10] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
8. Diagnostic Chart with Trouble Code
8Q10 : CHECK OUTPUT SIGNAL EMITTED 8Q11 : CHECK OUTPUT SIGNAL EMITTED
FROM TCM. FROM TCM USING SUBARU
SELECT MONITOR.
1) Return the engine to idling speed and move
selector lever to “N”. 1) Connect connectors to TCM and transmission.
2) Measure voltage between TCM connector ter- 2) Lift-up the vehicle and place safety stand.
minals. CAUTION:
Connector & terminal On AWD models, raise all wheels off ground.
(B54) No. 16 (+) — (B55) No. 19 (−): 3) Connect Subaru Select Monitor to data link
connector.
B3M1327A
S2M0258
: Is the voltage less than 0.5 V?
: Even if “AT OIL TEMP” lights up, the 4) Start the engine, and turn Subaru Select Moni-
circuit has returned to a normal condi- tor switch to ON.
tion at this time. A temporary poor con- 5) Start the engine and warm-up the transmission
tact of the connector or harness may be until ATF temperature is above 80°C (176°F).
the cause. Repair harness or connector NOTE:
in TCM. If ambient temperature is below 0°C (32°F), drive
: Go to step 8Q13. the vehicle until the ATF reaches its operating tem-
perature.
6) Read data of duty solenoid B using Subaru
Select Monitor.
I Lock-up duty is indicated in “%”.
7) Move selector lever to “D” and slowly increase
vehicle speed to 75 km/h (47 MPH). Wheels will
lock-up.
NOTE:
The speed difference between front and rear
wheels may light the ABS warning light, but this
indicates no malfunction. When AT control diagno-
sis is finished, perform the ABS memory clearance
procedure of on-board diagnostics system. <Ref.
to 4-4 [T6D2].>
: Is the value 95%?
: Go to step 8Q12.
: Go to step 8Q13.
102
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T8Q14] 3-2
8. Diagnostic Chart with Trouble Code
8Q12 : CHECK OUTPUT SIGNAL EMITTED 8Q14 : CHECK DUTY SOLENOID B (IN
FROM TCM USING SUBARU TRANSMISSION).
SELECT MONITOR.
1) Remove transmission connector from bracket.
Return the engine to idling speed and move selec- 2) Drain automatic transmission fluid.
tor lever to “N”.
CAUTION:
NOTE: Do not drain the automatic transmission fluid
The speed difference between front and rear until it cools down.
wheels may light the ABS warning light, but this
3) Remove oil pan, and disconnect connector
indicates no malfunction. When AT control diagno-
from duty solenoid B.
sis is finished, perform the ABS memory clearance
4) Measure resistance between duty solenoid B
procedure of on-board diagnostics system. <Ref.
connector and transmission ground.
to 4-4 [T6D2].>
Terminal
: Is the value 5%? No. 1 — Transmission ground:
: Even if “AT OIL TEMP” lights up, the
circuit has returned to a normal condi-
tion at this time. A temporary poor con-
tact of the connector or harness may be
the cause. Repair harness or connector
in TCM.
: Go to step 8Q13.
103
3-2 [T8Q15] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
8. Diagnostic Chart with Trouble Code
Measure resistance of harness between duty sole- Measure resistance of harness between transmis-
noid B and transmission connector. sion connector and transmission ground.
Connector & terminal Connector & terminal
(T4) No. 13 — (AT3) No. 1: (T4) No. 13 — Transmission ground:
B3M1328A B3M1329A
104
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T8R2] 3-2
8. Diagnostic Chart with Trouble Code
B3M1336
B3M1337A
105
3-2 [T8R3] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
8. Diagnostic Chart with Trouble Code
B3M1339A
B3M1338A
: Is the resistance more than 1 MΩ?
: Is the resistance less than 1 Ω? : Go to step 8R6.
: Go to step 8R4. : Repair short circuit in harness between
: Repair open circuit in harness between TCM and transmission connector.
TCM and transmission connector.
8R6 : CHECK HARNESS CONNECTOR
8R4 : CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMIS-
BETWEEN TCM AND TRANSMIS- SION.
SION.
Measure resistance harness connector between
Measure resistance harness connector between TCM and chassis ground.
TCM and transmission connector. Connector & terminal
Connector & terminal (B55) No. 19 — Chassis ground:
(B55) No. 19 — (B11) No. 16:
H3M1791A
H3M1790A
: Is the resistance more than 1 MΩ?
: Is the resistance less than 1 Ω? : Go to step 8R7.
: Go to step 8R5. : Repair short circuit in harness between
: Repair open circuit in harness between TCM and transmission connector.
TCM and transmission connector.
106
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T8R9] 3-2
8. Diagnostic Chart with Trouble Code
8R7 : PREPARE SUBARU SELECT MONI- 8R9 : CHECK OUTPUT SIGNAL EMITTED
TOR. FROM TCM.
: Do you have a Subaru Select Moni- Measure voltage between TCM connector termi-
tor? nals.
: Go to step 8R10. Connector & terminal
: Go to step 8R8. (B54) No. 15 (+) — (B55) No. 19 (−):
107
3-2 [T8R10] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
8. Diagnostic Chart with Trouble Code
8R10 : CHECK OUTPUT SIGNAL EMITTED 8R13 : CHECK DUTY SOLENOID C (IN
FROM TCM USING SUBARU TRANSMISSION).
SELECT MONITOR.
1) Lift-up the vehicle and place safety stand.
1) Connect connectors to TCM and transmission.
CAUTION:
2) Connect Subaru Select Monitor to data link
On AWD models, raise all wheels off ground.
connector.
2) Drain automatic transmission fluid.
CAUTION:
Do not drain the automatic transmission fluid
until it cools down.
3) Remove extension case, and disconnect con-
nector from duty solenoid C.
4) Measure resistance between duty solenoid C
connector and transmission ground.
Connector & terminal
S2M0258 (AT4) No. 1 — Transmission ground:
3) Turn ignition switch to ON (engine OFF) and
turn Subaru Select Monitor switch to ON.
4) Move selector lever to “D” with throttle fully
open (vehicle speed 0 km/h or 0 MPH).
5) Read data of duty solenoid C using Subaru
Select Monitor.
I Duty solenoid C is indicated in “%”.
: Is the value between 5 and 10%?
: Go to step 8R11.
H3M1295C
: Go to step 8R12.
: Is the resistance between 10 and 17
8R11 : CHECK OUTPUT SIGNAL EMITTED Ω?
FROM TCM USING SUBARU
: Go to step 8R14.
SELECT MONITOR.
: Replace duty solenoid C. <Ref. to 3-2
[W5A0].>
1) Set FWD mode.
2) Throttle fully closed.
: Is the value 95%?
: Even if “AT OIL TEMP” lights up, the
circuit has returned to a normal condi-
tion at this time. A temporary poor con-
tact of the connector or harness may be
the cause. Repair harness or connector
in the duty solenoid C and TCM connec-
tor.
: Go to step 8R12.
108
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T8R15] 3-2
8. Diagnostic Chart with Trouble Code
Measure resistance of harness between duty sole- Measure resistance of harness between transmis-
noid C and transmission connector. sion connector and transmission ground.
Connector & terminal Connector & terminal
(T4) No. 6 — (AT4) No. 1: (T4) No. 6 — Transmission ground:
B3M1341A B3M1342A
109
3-2 [T8R15] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
8. Diagnostic Chart with Trouble Code
MEMO:
110
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T8S2] 3-2
8. Diagnostic Chart with Trouble Code
H3M1803
B3M1266A
B3M1267A
111
3-2 [T8S3] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
8. Diagnostic Chart with Trouble Code
Measure resistance of harness between TCM and Measure resistance of harness between TCM and
transmission connector. transmission connector.
Connector & terminal Connector & terminal
(B55) No. 21 — (B11) No. 20: (B55) No. 21 — Chassis ground:
B3M1268A B3M1249A
B3M1269A
112
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T8S9] 3-2
8. Diagnostic Chart with Trouble Code
8S8 : CHECK INPUT SIGNAL FOR TCM. 8S9 : CHECK INPUT SIGNAL FOR TCM
USING SUBARU SELECT MONITOR.
1) Connect connectors to TCM and transmission.
2) Lift-up or raise the vehicle and place safety 1) Connect connectors to TCM and transmission.
stands. 2) Connect Subaru Select Monitor to data link
connector.
CAUTION:
On AWD models, raise all wheels off floor.
3) Start the engine and set vehicle in 20 km/h (12
MPH) condition.
NOTE:
The speed difference between front and rear
wheels may light the ABS warning light, but this
indicates no malfunction. When AT control diagno-
sis is finished, perform the ABS memory clearance
procedure of on-board diagnostics system. <Ref.
to 4-4 [T6D2].> S2M0258
4) Measure voltage between TCM connector ter- 3) Lift-up or raise the vehicle and place safety
minals. stands.
Connector & terminal CAUTION:
(B55) No. 3 (+) — No. 21 (−): On AWD models, raise all wheels off floor.
4) Turn ignition switch to ON and turn Subaru
Select Monitor switch to ON.
5) Start the engine.
6) Read data of vehicle speed using Subaru
Select Monitor.
I Compare speedometer with Subaru Select
Monitor indications.
I Vehicle speed is indicated in “km/h” or “MPH”.
7) Slowly increase vehicle speed to 60 km/h or 37
MPH.
B3M1270A
NOTE:
: Is the voltage more than AC 1 V? The speed difference between front and rear
wheels may light the ABS warning light, but this
: Even if “AT OIL TEMP” lights up, the
indicates no malfunction. When AT control diagno-
circuit has returned to a normal condi-
sis is finished, perform the ABS memory clearance
tion at this time. A temporary poor con-
procedure of on-board diagnostics system. <Ref.
tact of the connector or harness may be
to 4-4 [T6D2].>
the cause. Repair harness or connector
in the TCM and transmission. : Does the speedometer indication
: Go to step 8S11. increase as the Subaru Select Moni-
tor data increases?
: Even if “AT OIL TEMP” lights up, the
circuit has returned to a normal condi-
tion at this time. A temporary poor con-
tact of the connector or harness may be
the cause. Repair harness or connector
in the TCM and transmission.
: Go to step 8S11.
113
3-2 [T8S10] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
8. Diagnostic Chart with Trouble Code
8S10 : CHECK INPUT SIGNAL FOR TCM 5) Measure signal voltage indicated on oscillo-
USING OSCILLOSCOPE. scope.
4) Start the engine and set vehicle in 20 km/h (12 8S11 : CHECK POOR CONTACT.
MPH) condition.
NOTE: : Is there poor contact in vehicle speed
The speed difference between front and rear sensor 1 circuit?
wheels may light the ABS warning light, but this : Repair poor contact.
indicates no malfunction. When AT control diagno- : Replace TCM. <Ref. to 3-2 [W22A0].>
sis is finished, perform the ABS memory clearance
procedure of on-board diagnostics system. <Ref.
to 4-4 [T6D2].>
114
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T9D1] 3-2
9. Diagnostic Chart with Select Monitor
115
3-2 [T9E1] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
9. Diagnostic Chart with Select Monitor
116
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T9I3] 3-2
9. Diagnostic Chart with Select Monitor
9G3 : CHECK INPUT SIGNAL FOR TCM. I: CHECK LINE PRESSURE DUTY.
9I1 : CHECK OUTPUT SIGNAL EMITTED
: Does voltage decrease smoothly FROM TCM.
when the accelerator pedal is fully
depressed and then fully released?
1) Warm-up the transmission until ATF tempera-
: Go to step GEAR POSITION. <Ref. to
ture is above 80°C (176°F).
3-2 [T9H0].>
: Check throttle position sensor circuit. NOTE:
<Ref. to 3-2 [T8F0].> If ambient temperature is below 0°C (32°F), drive
the vehicle until the ATF reaches its operating tem-
H: CHECK GEAR POSITION. perature.
2) Stop the engine and turn ignition switch to ON
9H1 : CHECK GEAR POSITION. (engine OFF).
3) Move selector lever to “N”.
1) Lift-up the vehicle and place safety stand. 4) Read data of line pressure duty ratio using
Subaru Select Monitor.
CAUTION: I Line pressure duty is indicated in “%”.
On AWD models, raise all wheels off ground.
: Does the Subaru Select Monitor indi-
2) Start the engine. cate 100% when the accelerator
3) Move select lever to “D”, and drive vehicle. pedal is completely released?
4) Read data of gear position using Subaru Select
Monitor. : Go to step 9I2.
I Gear position is indicated. : Go to step 9I4.
NOTE:
The speed difference between front and rear 9I2 : CHECK OUTPUT SIGNAL EMITTED
wheels may light the ABS warning light, but this FROM TCM.
indicates no malfunction. When AT control diagno-
sis is finished, perform the ABS memory clearance : Does the Subaru Select Monitor indi-
procedure of on-board diagnostics system. <Ref. cate between 10 and 20% when the
to 4-4 [T6D2].> accelerator pedal is completely
: Does the transmission gear corre- depressed?
spond to the gear which is shown on : Go to step 9I3.
display? : Go to step 9I4.
: Go to step LINE PRESSURE DUTY.
<Ref. to 3-2 [T9I0].> 9I3 : CHECK OUTPUT SIGNAL EMITTED
: Check shift solenoid 1 and shift solenoid FROM TCM.
2 signal circuit. <Ref. to 3-2 [T8K0].>
and <Ref. to 3-2 [T8L0].> : Does the Subaru Select Monitor
change smoothly when the accelera-
tor pedal is fully depressed and then
fully released?
: Go to step LOCK-UP DUTY. <Ref. to 3-2
[T9J0].>
: Go to step 9I4.
117
3-2 [T9I4] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
9. Diagnostic Chart with Select Monitor
118
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T9K4] 3-2
9. Diagnostic Chart with Select Monitor
119
3-2 [T9K5] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
9. Diagnostic Chart with Select Monitor
120
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T9O1] 3-2
9. Diagnostic Chart with Select Monitor
121
3-2 [T9P1] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
9. Diagnostic Chart with Select Monitor
122
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T9Q1] 3-2
9. Diagnostic Chart with Select Monitor
H3M1804
123
3-2 [T9Q2] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
9. Diagnostic Chart with Select Monitor
9Q2 : CHECK HARNESS CONNECTOR 9Q4 : CHECK INPUT SIGNAL FOR TCM.
BETWEEN TCM AND FWD SWITCH.
1) Turn ignition switch to OFF.
1) Turn ignition switch to OFF. 2) Connect connector to TCM and FWD switch.
2) Disconnect connector from TCM and FWD 3) Turn ignition switch to ON.
switch. 4) Measure signal voltage for TCM while installing
3) Measure resistance of harness between TCM the fuse to FWD switch connector.
and FWD switch connector.
Connector & terminal
Connector & terminal (B55) No. 14 (+) — Chassis ground (−):
(F67) No. 30 — (B55) No. 14:
B3M1345A
H3M1805A
: Is the voltage less than 1 V in FWD
: Is the resistance less than 1 Ω? switch while installing?
: Go to step 9Q3. : Go to step 9Q5.
: Repair open circuit in harness between : Go to step 9Q10.
TCM and FWD switch connector.
9Q5 : CHECK INPUT SIGNAL FOR TCM.
9Q3 : CHECK HARNESS CONNECTOR
BETWEEN TCM AND FWD SWITCH. Measure signal voltage for TCM while removing
the fuse from FWD switch connector.
Measure resistance of harness connector between
Connector & terminal
TCM and body to make sure that circuit does not
(B55) No. 14 (+) — Chassis ground (−):
short.
Connector & terminal
(B55) No. 14 — Chassis ground:
B3M1345A
124
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T9Q8] 3-2
9. Diagnostic Chart with Select Monitor
B3M1347A
B3M1348A
125
3-2 [T9Q9] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
9. Diagnostic Chart with Select Monitor
126
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T9U2] 3-2
9. Diagnostic Chart with Select Monitor
B2M2218
127
3-2 [T9U3] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
9. Diagnostic Chart with Select Monitor
B3M1349B
128
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T9U7] 3-2
9. Diagnostic Chart with Select Monitor
B3M1349B
B2M2558A
129
3-2 [T9U8] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
9. Diagnostic Chart with Select Monitor
H2M1673
H2M1748
130
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T9U15] 3-2
9. Diagnostic Chart with Select Monitor
9U12 : CHECK INHIBITOR SWITCH. 9U14 : CHECK INPUT SIGNAL FOR TCM.
Measure resistance between inhibitor switch con- Measure voltage between TCM and chassis
nector receptacle’s terminals. ground.
Terminals Connector & terminal
No. 5 — No. 10: (B55) No. 23 (+) — Chassis ground (–):
H2M1748 B2M2565A
9U13 : CHECK INPUT SIGNAL FOR TCM. 9U15 : CHECK INPUT SIGNAL FOR TCM.
B2M2565A B2M2567A
: Is the voltage less than 1 V in “P” : Is the voltage less than 1 V in “N”
range? range?
: Go to step 9U14. : Go to step 9U16.
: Go to step 9U17. : Go to step 9U17.
131
3-2 [T9U16] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
9. Diagnostic Chart with Select Monitor
B2M2567A
132
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T9V1] 3-2
9. Diagnostic Chart with Select Monitor
B2M2218
133
3-2 [T9V2] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
9. Diagnostic Chart with Select Monitor
B3M1349B
B2M2559A
134
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T9V8] 3-2
9. Diagnostic Chart with Select Monitor
9V5 : CHECK INHIBITOR SWITCH. 9V7 : CHECK INPUT SIGNAL FOR TCM.
Measure resistance between inhibitor switch con- 1) Turn ignition switch to OFF.
nector receptacle’s terminals. 2) Connect connector to TCM and inhibitor switch.
3) Turn ignition switch to ON.
Terminals 4) Measure voltage between TCM and chassis
No. 9 — No. 10: ground.
Connector & terminal
(B55) No. 17 (+) — Chassis ground (–):
H2M1674
Measure resistance between inhibitor switch con- 9V8 : CHECK INPUT SIGNAL FOR TCM.
nector receptacle’s terminals.
Terminals Measure voltage between TCM and chassis
No. 9 — No. 10: ground.
Connector & terminal
(B55) No. 17 (+) — Chassis ground (–):
H2M1674
135
3-2 [T9V9] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
9. Diagnostic Chart with Select Monitor
136
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T9W1] 3-2
9. Diagnostic Chart with Select Monitor
B2M2218
137
3-2 [T9W2] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
9. Diagnostic Chart with Select Monitor
B3M1349B
B2M2561A
138
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T9W8] 3-2
9. Diagnostic Chart with Select Monitor
9W5 : CHECK INHIBITOR SWITCH. 9W7 : CHECK INPUT SIGNAL FOR TCM.
Measure resistance between inhibitor switch con- 1) Turn ignition switch to OFF.
nector receptacle’s terminals. 2) Connect connector to TCM and inhibitor switch.
3) Turn ignition switch to ON.
Terminals 4) Measure voltage between TCM and chassis
No. 6 — No. 10: ground.
Connector & terminal
(B55) No. 8 (+) — Chassis ground (–):
H2M1676
Measure resistance between inhibitor switch con- 9W8 : CHECK INPUT SIGNAL FOR TCM.
nector receptacle’s terminals.
Terminals Measure voltage between TCM and chassis
No. 6 — No. 10: ground.
Connector & terminal
(B55) No. 8 (+) — Chassis ground (–):
H2M1676
139
3-2 [T9W9] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
9. Diagnostic Chart with Select Monitor
140
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T9X1] 3-2
9. Diagnostic Chart with Select Monitor
B2M2218
141
3-2 [T9X2] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
9. Diagnostic Chart with Select Monitor
B3M1349B
B2M2562A
142
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T9X8] 3-2
9. Diagnostic Chart with Select Monitor
9X5 : CHECK INHIBITOR SWITCH. 9X7 : CHECK INPUT SIGNAL FOR TCM.
Measure resistance between inhibitor switch con- 1) Turn ignition switch to OFF.
nector receptacle’s terminals. 2) Connect connector to TCM and inhibitor switch.
Terminals 3) Turn ignition switch to ON.
No. 4 — No. 10: 4) Measure voltage between TCM and chassis
ground.
Connector & terminal
(B55) No. 18 (+) — Chassis ground (–):
H2M1677
: Go to step 9X6.
: Is the voltage less than 1 V in “3”
: Go to step 9X7.
range?
: Go to step 9X8.
9X6 : CHECK INHIBITOR SWITCH.
: Go to step 9X9.
Measure resistance between inhibitor switch con-
nector receptacle’s terminals. 9X8 : CHECK INPUT SIGNAL FOR TCM.
Terminals
No. 4 — No. 10: Measure voltage between TCM and chassis
ground.
Connector & terminal
(B55) No. 18 (+) — Chassis ground (–):
H2M1677
: Go to step 9X7.
: Is the voltage more than 9.5 V in other
: Go to step 9X10.
ranges?
: Go to step 9X9.
: Go to step 9X10.
143
3-2 [T9X9] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
9. Diagnostic Chart with Select Monitor
144
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T9Y1] 3-2
9. Diagnostic Chart with Select Monitor
B2M2218
145
3-2 [T9Y2] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
9. Diagnostic Chart with Select Monitor
B3M1349B
B2M2563A
146
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T9Y8] 3-2
9. Diagnostic Chart with Select Monitor
9Y5 : CHECK INHIBITOR SWITCH. 9Y7 : CHECK INPUT SIGNAL FOR TCM.
Measure resistance between inhibitor switch con- 1) Turn ignition switch to OFF.
nector receptacle’s terminals. 2) Connect connector to TCM and inhibitor switch.
Terminals 3) Turn ignition switch to ON.
No. 11 — No. 10: 4) Measure voltage between TCM and chassis
ground.
Connector & terminal
(B54) No. 10 (+) — Chassis ground (–):
H2M1678
: Go to step 9Y6.
: Is the voltage less than 1 V in “2”
: Go to step 9Y10.
range?
: Go to step 9Y8.
9Y6 : CHECK INHIBITOR SWITCH.
: Go to step 9Y9.
Measure resistance between inhibitor switch con-
nector receptacle’s terminals. 9Y8 : CHECK INPUT SIGNAL FOR TCM.
Terminals
No. 11 — No. 10: Measure voltage between TCM and chassis
ground.
Connector & terminal
(B54) No. 10 (+) — Chassis ground (–):
H2M1678
: Go to step 9Y7.
: Is the voltage more than 9.5 V in other
: Go to step 9Y10.
ranges?
: Go to step 9Y9.
: Go to step 9Y10.
147
3-2 [T9Y9] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
9. Diagnostic Chart with Select Monitor
148
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T9Z1] 3-2
9. Diagnostic Chart with Select Monitor
B2M2218
149
3-2 [T9Z2] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
9. Diagnostic Chart with Select Monitor
B3M1349B
B2M2090A
150
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T9Z8] 3-2
9. Diagnostic Chart with Select Monitor
9Z5 : CHECK INHIBITOR SWITCH. 9Z7 : CHECK INPUT SIGNAL FOR TCM.
Measure resistance between inhibitor switch con- 1) Turn ignition switch to OFF.
nector receptacle’s terminals. 2) Connect connector to TCM and inhibitor switch.
Terminals 3) Turn ignition switch to ON.
No. 3 — No. 10: 4) Measure voltage between TCM and chassis
ground.
Connector & terminal
(B54) No. 1 (+) — Chassis ground (–):
H2M1679
: Go to step 9Z6.
: Is the voltage less than 1 V in “1”
: Go to step 9Z10.
range?
: Go to step 9Z8.
9Z6 : CHECK INHIBITOR SWITCH.
: Go to step 9Z9.
Measure resistance between inhibitor switch con-
nector receptacle’s terminals. 9Z8 : CHECK INPUT SIGNAL FOR TCM.
Terminals
No. 3 — No. 10: Measure voltage between TCM and chassis
ground.
Connector & terminal
(B54) No. 1 (+) — Chassis ground (–):
H2M1679
: Go to step 9Z7.
: Is the voltage more than 9.5 V in other
: Go to step 9Z10.
ranges?
: Go to step 9Z9.
: Go to step 9Z10.
151
3-2 [T9Z9] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
9. Diagnostic Chart with Select Monitor
152
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T9AH1] 3-2
9. Diagnostic Chart with Select Monitor
Turn ignition switch to ON (engine ON). : Does the LED of FWD lamp light up?
: Check FWD lamp circuit. <Ref. to 3-2
: Does the LED of torque control 2 sig- [T9Q0].>
nal light up?
: Go to step General Diagnostic Table.
: Go to step 2-4 BRAKE TIMING SOLE- <Ref. to 3-2 [T1000].>
NOID. <Ref. to 3-2 [T9AE0].>
: Check torque control 2 signal circuit.
<Ref. to 3-2 [T8I0].>
153
3-2 [T9AH1] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
9. Diagnostic Chart with Select Monitor
MEMO:
154
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T1000] 3-2
10. General Diagnostic Table
155
3-2 [T1000] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
10. General Diagnostic Table
156
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T1000] 3-2
10. General Diagnostic Table
157
3-2 [T1000] AUTOMATIC TRANSMISSION AND DIFFERENTIAL
10. General Diagnostic Table
158
AUTOMATIC TRANSMISSION AND DIFFERENTIAL [T1000] 3-2
10. General Diagnostic Table
159
3-2 AUTOMATIC TRANSMISSION AND DIFFERENTIAL
MEMO:
160
TRANSMISSION CONTROL
SYSTEM 3-3
Page
C COMPONENT PARTS .......................................................................................2
1. Manual Transmission ..................................................................................2
2. Automatic Transmission ..............................................................................3
W SERVICE PROCEDURE ...................................................................................4
1. Manual Transmission ..................................................................................4
2. Automatic Transmission ..............................................................................7
3-3 [C100] COMPONENT PARTS
1. Manual Transmission
1. Manual Transmission
H3M1189B
(1) Gear shift knob (11) Bush (Shift lever) Tightening torque: N·m (kg-m, ft-lb)
(2) Console boot (12) Cushion rubber
T1: 4.4±1.5 (0.45±0.15, 3.3±1.1)
(3) Boot plate (13) Bush (Stay rear)
T2: 5 (0.51, 3.7)
(4) Gear shift lever (14) Joint
T3: 12±3 (1.2±0.3, 8.7±2.2)
(5) Bush (15) Rod
(6) Spacer (16) Bracket T4: 18±5 (1.8±0.5, 13.0±3.6)
(7) Locking wire (17) Spring T5: 24.5±2 (2.50±0.20,
(8) Boot (18) Washer 18.07±1.48)
(9) Snap ring (19) Stay
(10) O-ring (20) Bush (Stay front)
2
COMPONENT PARTS [C200] 3-3
2. Automatic Transmission
2. Automatic Transmission
S3M0015A
3
3-3 [W1A0] SERVICE PROCEDURE
1. Manual Transmission
A: REMOVAL
1) Remove console box. <Ref. to 5-4 [W1A0].>
2) Remove boot plate from the body.
G3M0683
B3M0615
G3M0684
B: DISASSEMBLY
G3M0680
1) Disconnect locking wire.
B3M0617A
H3M1190A
B3M0616A
4
SERVICE PROCEDURE [W1D0] 3-3
1. Manual Transmission
B3M0619A
H3M1191A
H3M1193A
6) Draw out spring pin, then remove bush (Shift
lever) from gearshift lever.
D: ASSEMBLY
1) Clean all parts before assembly.
2) Mount the following parts on the stay.
H3M1192A
H3M1601A
5
3-3 [W1E0] SERVICE PROCEDURE
1. Manual Transmission
3) Mount each parts (Boot, O-ring, bush and 9) Connect rod to gearshift lever.
spacer) on the gearshift lever. Tightening torque:
CAUTION: 12±3 N·m (1.2±0.3 kg-m, 8.7±2.2 ft-lb)
I Always use new O-rings. Rocking torque:
I Apply grease [NIGTIGHT LYW No.2 or 0.74±0.25 N·m (0.075±0.025 kg-m,
equivalent] to the inner and side surfaces of 0.54±0.18 ft-lb) or less
the bush when installing spacer.
H3M1190A
H3M1194A
10) Check that there is no excessive play and that
4) Insert the gearshift lever into the boot hole. parts move smoothly.
5) Mount gearshift lever on the stay.
6) Install snap ring to the bottom of the bush (Stay E: INSTALLATION
rear).
1) Put into gearshift lever to passenger compart-
ment.
2) Mount boot plate on the body.
3) Install console box and gearshift knob. <Ref. to
5-4 [W1B0].>
B3M0619A
B3M0617A
G3M0684
6
SERVICE PROCEDURE [W2A0] 3-3
2. Automatic Transmission
B3M0616A
G3M0681
S3M0013A
7
3-3 [W2B0] SERVICE PROCEDURE
2. Automatic Transmission
2) Remove console box. <Ref. to 5-4 [W1A0].> 4) Remove shift-lock solenoid and “P” position
3) Disconnect the connectors, then remove the six switch.
screws to take out the selector lever assembly
from the body.
S3M0018A
S3M0017A
5) Remove cap and clip, then extract pin.
6) Remove selector lever lower then take away
selector lever upper from plate.
B: DISASSEMBLY
1) Remove connector from plate.
B3M0647A
B3M0645 C: INSPECTION
2) Remove indicator light and two screws. 1) Inspect removed parts by comparing with new
3) Remove retainer spring, then pull up selector ones for deformation, damage and wear. Correct
lever grip with indicator cover for holding selector or replace if defective.
lever button. 2) Confirm the following parts for operating condi-
CAUTION: tion before assembly.
Pull the selector lever grip carefully so that the (1) Sliding condition of the button in the grip ...
selector lever button may not jump out. it should move smoothly.
(2) Insertion of the grip on the selector lever ...
when pushing the grip on the selector lever by
hand, screw holes should be aligned.
(3) Operation of selector lever and rod ... they
should move smoothly.
D: ASSEMBLY
1) Clean all parts before assembly.
2) Apply grease [NIGTIGHT LYW No. 2 or equiva-
lent] to each parts. <Ref. to 3-3 [C200].>
B3M0646A 3) Assembly is in the reverse order of disassem-
bly.
4) After completion of fitting, transfer selector
lever to range “P” — “1”, pressing the button of the
grip; then check whether the indicator and selector
lever agree, whether the pointer and position mark
agree and what the operating force is.
8
SERVICE PROCEDURE [W2E0] 3-3
2. Automatic Transmission
S3M0019A
G3M0717
9
3-3 [W2E0] SERVICE PROCEDURE
2. Automatic Transmission
(2) Ensure selector lever moves from “P” to any depressed with ignition key set at “ON” or
other position when the brake pedal is “START”.
10
AWD SYSTEM 3-4
Page
S SPECIFICATIONS AND SERVICE DATA..........................................................2
1. Propeller Shaft.............................................................................................2
2. Rear Differential ..........................................................................................3
C COMPONENT PARTS .......................................................................................8
1. Propeller Shaft.............................................................................................8
2. Rear Differential ..........................................................................................9
3. Rear Differential Mounting System............................................................11
W SERVICE PROCEDURE .................................................................................12
1. Propeller Shaft...........................................................................................12
2. Rear Differential (VA-Type) .......................................................................14
3. Rear Differential (T-Type)..........................................................................33
4. Rear Differential Front Member ................................................................52
K DIAGNOSTICS.................................................................................................54
1. Propeller Shaft...........................................................................................54
2. Rear Differential ........................................................................................54
3-4 [S1A0] SPECIFICATIONS AND SERVICE DATA
1. Propeller Shaft
1. Propeller Shaft
A: SPECIFICATIONS
AT 693 (27.28)
Front propeller shaft Joint-to-joint length: L1 mm (in)
MT 634 (24.96)
Rear propeller shaft Joint-to-joint
768 (30.24)
length: L2 mm (in)
D1 63.5 (2.500)
Outside dia. of tube mm (in)
D2 57.0 (2.244)
B3M0851A
2
SPECIFICATIONS AND SERVICE DATA [S2B0] 3-4
2. Rear Differential
2. Rear Differential
A: SPECIFICATIONS
Hypoid
Type of gear MT AT
2200 cc 2500 cc 2200 cc 2500 cc
Gear ratio (Number of gear teeth) 3.900 (39/10) 4.111 (37/9) 4.111 (37/9) 4.444 (40/9)
Oil capacity 0.8 (0.8 US qt, 0.7 Imp qt)
Rear differential gear oil GL-5
B: IDENTIFICATION
When replacing a rear differential assembly, select
the correct one according to the following table.
CAUTION:
Using the different rear differential assembly
causes the drive line and tires to “drag” or emit
abnormal noise when AWD is selected.
H3M1662A
3
3-4 [S2C1] SPECIFICATIONS AND SERVICE DATA
2. Rear Differential
H3M1159
2200 cc MT 3.900
B3M0124
B3M0127
2500 cc AT 4.444
B3M0421
C: SERVICE DATA
1. VA-TYPE
Front and rear bearing preload at 12.7 — 32.4 N
New bearing
companion flange bolt hole (1.3 — 3.3 kg, 2.9 — 7.3 lb)
Part No. Length mm (in)
32288AA040 52.3 (2.059)
32288AA050 52.5 (2.067)
31454AA100 52.6 (2.071)
32288AA060 52.7 (2.075)
Preload adjusting spacer
31454AA110 52.8 (2.079)
32288AA070 52.9 (2.083)
31454AA120 53.0 (2.087)
32288AA080 53.1 (2.091)
32288AA090 53.3 (2.098)
4
SPECIFICATIONS AND SERVICE DATA [S2C2] 3-4
2. Rear Differential
2. T-TYPE
Front and rear bearing preload at 19.6 — 28.4 N
New bearing
companion flange bolt hole (2.0 — 2.9 kg, 4.4 — 6.4 lb)
Part No. Length mm (in)
383695201 56.2 (2.213)
383695202 56.4 (2.220)
Preload adjusting spacer 383695203 56.6 (2.228)
383695204 56.8 (2.236)
383695205 57.0 (2.244)
383695206 57.2 (2.252)
5
3-4 [S2C2] SPECIFICATIONS AND SERVICE DATA
2. Rear Differential
6
SPECIFICATIONS AND SERVICE DATA [S2C3] 3-4
2. Rear Differential
H3M1272A
7
3-4 [C100] COMPONENT PARTS
1. Propeller Shaft
1. Propeller Shaft
B3M0852A
8
COMPONENT PARTS [C2A0] 3-4
2. Rear Differential
2. Rear Differential
A: VA-TYPE
H3M1663A
(1) Pinion crown gear set (13) Lock plate (26) Gasket
(2) Pinion height adjusting shim (14) Side bearing (27) Oil filler plug
(3) Rear bearing (15) O-ring (28) Oil drain plug
(4) Bearing preload adjusting spacer (16) Axle shaft holder (29) Rear cover
(5) Bearing preload adjusting (17) Side oil seal
washer (18) Side gear thrust washer Tightening torque: N·m (kg-m, ft-lb)
(6) Differential carrier (19) Side gear T1: 25±3 (2.5±0.3, 18.1±2.2)
(7) Front bearing (20) Pinion mate gear T2: 25±2 (2.5±0.2, 18.1±1.4)
(8) Collar (21) Pinion shaft lock pin T3: 34±4 (3.5±0.4, 25.3±2.9)
(9) Pilot bearing (22) Differential case T4: 62±5 (6.3±0.5, 45.6±3.6)
(10) Front oil seal (23) Pinion mate shaft T5: 188±26 (19.2±2.7, 139±20)
(11) Companion flange (24) Air breather cap
(12) Self-locking nut (25) Stud bolt
9
3-4 [C2B0] COMPONENT PARTS
2. Rear Differential
B: T-TYPE
H3M1096B
(1) Pinion crown gear set (14) O-ring (28) Rear cover
(2) Pinion height adjusting washer (15) Side bearing retainer shim (29) Differential case
(3) Rear bearing (16) Side bearing retainer
(4) Bearing preload adjusting spacer (17) Side oil seal Tightening torque: N·m (kg-m, ft-lb)
(5) Bearing preload adjusting (18) Side gear thrust washer T1: 10.3±1.5 (1.05±0.15, 7.6±1.1)
washer (19) Side gear T2: 29.4±4.9 (3.00±0.50, 21.7±3.6)
(6) Differential carrier (20) Pinion mate gear T3: 44.1±3.9 (4.50±0.40, 32.5±2.9)
(7) Front bearing (21) Pinion mate gear washer T4: 103.0±9.8 (10.50±1.00,
(8) Spacer (22) Pinion shaft lock pin 75.9±7.2)
(9) Pilot bearing (23) Pinion mate shaft T5: 181.4±14.7 (18.50±1.50,
(10) Front oil seal (24) Air breather cap 133.8±10.8)
(11) Companion flange (25) Stud bolt
(12) Self-locking nut (26) Oil filler plug
(13) Side bearing (27) Oil drain plug
10
COMPONENT PARTS [C300] 3-4
3. Rear Differential Mounting System
H3M1674A
(1) Differential front member (7) Stopper Tightening torque: N·m (kg-m, ft-lb)
(2) Plate (8) Dynamic damper
T1: 20±5 (2.0±0.5, 14.5±3.6)
(3) Crossmember (9) Differential mount bracket
T2: 32±8 (3.3±0.8, 23.9±5.8)
(4) Rear bushing (10) Differential mount front cover
T3: 64±8 (6.5±0.8, 47.0±5.8)
(5) Differential mount lower bracket
(2500 cc model) T4: 69+13/−8 (7.0+1.3/−0.8, 50.6+9.4/
(6) Differential mount lower bracket
)
−5.8
11
3-4 [W1A0] SERVICE PROCEDURE
1. Propeller Shaft
S3M0024
B: REMOVAL
NOTE:
Before removing propeller shaft, wrap metal parts
with a cloth or rubber material.
1) Disconnect ground cable from battery.
G3M0019
2) Move selector lever or gear shift lever to “N”.
3) Release the parking brake.
3) Runout of propeller shaft 4) Jack-up vehicle and support it with sturdy
Turn rear wheels by hand to check for “runout” of racks.
propeller shaft. 5) Remove rear exhaust pipe and muffler.
NOTE: <Ref. to 2-9 [W3A0].> and <Ref. to 2-9 [W2A0].>
Measure runout with a dial gauge at the center of 6) Remove front exhaust cover.
front and rear propeller shaft tubes.
Runout:
Limit 0.6 mm (0.024 in)
G3M0021
G3M0020
G3M0022
12
SERVICE PROCEDURE [W1F0] 3-4
1. Propeller Shaft
8) Remove the four bolts which hold propeller 11) Install the extension cap to transmission.
shaft to rear differential.
NOTE:
I Put matching mark on affected parts before
removal.
I Remove all but one bolt.
G3M0026
C: DISASSEMBLY
NOTE:
G3M0782
Do not disassemble propeller shaft. It is a single
unit.
9) Remove the two bolts which hold center bear- D: INSPECTION
ing to vehicle body.
NOTE:
Do not disassemble propeller shaft. Check the fol-
lowing and replace if necessary.
1) Tube surfaces for dents or cracks
2) Splines for deformation or abnormal wear
3) Joints for non-smooth operation or abnormal
noise
4) Center bearing for free play, noise or non-
smooth operation
5) Oil seals for abnormal wear or damage
S3M0028 6) Center bearing for breakage
10) Remove propeller shaft from transmission. E: ASSEMBLY
CAUTION: NOTE:
Be sure not to damage oil seals and the fric- Do not disassemble propeller shaft. It is a single
tional surface of sleeve yoke. unit.
NOTE:
I Be sure to use an empty oil can to catch oil F: INSTALLATION
flowing out when removing propeller shaft. 1) Insert sleeve yoke into transmission and attach
I Be sure to plug the opening in transmission after center bearing to vehicle body.
removal of propeller shaft.
Tightening torque:
52±5 N·m (5.3±0.5 kg-m, 38.3±3.6 ft-lb)
G3M0025
S3M0028
13
3-4 [W2A1] SERVICE PROCEDURE
2. Rear Differential (VA-Type)
2) Align matching marks and connect flange yoke 2. Rear Differential (VA-Type)
and rear differential.
Tightening torque: A: ON-CAR SERVICE
31±8 N·m (3.2±0.8 kg-m, 23.1±5.8 ft-lb) 1. FRONT OIL SEAL
1) Disconnect ground cable from battery.
2) Move selector lever or gear shift lever to “N”.
3) Release the parking brake.
4) Remove oil drain plug, and drain gear oil.
G3M0782
S3M0028
G3M0021
7) Remove self-locking nut while holding compan-
ion flange with ST.
5) Install rear exhaust pipe and muffler. ST 498427200 FLANGE WRENCH
G3M0034
14
SERVICE PROCEDURE [W2A2] 3-4
2. Rear Differential (VA-Type)
8) Extract companion flange with a puller. 12) Tighten self-locking nut within the specified
torque range so that the turning resistance of com-
panion flange becomes the same as that before
replacing oil seal.
ST 498427200 FLANGE WRENCH
CAUTION:
Use a new self-locking nut.
Tightening torque:
188±26 N·m (19.2±2.7 kg-m, 139±20 ft-lb)
G3M0035
G3M0034
H3M1397A
15
3-4 [W2A2] SERVICE PROCEDURE
2. Rear Differential (VA-Type)
(2) Remove the ABS sensor cable clamp from (6) Remove the bolts which secure the front
the trailing link. and rear lateral link to the rear housing.
H3M1398A G3M0043
(3) Remove the ABS sensor cable clamp and (7) Remove the DOJ from the rear differential
parking brake cable guide from the trailing link. with tire lever.
CAUTION:
When removing the DOJ from the rear
differential, fit tire lever to the bolt as shown in
figure so as not to damage the axle shaft
holder.
NOTE:
The side spline shaft circlip comes out together
with the shaft.
H3M1399A
H3M1396A
H3M1664A
G3M0042
16
SERVICE PROCEDURE [W2B0] 3-4
2. Rear Differential (VA-Type)
9) Secure rear drive shaft to rear crossmember (1) Install ST to rear differential.
using wire. ST 28099PA090 SIDE OIL SEAL PROTEC-
TOR
G3M0046
G3M0256
10) Remove oil seal with screwdriver.
(2) Insert the spline shaft until the spline portion
is inside the side oil seal.
G3M0047
G3M0048
B: REMOVAL
1) Disconnect ground cable from battery.
2) Move selector lever or gear shift lever to “N”.
3) Release the parking brake.
4) Loosen wheel nuts.
17
3-4 [W2B0] SERVICE PROCEDURE
2. Rear Differential (VA-Type)
5) Jack-up vehicle and support it with sturdy 10) Remove propeller shaft.
racks. CAUTION:
6) Remove wheels. When removing propeller shaft, pay attention
7) Remove rear exhaust pipe and muffler. not to damage the sliding surfaces of rear drive
<Ref. to 2-9 [W3A0].> and <Ref. to 2-9 [W2A0].> shaft (extension) spline, oil seal and sleeve
8) Remove front exhaust cover. yoke.
NOTE:
I Prepare an oil can and cap since the transmis-
sion oil flows out from the extension at removing
propeller shaft.
I Insert the cap into the extension to prevent
transmission oil from flowing out immediately after
removing the propeller shaft.
G3M0021
G3M0022
S3M0033A
G3M0053
18
SERVICE PROCEDURE [W2B0] 3-4
2. Rear Differential (VA-Type)
13) Remove DOJ of rear drive shaft from rear dif- 17) Remove self-locking nuts connecting rear dif-
ferential. <Ref. to 3-4 [W2A2].> ferential to rear crossmember.
G3M0257 B3M0131
14) Secure rear drive shaft to rear crossmember 18) Remove bolts which secure rear differential
using wire. front member to body. Loosen bolt A first, then
removal bolts B .
NOTE:
Support front member with the use of a helper to
prevent it from dropping.
G3M0046
B3M0657C
(A) Bolt A
(B) Bolt B
G3M0058
G3M0055
19
3-4 [W2C0] SERVICE PROCEDURE
2. Rear Differential (VA-Type)
22) Remove rear differential from body. 4) Replace air breather cap.
NOTE:
Do not attempt to replace the air breather cap
unless necessary.
G3M0059
C: DISASSEMBLY
G3M0062
To detect real cause of trouble, inspect the follow-
ing items before disassembling. 5) Remove right and left lock plates.
I Tooth contact of crown gear and pinion, and
backlash
I Runout of crown gear at its back surface
I Turning resistance of drive pinion
1) Set ST on vise and install the differential
assembly to ST.
G3M0063
G3M0060
ST 398217700 ATTACHMENT
2) Drain gear oil by removing plug.
3) Remove rear cover by loosening retaining
bolts.
G3M0064
G3M0061
20
SERVICE PROCEDURE [W2C0] 3-4
2. Rear Differential (VA-Type)
7) Pull out differential assembly from differential 10) Extract bearing cone with ST.
carrier. CAUTION:
CAUTION: Do not attempt to disassemble the parts unless
Be careful not to hit the teeth against the case. necessary.
NOTE:
I Set Puller so that its claws catch the edge of the
bearing cone.
I Never mix up the right and left hand bearing
cups and cones.
ST 899524100 PULLER SET
G3M0065
G3M0066
CAUTION: 12) Drive out pinion shaft lock pin from crown gear
Perform this operation only when changing oil side.
seal. NOTE:
ST 899580100 INSTALLER The lock pin is staked at the pin hole end on the
differential carrier; do not drive it out forcibly before
unstaking it.
ST 899904100 STRAIGHT PIN REMOVER
B3M0132
B3M0133
21
3-4 [W2C0] SERVICE PROCEDURE
2. Rear Differential (VA-Type)
13) Draw out pinion mate shaft and remove pinion 16) Press the end of drive pinion shaft and extract
mate gears, side gears and thrust washers. it together with rear bearing cone, preload adjust-
NOTE: ing spacer and washer.
The gears as well as thrust washers should be NOTE:
marked or kept separated left and right, and front Hold the drive pinion so as not to drop it.
and rear. ST 398467700 DRIFT
G3M0071
G3M0074
14) Hold companion flange with ST and remove 17) Remove rear bearing cone from drive pinion
drive pinion nut. by supporting cone with ST.
ST 498427200 FLANGE WRENCH NOTE:
Place the replacer so that its center-recessed side
faces the pinion gear.
ST 498515500 REPLACER
G3M0072
G3M0075
G3M0073
G3M0076
22
SERVICE PROCEDURE [W2E0] 3-4
2. Rear Differential (VA-Type)
19) Remove pilot bearing together with front bear- 5) Oil seal
ing cone using ST. Replace if deformed or damaged, and at every
ST 398467700 DRIFT disassembling.
6) Differential carrier
Replace if the bearing bores are worn or damaged.
7) Differential case
Replace if its sliding surfaces are worn or cracked.
8) Companion flange
Replace if the oil seal lip contacting surfaces have
flaws.
E: ASSEMBLY
1) Precautions for assembling
G3M0077
I Assemble in the reverse order of disassembling.
20) When replacing bearings, tap front bearing I Check and adjust each part during assembly.
cup and rear bearing cup in this order out of case I Keep the shims and washers in order, so that
by using a brass bar. they are not misinstalled.
I Thoroughly clean the surfaces on which the
shims, washers and bearings are to be installed.
I Apply gear oil when installing the bearings and
thrust washers.
I Be careful not to mix up the right and left hand
cups of the bearings.
I Replace the oil seal with new one at every dis-
assembly. Apply chassis grease between the lips
when installing the oil seal.
G3M0078
D: INSPECTION
Wash all the disassembled parts clean, and exam-
ine them for wear, damage, or other defects.
Repair or replace defective parts as necessary.
1) Crown gear and drive pinion
I If abnormal tooth contact is evident, find out the G3M0079
cause and adjust to give correct tooth contact at
assembly. Replace the gear if excessively worn or 2) Adjust preload for front and rear bearings.
incapable of adjustment. Adjust the bearing preload with spacer and washer
I If crack, score, or seizure is evident, replace as between front and rear bearings. Pinion height
a set. Slight damage of tooth can be corrected by adjusting washer are not affected by this adjust-
oil stone or the like. ment. The adjustment must be carried out without
2) Side gear and pinion mate gear oil seal inserted.
I Replace if crack, score, or other defects are evi-
dent on tooth surface.
I Replace if thrust washer contacting surface is
worn or seized. Slight damage of the surface can
be corrected by oil stone or the like.
3) Bearing
Replace if seizure, peeling, wear, rust, dragging
during rotation, abnormal noise or other defect is
evident.
4) Thrust washers of side gear and pinion mate
gear Replace if seizure, flaw, abnormal wear or
other defect is evident.
23
3-4 [W2E0] SERVICE PROCEDURE
2. Rear Differential (VA-Type)
(1) Press rear bearing race into differential car- (6) Turn ST1 with hand to make it seated, and
rier with ST1 and ST2. tighten drive pinion nut while measuring the pre-
ST1 398477701 HANDLE load with spring balance. Select preload adjust-
ST2 398477702 DRIFT ing washer and spacer so that the specified pre-
(2) Press front bearing race into differential car- load is obtained when nut is tightened to the
rier with ST1 and ST2. specified torque with ST2.
ST1 398477701 HANDLE CAUTION:
ST2 498447110 DRIFT Use a new lock nut.
NOTE:
I Be careful not to give excessive preload.
I When tightening the drive pinion nut, lock ST1
with ST2.
ST1 398507704 BLOCK
ST2 498447150 DUMMY SHAFT
Tightening torque:
188±26 N·m (19.2±2.7 kg-m, 139±20 ft-lb)
G3M0080
G3M0082
G3M0081
24
SERVICE PROCEDURE [W2E0] 3-4
2. Rear Differential (VA-Type)
Part No. Thickness mm (in) Adjust preload for front and rear bearings.
38336AA000 1.500 (0.0591) NOTE:
38336AA120 1.513 (0.0596) At this time, install an original pinion height adjust-
38336AA010 1.525 (0.0600) ing shim.
38336AA130 1.538 (0.0606)
38336AA020 1.550 (0.0610) ST1 498447150 DUMMY SHAFT
38336AA140 1.563 (0.0615) ST2 32285AA000 DUMMY COLLAR
38336AA030 1.575 (0.0620) ST3 498505501 DIFFERENTIAL CARRIER
38336AA150 1.588 (0.0625) GAUGE
38336AA040 1.600 (0.0630)
38336AA160 1.613 (0.0635)
I Preload adjust- 38336AA050 1.625 (0.0640)
ing washer 38336AA170 1.638 (0.0645)
38336AA060 1.650 (0.0650)
38336AA180 1.663 (0.0655)
38336AA070 1.675 (0.0659)
38336AA190 1.688 (0.0665)
38336AA080 1.700 (0.0669)
38336AA200 1.713 (0.0674)
38336AA090 1.725 (0.0679)
38336AA210 1.738 (0.0684)
38336AA100 1.750 (0.0689) G3M0083
38336AA220 1.763 (0.0694)
38336AA110 1.775 (0.0699) (2) Measure the clearance N between the end
Part No. Length mm (in) of ST2 and the end surface of ST1 by using a
32288AA040 52.3 (2.059) thickness gauge.
32288AA050 52.5 (2.067) NOTE:
31454AA100 52.6 (2.071) Make sure there is no clearance between ST2 and
I Preload adjust- 32288AA060 52.7 (2.075)
ing spacer 31454AA110 52.8 (2.079)
ST1.
32288AA070 52.9 (2.083) ST1 498447150 DUMMY SHAFT
31454AA120 53.0 (2.087) ST2 498505501 DIFFERENTIAL CARRIER
32288AA080 53.1 (2.091) GAUGE
32288AA090 53.3 (2.098)
25
3-4 [W2E0] SERVICE PROCEDURE
2. Rear Differential (VA-Type)
H3M1666A
G3M0085
26
SERVICE PROCEDURE [W2E0] 3-4
2. Rear Differential (VA-Type)
7) Insert spacer, then press-fit pilot bearing with 10) Install self-locking nut. Then tighten self-lock-
ST1 and ST2. ing nut with ST.
ST1 399780104 WEIGHT ST 398427700 FLANGE WRENCH
ST2 899580100 INSTALLER Tightening torque:
188±26 N·m (19.2±2.7 kg-m, 139±20 ft-lb)
G3M0719
G3M0721
8) Fit a new oil seal with ST.
NOTE: 11) Assembling differential case
I Press-fit until end of oil seal is 1 mm (0.04 in) (1) Install side gears and pinion mate gears,
inward from end of carrier. with their thrust washers and pinion mate shaft,
into differential case.
I Apply grease between the oil seal lips.
NOTE:
ST 498447120 OIL SEAL INSTALLER
I Apply gear oil on both sides of the washer and
on the side gear shaft before installing.
I Insert the pinion mate shaft into the differential
case by aligning the lock pin holes.
G3M0087
G3M0089
G3M0720
27
3-4 [W2E0] SERVICE PROCEDURE
2. Rear Differential (VA-Type)
(2) Measure the clearance between differential (1) Install oil seal into right and left holders.
case and the back of side gear. ST 498447100 AXLE SHAFT OIL SEAL
(3) Adjust the clearance as specified by select- INSTALLER
ing side gear thrust washer.
Side gear backlash:
0.05 — 0.15 mm (0.0020 — 0.0059 in)
Side gear thrust washer
Part No. Thickness mm (in)
803135011 0.925 — 0.950 (0.0364 — 0.0374)
803135012 0.950 — 0.975 (0.0374 — 0.0384)
803135013 0.975 — 1.000 (0.0384 — 0.0394)
803135014 1.000 — 1.025 (0.0394 — 0.0404)
803135015 1.025 — 1.050 (0.0404 — 0.0413) G3M0092
(4) Check the condition of rotation after apply- (2) Install bearing race into right and left hold-
ing oil to the gear tooth surfaces and thrust sur- ers.
faces. ST 398477702 BEARING OUTER RACE
(5) After driving in pinion shaft lock pin, stake DRIFT
the both sides of the hole to prevent pin from
falling off.
(6) Install crown gear on differential case.
NOTE:
Tighten diagonally while tapping the bolt heads.
Tightening torque:
62±5 N·m (6.3±0.5 kg-m, 45.6±3.6 ft-lb)
G3M0093
G3M0069
G3M0065
G3M0091
28
SERVICE PROCEDURE [W2E0] 3-4
2. Rear Differential (VA-Type)
(1) Turn drive pinion with ST for better fitting of (5) Measure the crown gear-to-drive pinion
differential side bearing. backlash. Set magnet base on differential car-
ST 498427200 FLANGE WRENCH rier. Align contact point of dial gauge with tooth
face of crown gear, and move crown gear while
holding drive pinion still. Read value indicated
on dial gauge.
NOTE:
If measured backlash is not within specified range,
repeat procedures for pinion crown gear set back-
lash adjustment and differential side bearing pre-
load adjustment.
Backlash:
G3M0094 0.10 — 0.15 mm (0.0039 — 0.0059 in)
G3M0095
G3M0063
G3M0063
29
3-4 [W2E0] SERVICE PROCEDURE
2. Rear Differential (VA-Type)
G3M0095
H3M1309A
18) Check the crown gear runout on its back
surface, and make sure pinion and crown gear T = To + N − 0.05 (mm)
rotate smoothly. where
Limit of runout: T = Thickness of pinion height adjusting shim (mm)
0.05 mm (0.0020 in) To = Thickness of shim originally installed (mm)
N = Reading of thickness gauge (mm)
G3M0097
G3M0095
30
SERVICE PROCEDURE [W2E0] 3-4
2. Rear Differential (VA-Type)
G3M0098A
Face contact This may cause noise and chipping at Increase thickness of drive pinion height
Backlash is too large. tooth ends. adjusting washer in order to bring drive
pinion closer to crown gear center.
G3M0098B
G3M0098F
Flank contact This may cause noise and stepped wear Reduce thickness of drive pinion height
Backlash is too small. on surfaces. adjusting washer in order to move drive
pinion away from crown gear.
G3M0098C
G3M0098G
Toe contact Contact area is small. Adjust as for flank contact.
This may cause chipping at toe ends.
G3M0098G
G3M0098D
Heel contact Contact area is small. Adjust as for face contact
This may cause chipping at heel ends.
G3M0098F
G3M0098E
31
3-4 [W2F0] SERVICE PROCEDURE
2. Rear Differential (VA-Type)
21) Install rear cover and tighten bolts to specified 4) After installation, fill differential carrier with gear
torque. oil to the upper plug level.
Tightening torque: CAUTION:
25±2 N·m (2.5±0.2 kg-m, 18.1±1.4 ft-lb) Use a new aluminum gasket when installing the
plug.
Oil capacity:
0.8 (0.8 US qt, 0.7 Imp qt)
G3M0099
F: INSTALLATION G3M0100
To install, reverse the removal sequence.
1) Position front member on body by passing it
under parking brake cable and securing to rear
differential.
NOTE:
When installing rear differential front member, do
not confuse the installation sequence of the upper
and lower stoppers.
2) Install DOJ of rear drive shaft into rear differen-
tial. <Ref. to 3-4 [W2A2].>
ST 28099PA090 SIDE OIL SEAL PROTEC-
TOR
G3M0049
32
SERVICE PROCEDURE [W3A1] 3-4
3. Rear Differential (T-Type)
A: ON-CAR SERVICE
1. FRONT OIL SEAL
1) Disconnect ground cable from battery.
2) Move selector lever or gear shift lever to “N”.
3) Release the parking brake.
4) Remove oil drain plug, and drain gear oil.
G3M0035
B3M0316A
Wrap metal parts with a cloth or rubber mate- 10) Fit a new oil seal using ST.
rial to prevent damage from adjacent metal ST 498447120 OIL SEAL INSTALLER
parts.
G3M0037
S3M0028
11) Install companion flange.
7) Remove self-locking nut while holding compan-
ion flange with ST.
ST 498427200 FLANGE WRENCH
G3M0034
33
3-4 [W3A2] SERVICE PROCEDURE
3. Rear Differential (T-Type)
12) Tighten self-locking nut within the specified (2) Remove the ABS sensor cable clamp from
torque range so that the turning resistance of com- the trailing link.
panion flange becomes the same as that before
replacing oil seal.
CAUTION:
Use a new self-locking nut.
ST 498427200 FLANGE WRENCH
Tightening torque:
181.4±14.7 N·m (18.50±1.50 kg-m,
133.8±10.8 ft-lb)
H3M1398A
G3M0034
1) Disconnect ground cable from battery. (4) Remove the rear stabilizer link.
2) Move selector lever or gear shift lever to “N”.
3) Release the parking brake.
4) Loosen both wheel nuts.
5) Jack-up the vehicle and support it with rigid
racks.
6) Remove wheels.
7) Remove rear exhaust pipe and muffler.
<Ref. to 2-9 [W3A0].> and <Ref. to 2-9 [W2A0].>
8) Remove the DOJ of rear drive shaft from rear
differential.
(1) Remove the ABS sensor cable clamp and H3M1396A
parking brake cable clamp from bracket.
(5) Remove the bolts which secure the trailing
link to the rear housing.
H3M1397A
G3M0042
34
SERVICE PROCEDURE [W3A2] 3-4
3. Rear Differential (T-Type)
(6) Remove the bolts which secure the front 9) Secure rear drive shaft to rear crossmember
and rear lateral link to the rear housing. using wire.
G3M0043 G3M1022
(7) Remove the DOJ from the rear differential 10) Remove side oil seal with ST.
by using ST. ST 398527700 PULLER ASSY
CAUTION:
When removing the DOJ from the rear
differential, fit ST to the bolt as shown in figure
so as not to damage the side bearing retainer.
ST 208099PA100 DRIVE SHAFT REMOVER
G3M1023
G3M1024
H3M1667A
35
3-4 [W3B0] SERVICE PROCEDURE
3. Rear Differential (T-Type)
G3M0021
G3M1025
9) Remove front cover of rear differential mount.
G3M0022
G3M1026
B: REMOVAL
1) Disconnect ground cable from battery.
2) Move selector lever or gear shift lever to “N”.
3) Release the parking brake.
4) Loosen wheel nuts.
5) Jack-up vehicle and support it with sturdy
racks.
6) Remove wheels.
7) Remove rear exhaust pipe and muffler.
<Ref. to 2-9 [W3A0].> and <Ref. to 2-9 [W2A0].>
36
SERVICE PROCEDURE [W3B0] 3-4
3. Rear Differential (T-Type)
10) Remove propeller shaft. 13) Remove DOJ of rear drive shaft from rear dif-
CAUTION: ferential using ST. <Ref. to 3-4 [W3A2].>
When removing propeller shaft, pay attention ST 28099PA100 DRIVE SHAFT REMOVER
not to damage the sliding surfaces of rear drive
shaft (extension) spline, oil seal and sleeve
yoke.
NOTE:
I Prepare an oil can and cap since the transmis-
sion oil flows out from the extension at removing
propeller shaft.
I Insert the cap into the extension to prevent
transmission oil from flowing out immediately after
removing the propeller shaft. G3M1020
G3M1022
S3M0033A
G3M0053
G3M0055
37
3-4 [W3C0] SERVICE PROCEDURE
3. Rear Differential (T-Type)
17) Remove self-locking nuts connecting rear dif- 21) Remove rear differential from front member.
ferential to rear crossmember.
G3M1030
G3M1028
B3M0657C
(A) Bolt A
(B) Bolt B
G3M1029
G3M1033
38
SERVICE PROCEDURE [W3C0] 3-4
3. Rear Differential (T-Type)
4) Remove rear cover by loosening retaining 7) When replacing side bearing, pull bearing cup
bolts. from side bearing retainer using ST.
ST 398527700 PULLER ASSY
G3M1032
G3M1036
5) Make right and left side bearing retainers in
order to identify them at reassembly. Remove side 8) Extract bearing cone with ST.
bearing retainer attaching bolts, set ST to differen- CAUTION:
tial case, and extract right and left side bearing Do not attempt to disassemble the parts unless
retainers with a puller. necessary.
CAUTION: NOTE:
Each shim, which is installed to adjust the side I Set puller so that its claw catch the edge of the
bearing preload, should be kept together with bearing cone.
its mating retainer. I Never mix up the right and left hand bearing
ST 398457700 ATTACHMENT cups and cones.
ST 399527700 PULLER SET
G3M1034
G3M1035
G3M0069
39
3-4 [W3C0] SERVICE PROCEDURE
3. Rear Differential (T-Type)
10) Drive out pinion shaft lock pin from crown gear 13) Extract the companion flange with a puller.
side.
NOTE:
The lock pin is staked at the pin hole end on the
differential carrier; do not drive it out forcibly before
unstaking it.
ST 899904100 STRAIGHT PIN REMOVER
G3M0073
G3M0074
G3M0075
G3M1052
40
SERVICE PROCEDURE [W3E0] 3-4
3. Rear Differential (T-Type)
16) Remove front oil seal from differential carrier I If crack, score, or seizure is evident, replace as
using ST. a set. Slight damage of tooth can be corrected by
ST 398527700 PULLER ASSY oil stone or the like.
2) Side gear and pinion mate gear
I Replace if crack, score, or other defects are evi-
dent on tooth surface.
I Replace if thrust washer contacting surface is
worn or seized. Slight damage of the surface can
be corrected by oil stone or the like.
3) Bearing
Replace if seizure, peeling, wear, rust, dragging
during rotation, abnormal noise or other defect is
evident.
G3M0076 4) Thrust washers of side gear and pinion mate
gear Replace if seizure, flaw, abnormal wear or
17) Remove pilot bearing together with front bear- other defect is evident.
ing cone using ST. 5) Oil seal
ST 398467700 DRIFT Replace if deformed or damaged, and at every
disassembling.
6) Differential carrier
Replace if the bearing bores are worn or damaged.
7) Differential case
Replace if its sliding surfaces are worn or cracked.
8) Companion flange
Replace if the oil seal lip contacting surfaces have
flaws.
E: ASSEMBLY
G3M0077
1) Precautions for assembling
18) When replacing bearings, tap front bearing I Assemble in the reverse order of disassembling.
cup and rear bearing cup in this order out of case I Check and adjust each part during assembly.
by using a brass bar. I Keep the shims and washers in order, so that
they are not misinstalled.
I Thoroughly clean the surfaces on which the
shims, washers and bearings are to be installed.
I Apply gear oil when installing the bearings and
thrust washers.
I Be careful not to mix up the right and left hand
cups of the bearings.
I Replace the oil seal with new one at every dis-
assembly. Apply chassis grease between the lips
when installing the oil seal.
G3M0078
D: INSPECTION
Wash all the disassembled parts clean, and exam-
ine them for wear, damage, or other defects.
Repair or replace defective parts as necessary.
1) Crown gear and drive pinion
I If abnormal tooth contact is evident, find out the
cause and adjust to give correct tooth contact at
G3M0079
assembly. Replace the gear if excessively worn or
incapable of adjustment.
41
3-4 [W3E0] SERVICE PROCEDURE
3. Rear Differential (T-Type)
2) Adjusting preload for front and rear bearings (4) Turn ST1 with hand to make it seated, and
Adjust the bearing preload with spacer and washer tighten drive pinion nut while measuring the pre-
between front and rear bearings. Pinion height load with spring balance. Select preload adjust-
adjusting washer are not affected by this adjust- ing washer and spacer so that the specified pre-
ment. The adjustment must be carried out without load is obtained when nut is tightened to the
oil seal inserted. specified torque with ST2.
(1) Press rear bearing race into differential car- CAUTION:
rier with ST1 and ST2. Use a new lock nut.
ST1 398477701 HANDLE
ST2 398427703 DRIFT 2 NOTE:
I Be careful not to give excessive preload.
I When tightening the drive pinion nut, lock ST1
with ST2.
ST1 398507704 BLOCK
ST2 398507702 DUMMY SHAFT
Tightening torque:
181±15 N·m (18.5±1.5 kg-m, 134±11 ft-lb)
G3M1037
G3M0082
G3M0081
42
SERVICE PROCEDURE [W3E0] 3-4
3. Rear Differential (T-Type)
Part No. Thickness mm (in) (2) Measure the clearance between the end of
2.59 (0.1020)
ST2 and the end surface of ST1 by using a
383715200 thickness gauge.
2.57 (0.1012)
383725200
2.55 (0.1004) NOTE:
383735200
2.53 (0.0996)
383745200 Make sure there is no clearance between ST2 and
2.51 (0.0988)
383755200
2.49 (0.0980)
ST1.
383765200
I Preload adjust- 2.47 (0.0972) ST1 398507702 DUMMY SHAFT
383775200
ing washer 2.45 (0.0965) ST2 398507701 DIFFERENTIAL CARRIER
383785200
2.43 (0.0957)
383795200 GAUGE
2.41 (0.0949)
383805200
2.39 (0.0941)
383815200
2.37 (0.0933)
383825200
2.35 (0.0925)
383835200
2.33 (0.0917)
383845200
2.31 (0.0909)
Part No. Length mm (in)
383695201 56.2 (2.213)
383695202 56.4 (2.220)
I Preload adjust-
383695203 56.6 (2.228)
ing spacer
383695204 56.8 (2.236)
383695205 57.0 (2.244)
H3M1309A
383695206 57.2 (2.252)
3) Adjusting drive pinion height (3) Obtain the thickness of pinion height adjust-
Adjust drive pinion height with shim installed ing shim to be inserted from the following
between rear bearing cone and the back of pinion formula, and replace the temporarily installed
gear. shim with this one.
(1) Install ST1, ST2 and ST3, as shown in the T = To + N − (H x 0.01) − 0.20 (mm)
figure, and apply the specified preload on the where
bearings. T = Thickness of pinion height adjusting shim (mm)
Front and rear bearing preload To = Thickness of shim temporarily inserted (mm)
For new bearing: N = Reading of thickness gauge (mm)
19.6 — 28.4 N (2.0 — 2.9 kg, 4.4 — 6.4 lb) H = Figure marked on drive pinion head
at companion flange bolt hole (Example of calculation)
To = 2.20 + 1.20 = 3.40 mm
Adjust preload for front and rear bearings.
N = 0.23 mm H = + 1,
NOTE: T = 3.40 + 0.23 − 0.01 − 0.20 = 3.42
At this time, install a pinion height adjusting shim Result: Thickness = 3.42 mm
which is temporarily selected or the same as that Therefore use the shim 383605200.
used before.
ST1 398507702 DUMMY SHAFT
ST2 398507703 DUMMY COLLAR
ST3 398507701 DIFFERENTIAL CARRIER
GAUGE
G3M0083
43
3-4 [W3E0] SERVICE PROCEDURE
3. Rear Differential (T-Type)
Pinion height adjusting shim 6) Press-fit front bearing cone into case with ST1,
Part No. Thickness mm (in)
ST2 and ST3.
383495200 3.09 (0.1217)
ST1 398507703 DUMMY COLLAR
383505200 3.12 (0.1228) ST2 399780104 WEIGHT
383515200 3.15 (0.1240) ST3 899580100 INSTALLER
383525200 3.18 (0.1252)
383535200 3.21 (0.1264)
383545200 3.24 (0.1276)
383555200 3.27 (0.1287)
383565200 3.30 (0.1299)
383575200 3.33 (0.1311)
383585200 3.36 (0.1323)
383595200 3.39 (0.1335)
383605200 3.42 (0.1346)
383615200 3.45 (0.1358)
383625200 3.48 (0.1370)
383635200 3.51 (0.1382) G3M0085
383645200 3.54 (0.1394)
383655200 3.57 (0.1406) 7) Insert spacer, then press-fit pilot bearing with
383665200 3.60 (0.1417) ST1 and ST2.
383675200 3.63 (0.1429)
383685200 3.66 (0.1441)
ST1 399780104 WEIGHT
ST2 899580100 INSTALLER
4) Install the selected pinion height adjusting shim
on drive pinion, and press the rear bearing cone
into position with ST.
ST 398177700 INSTALLER
G3M0719
H3M1666A G3M0087
44
SERVICE PROCEDURE [W3E0] 3-4
3. Rear Differential (T-Type)
9) Press-fit companion flange with ST1 and ST2. (1) Install side gears and pinion mate gears,
CAUTION: with their thrust washers and pinion mate shaft,
Be careful not to damage bearing. into differential case.
G3M0720
G3M0089
G3M1052
(2) Measure the clearance between differential
case and the back of side gear.
11) Assembling differential case (3) Adjust the clearance as specified by select-
ing side gear thrust washer.
Side gear backlash:
0.10 — 0.20 mm (0.0039 — 0.0079 in)
Side gear thrust washer
Part No. Thickness mm (in)
383445201 0.75 — 0.8 (0.0295 — 0.0315)
383445202 0.8 — 0.85 (0.0315 — 0.0335)
383445203 0.85 — 0.9 (0.0335 — 0.0345)
45
3-4 [W3E0] SERVICE PROCEDURE
3. Rear Differential (T-Type)
12) Install crown gear on differential case. (1) The drive gear backlash and side bearing
NOTE: preload can be determined by the side bearing
Tighten diagonally while tapping the bolt heads. retainer shim thickness.
(2) When replacing differential case, differential
Tightening torque: carrier, side bearing and side bearing retainer,
103±10 N·m (10.5±1.0 kg-m, 76±7 ft-lb) obtain the right and left retainer shim thickness
from the following formulas.
T1 (Left) = (A + C + G1− D) x 0.01 + 0.76 − E (mm)
T2 (Right) = (B + D + G2) x 0.01 + 0.76 − F (mm)
G3M0069
G3M1041
B3M0134A
NOTE:
Use several shims to obtain the calculated thick-
ness.
G3M0091
46
SERVICE PROCEDURE [W3E0] 3-4
3. Rear Differential (T-Type)
Side bearing retainer shim (3) Install the differential case assembly into
Part No. Thickness mm (in)
differential carrier in the reverse order of disas-
383475201 0.20 (0.0079)
sembly.
383475202 0.25 (0.0098)
383475203 0.30 (0.0118)
383475204 0.40 (0.0157)
383475205 0.50 (0.0197)
Example of calculation
Ex. 1
A = 5, B = 5, C = 3, D = 3, G1 = 4, G2 = 1, E = 0.10
mm, F = 0.15 mm
Left side
T1 = (A + C + G1− D) × 0.01 + 0.76 − E
G3M1035
= (5 + 3 + 4 − 3) × 0.01 + 0.76 − 0.10
= 0.09 + 0.76 − 0.10 = 0.75 mm (4) Fit the selected shims and O-ring on side
The correct shims are as follows: bearing retainer and install them on differential
Thickness Q’ty carrier with the arrow mark on the retainer
0.25 × 1 = 0.25 directed as shown in figure.
0.50 × 1 = 0.50 CAUTION:
Total shim thickness = 0.75 mm Be careful that side bearing cup is not dam-
Right side aged by bearing roller.
T2 = (B + D + G2) × 0.01 + 0.76 − F
= (5 + 3 + 1) × 0.01 + 0.76 − 0.15
= 0.09 + 0.76 − 0.15
= 0.70 mm
The correct shims are as follows:
Thickness Q’ty
0.20 × 1 = 0.20
0.50 × 1 = 0.50
Total shim thickness = 0.70 mm
Ex. 2
A = 2, B = 3, C = 0, D = 3, G1 = 2, G2 = 3, E = 0.22 G3M1045
mm, F = 0.10 mm
Left side
(5) Tighten side bearing retainer bolts.
T1 = (A + C + G1− D) × 0.01 + 0.76 − E Tightening torque:
= (2 + 0 + 2 − 3) × 0.01 + 0.76 − 0.22 10.3±1.5 N·m (1.05±0.15 kg-m, 7.6±1.1
= 0.01 + 0.76 − 0.22 ft-lb)
= 0.55 mm
The correct shims are as follows:
Thickness Q’ty
0.25 × 1 = 0.25
0.30 × 1 = 0.30
Total shim thickness = 0.55 mm
Right side
T2 = (B + D + G2) × 0.01 + 0.76 − F
= (3 + 3 + 3) × 0.01 + 0.76 − 0.10
= 0.09 + 0.76 − 0.10
G3M1046
= 0.75 mm
The correct shims are as follows:
Thickness Q’ty
0.25 × 1 = 0.25
0.50 × 1 = 0.50
Total shim thickness = 0.75 mm
47
3-4 [W3E0] SERVICE PROCEDURE
3. Rear Differential (T-Type)
(6) Measure the crown gear-to-drive pinion 17) Check the crown gear runout on its back
backlash. Set magnet base on differential car- surface, and make sure pinion and crown gear
rier. Align contact point of dial gauge with tooth rotate smoothly.
face of crown gear, and move crown gear while Limit of runout:
holding drive pinion still. Read value indicated 0.05 mm (0.0020 in)
on dial gauge.
Backlash:
0.10 — 0.20 mm (0.0039 — 0.0079 in)
G3M1048
G3M1047
48
SERVICE PROCEDURE [W3E0] 3-4
3. Rear Differential (T-Type)
G3M1047
H3M1309A
49
3-4 [W3E0] SERVICE PROCEDURE
3. Rear Differential (T-Type)
B3M0317A
Face contact This may cause noise and chipping at Increase thickness of drive pinion height
Backlash is too large. tooth ends. adjusting shim in order to bring drive pin-
ion closer to crown gear center.
B3M0319
B3M0323
Flank contact This may cause noise and stepped wear Reduce thickness of drive pinion height
Backlash is too small. on surfaces. adjusting shim in order to move drive
pinion away from crown gear.
B3M0320
B3M0324
Toe contact This may cause chipping at toe ends. Adjust as for flank contact.
Contact area is small.
B3M0321 B3M0324
Heel contact This may cause chipping at heel ends. Adjust as for face contact.
Contact area is small.
B3M0322 B3M0323
50
SERVICE PROCEDURE [W3F0] 3-4
3. Rear Differential (T-Type)
20) Install rear cover and tighten bolts to specified 5) After installation, fill differential carrier with gear
torque. oil to the upper plug level.
Tightening torque: CAUTION:
29±5 N·m (3.0±0.5 kg-m, 21.7±3.6 ft-lb) Apply fluid packing to plug.
Fluid packing:
THREE BOND 1105 or equivalent
Oil capacity:
0.8 (0.8 US qt, 0.7 Imp qt)
Tightening torque:
44±4 N·m (4.5±0.4 kg-m, 32.5±2.9 ft-lb)
G3M1050
F: INSTALLATION
To install, reverse the removal sequence.
1) Install the air breather cap tapping with a plas-
tic hammer. G3M1051
CAUTION:
Be sure to install new air breather cap.
2) Position front member on body by passing it
under parking brake cable and securing to rear
differential.
NOTE:
When installing rear differential front member, do
not confuse the installation sequence of the upper
and lower stoppers.
3) Install DOJ of rear drive shaft into rear differen-
tial. <Ref. to 3-4 [W3A2].>
ST 28099PA090 SIDE OIL SEAL PROTEC-
TOR
G3M1026
51
3-4 [W4A1] SERVICE PROCEDURE
4. Rear Differential Front Member
G3M0049
52
SERVICE PROCEDURE [W4B2] 3-4
4. Rear Differential Front Member
G3M1029
G3M1026
53
3-4 [K100] DIAGNOSTICS
1. Propeller Shaft
1. Propeller Shaft
NOTE:
Vibration while cruising may be caused by an
unbalanced tire, improper tire inflation pressure,
improper wheel alignment, etc.
2. Rear Differential
Symptom and possible cause Remedy
1. Oil leakage
(1) Worn, scratched, or incorrectly seated front or side oil seal.
Scored, battered, or excessively worn sliding surface of compan- Repair or replace.
ion flange.
(2) Clogged or damaged air breather. Clean, repair or replace.
(3) Loose bolts on differential spindle or side retainer, or incorrectly
Tighten bolts to specified torque. Replace O-ring.
fitted O-ring.
(4) Loose rear cover attaching bolts or damaged gasket. Tighten bolts
Replace gasket and apply liquid packing.
to specified torque.
(5) Loose oil filler or drain plug. Retighten and apply liquid packing.
(6) Wear, damage or incorrectly fitting for spindle, side retainer and
Repair or replace.
oil seal.
2. Seizure
Seized or damaged parts should be replaced, and also other parts should be thoroughly checked for any defect and should
be repaired or replaced as required.
(1) Insufficient backlash for hypoid gear. Readjust or replace.
(2) Excessive preload for side, rear, or front bearing. Readjust or replace.
(3) Insufficient or improper oil used. Replace seized part and fill with specified oil to speci-
fied level.
3. Damage
Damaged parts should be replaced, and also other parts should be thoroughly checked for any defect and should be repaired
or replaced as required.
(1) Improper backlash for hypoid gear. Replace.
(2) Insufficient or excessive preload for side, rear, or front bearing. Readjust or replace.
(3) Excessive backlash for differential gear. Replace gear or thrust washer.
(4) Loose bolts and nuts such as crown gear bolt. Retighten.
(5) Damage due to overloading. Replace.
54
DIAGNOSTICS [K200] 3-4
2. Rear Differential
55
3-4 DIAGNOSTICS
MEMO:
56
SUSPENSION 4-1
Page
S SPECIFICATION AND SERVICE DATA ............................................................2
1. Stabilizer......................................................................................................2
2. Wheel Alignment .........................................................................................2
C COMPONENT PARTS .......................................................................................4
1. Front Suspension ........................................................................................4
2. Rear Suspension.........................................................................................6
W SERVICE PROCEDURE ...................................................................................7
1. On-car Services...........................................................................................7
2. Front Transverse Link ...............................................................................14
3. Front Ball Joint ..........................................................................................16
4. Front Strut .................................................................................................18
5. Front Stabilizer ..........................................................................................22
6. Front Crossmenber ...................................................................................23
7. Rear Trailing Link ......................................................................................25
8. Lateral Link................................................................................................29
9. Rear Strut ..................................................................................................33
10. Rear Crossmember ...................................................................................35
11. Rear Stabilizer...........................................................................................37
K DIAGNOSTICS.................................................................................................39
1. Suspension................................................................................................39
4-1 [S100] SPECIFICATION AND SERVICE DATA
1. Stabilizer
1. Stabilizer
Bar dia. mm (in)
Model
Front Rear
COUPE AWD 19 (0.75) 13 (0.51)
SEDAN AWD 19 (0.75) 13 (0.51)
WAGON AWD 19 (0.75) 13 (0.51)
OUTBACK AWD 19 (0.75) 13 (0.51)
2. Wheel Alignment
2200 cc 2500 cc
Sedan, Coupe Wagon OUTBACK Coupe
AWD AWD AWD AWD
Camber
0° 0° 0° −0°25′
(tolerance: ±0°30′)
Caster
3° 3° 3° 3°05′
(common difference: ±1°)
0±3 (0±0.12)
Front
Toe-in mm (in) Toe-in angle: −0°09′ [when toe-in is −3 (−0.12)]
Toe-out angle: 0°09′ [when toe-out is 3 (0.12)]
Kingpin angle 14° 14° 14° 14°
Wheel arch height
mm (in) 391 (15.39) 391 (15.39) 394 (15.51) 371 (14.61)
[tolerance: +12/−24 mm (+0.47/− 0.94 in)]
Camber
−0°55′ −0°55′ −0°55′ −1°10′
(tolerance: ±0°45′)
Toe-in mm (in) 0±3 (0±0.12) Total toe angle: 0°±18′
Rear Wheel arch height
mm (in) 379 (14.92) 379 (14.92) 386 (15.20) 368 (14.49)
[tolerance: +12/−24 mm (+0.47/− 0.94 in)]
Thrust angle
0° 0° 0° 0°
(tolerance: 0°±20′)
2
SPECIFICATION AND SERVICE DATA [S200] 4-1
2. Wheel Alignment
NOTE:
I 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
specification.
I The other items indicated in the specification
table cannot be adjusted. If the other items
exceeds specifications, check suspension parts
and connections for deformities; and replace with
new ones as required.
B4M0182A
3
4-1 [C100] COMPONENT PARTS
1. Front Suspension
1. Front Suspension
H4M1287A
(1) Crossmember (16) Jack-up plate (Except 2500 cc (30) Jack-up plate (2500 cc MT
(2) Bolt ASSY MT model) model)
(3) Housing (17) Dust seal
(4) Washer (18) Strut mount
(5) Stop rubber (Rear) (19) Spacer
(6) Rear bushing (20) Upper spring seat
(7) Stop rubber (Front) (21) Rubber seat
(8) Ball joint (22) Dust cover
(9) Transverse link (23) Helper
(10) Cotter pin (24) Coil spring
(11) Front bushing (25) Damper strut
(12) Stabilizer link (26) Adjusting bolt
(13) Clamp (27) Castle nut
(14) Bushing (28) Self-locking nut
(15) Stabilizer (29) Dynamic damper (2500 cc MT
model)
4
COMPONENT PARTS [C100] 4-1
1. Front Suspension
5
4-1 [C200] COMPONENT PARTS
2. Rear Suspension
2. Rear Suspension
H4M1273A
(1) Stabilizer (16) Trailing link bracket Tightening torque: N·m (kg-m, ft-lb)
(2) Stabilizer bracket (17) Cap
T1: 20±6 (2.0±0.6, 14.5±4.3)
(3) Stabilizer bushing (18) Washer
T2: 25±7 (2.5±0.7, 18.1±5.1)
(4) Clamp (19) Crossmember
T3: 44±6 (4.5±0.6, 32.5±4.3)
(5) Floating bushing (20) Cap
(6) Stopper (21) Strut mount T4: 59±10 (6.0±1.0, 43±7)
(7) Stabilizer link (22) Spring seat T5: 98±15 (10.0±1.5, 72±11)
(8) Rear lateral link (23) Rubber seat upper T6: 98±20 (10.0±2.0, 72±14)
(9) Bushing (C) (24) Dust cover T7: 113±15 (11.5±1.5, 83±11)
(10) Bushing (A) (25) Coil spring T8: 127±20 (13.0±2.0, 94±14)
(11) Front lateral link (26) Helper T9: 137±20 (14.0±2.0, 101±14)
(12) Bushing (B) (27) Rubber seat lower T10: 196+39/−10 (20.0+4.0/−1.0,
(13) Trailing link rear bushing (28) Damper strut 145+29/−7 )
(14) Trailing link (29) Self-locking nut
(15) Trailing link front bushing
6
SERVICE PROCEDURE [W1A0] 4-1
1. On-car Services
1. On-car Services
A: WHEEL ALIGNMENT
PROCEDURES
Check, adjust and/or measure wheel alignment in
accordance with procedures indicated in figure.
B4M1088A
7
4-1 [W1B1] SERVICE PROCEDURE
1. On-car Services
G4M0479
8
SERVICE PROCEDURE [W1B2] 4-1
1. On-car Services
2) Set ST into the center of the wheel, and then 2) Turn camber adjusting bolt so that camber is
install the wheel alignment gauge. set at the specification.
ST 927380000 ADAPTER NOTE:
Moving the adjusting bolt by one scale graduation
changes camber by approximately 0°10′.
B4M0567A
NOTE:
Refer to the “SPECIFICATIONS AND SERVICE
DATA” for the camber values. <Ref. to 4-1 [S200].>
I Front camber adjustment
1) Loosen two self-locking nuts located at lower
front portion of strut.
CAUTION:
I When adjusting bolt needs to be loosened or
tightened, hold its head with a wrench and turn
self-locking nut.
I Discard loosened self-locking nut and S4M0300A
replace with a new one.
B4M0190 B4M0350
B4M0350 B4M0190
9
4-1 [W1B3] SERVICE PROCEDURE
1. On-car Services
G4M0482
M4A0059
10
SERVICE PROCEDURE [W1B5] 4-1
1. On-car Services
G4M0486
B4M0192 B4M0352
B4M0352 B4M0192
11
4-1 [W1B6] SERVICE PROCEDURE
1. On-car Services
B4M0193A
B4M0194A
Thrust angle: r
r = (α − β) / 2
G4M0488
α: Right rear wheel toe angle
β: Left rear wheel toe angle
I Adjustment
NOTE:
1) Make thrust angle adjustments by turning toe-in Here, use only positive toe-in values from each
adjusting bolts of rear suspension equally in the wheel to substitute for α and β in the equation.
same direction.
7. STEERING ANGLE
NOTE:
On FWD models, turn adjusting wheels one by I Inspection
one, by the some amount in the opposite direction 1) Place vehicle on a turning radius gauge.
of the adjusting bolts. 2) While depressing brake pedal, turn steering
2) When one rear wheel is adjusted in a toe-in wheel fully to the left and right. With steering wheel
direction, adjust the other rear wheel equally in held at each fully turned position, measure both the
toe-out direction, in order to make thrust angle inner and outer wheel steering angle.
adjustment. Steering angle:
3) When left and right adjusting bolts are turned Inner wheel 37.4°±1.5°
incrementally by one graduation in the same Outer wheel 32.5°±1.5°
direction, the thrust angle of the AWD model will
change approximately 10′ [“L” is almost equal to
7.5 mm (0.295 in)].
Thrust angle:
0°±20′
12
SERVICE PROCEDURE [W1B7] 4-1
1. On-car Services
I Adjustment
Turn tie-rod to adjust steering angle of both inner
and outer wheels.
CAUTION:
I Check toe-in.
I Correct boot if it is twisted.
G4M0482
13
4-1 [W2A0] SERVICE PROCEDURE
2. Front Transverse Link
B4M1084A
1) Disconnect stabilizer link from transverse link. 4) Remove two bolts securing bushing bracket of
2) Remove bolt securing ball joint of transverse transverse link to car body at rear bushing location.
link to housing.
G4M0492
G4M0491
5) Extract ball joint from housing.
3) Remove nuts (do not remove bolts.) securing
transverse link to crossmember.
14
SERVICE PROCEDURE [W2E0] 4-1
2. Front Transverse Link
G4M0493
B: DISASSEMBLY
1. FRONT BUSHING G4M0496
Using ST, press front bushing out of place.
ST 927680000 INSTALLER & REMOVER SET 2. REAR BUSHING
1) Install rear bushing to transverse link and align
aligning marks scribed on the two.
2) Tighten self-locking nut.
CAUTION:
I Discard loosened self-locking nut and
replace with a new one.
I While holding rear bushing so as not to
change position of aligning marks, tighten self-
locking nut.
G4M0494
Tightening torque:
196±25 N·m (20.0±2.5 kg-m, 145±18 ft-lb)
2. REAR BUSHING
E: INSTALLATION
1) Scribe an aligning mark on transverse link and
rear bushing. 1) Temporarily tighten the two bolts used to secure
rear bushing of the transverse link to body.
NOTE:
These bolts should be tightened to such an extent
that they can still move back and forth in the oblong
shaped hole in the bracket (which holds the bush-
ing).
2) Install bolts used to connect transverse link to
crossmember and temporarily tighten with nuts.
CAUTION:
G4M0495 Discard loosened self-locking nut and replace
with a new one.
2) Loosen nut and remove rear bushing.
3) Insert ball joint into housing.
C: INSPECTION
1) Check transverse link for wear, damage and
cracks, and correct or replace if defective.
2) Check bushings for cracks, fatigue or damage.
3) Check rear bushing for oil leaks.
15
4-1 [W3A0] SERVICE PROCEDURE
3. Front Ball Joint
G4M0497
G4M0500
G4M0928
G4M0501
16
SERVICE PROCEDURE [W3C0] 4-1
3. Front Ball Joint
C: INSTALLATION
1) Install ball joint onto housing.
Torque (Bolt):
49 N·m (5.0 kg-m, 36 ft-lb)
CAUTION:
Do not apply grease to tapered portion of ball
stud.
2) Connect ball joint to transverse link.
Torque (Castle nut):
39 N·m (4.0 kg-m, 29 ft-lb)
3) Retighten castle nut further within 60° until a
slot in castle nut is aligned with the hole in ball stud
end, then insert new cotter pin and bend it around
castle nut.
4) Install front wheels.
17
4-1 [W4A0] SERVICE PROCEDURE
4. Front Strut
4. Front Strut
A: REMOVAL
B4M1085A
(1) Dust seal (7) Helper Tightening torque: N·m (kg-m, ft-lb)
(2) Strut mount (8) Coil spring
T1: 20±6 (2.0±0.6, 14.5±4.3)
(3) Spacer (9) Damper strut
T2: 49+10/− 0(5.0+1.0/− 0, 36+7/− 0 )
(4) Upper spring seat (10) Adjusting bolt
T3: 152±20 (15.5±2.0, 112±14)
(5) Rubber seat (11) Self-locking nut
(6) Dust cover
G4M0504
18
SERVICE PROCEDURE [W4C1] 4-1
4. Front Strut
7) Remove two bolts securing housing to strut. 2) Using ST, remove self-locking nut.
CAUTION: ST 927760000 STRUT MOUNT SOCKET
While holding head of adjusting bolt, loosen
self-locking nut.
8) Remove the three nuts securing strut mount to
body.
G4M0507
C: INSPECTION
Check the disassembled parts for cracks, damage
and wear, and replace with new parts if defective.
1. DAMPER STRUT
1) Check for oil leakage.
2) Move the piston rod up and down to check its
operates smoothly without any binding.
G4M0505
3) Play of piston rod
I Measure the play as follows:
B: DISASSEMBLY Fix outer shell and fully extend the rod. Set a dial
gauge at the end of the rod: L [10 mm (0.39 in)],
1) Using a coil spring compressor, compress coil then apply a force of: W [±20 N (±2 kg, ±4 lb)] to
spring. threaded portion. With the force of ±20 N (±2 kg,
±4 lb) applied, read both dial gauge readings, P1
and P2.
G4M0506
G4M0508
19
4-1 [W4C2] SERVICE PROCEDURE
4. Front Strut
defective. 5) Set the coil spring correctly so that its end face
5. HELPER fits well into the spring seat as shown.
6) Install helper and dust cover to the piston rod.
Replace it with new one if cracked or damaged.
D: ASSEMBLY
1) Before installing coil spring, strut mount, etc.,
on the strut, check for the presence of air in the
dampening force generating mechanism of the
strut since air prevents proper dampening force
from being produced.
2) Checking for the presence of air
(1) Place the strut vertically with the piston rod
facing up. G4M0510
20
SERVICE PROCEDURE [W4F0] 4-1
4. Front Strut
9) Using hexagon wrench to prevent strut rod from F: DISPOSAL PROCEDURES FOR
turning, tighten self-locking nut with ST. GAS FILLED STRUT
Tightening torque: CAUTION:
49+10/− 0 N·m (5.0+1.0/− 0 kg-m, 36+7/− 0 I On struts which have “GAS FILLED” marked
ft-lb) on outer housing under spring seat, com-
ST 927760000 STRUT MOUNT SOCKET pletely discharge gas before disposing, follow-
ing the methods below.
I Do not disassemble strut damper or place
into a fire.
I Drill holes before disposing of gas filled
struts.
I Before handling gas filled struts, be sure to
wear goggles to protect eyes from gas, oil
and/or filings.
G4M0507
E: INSTALLATION
1) Install upper strut mount at upper side of strut
to body and tighten with nuts.
Tightening torque: B4M1201
20±6 N·m (2.0±0.6 kg-m, 14.5±4.3 ft-lb)
1) Place gas filled strut on a flat and level surface
2) Install ABS sensor harness to strut. (ABS
with piston rod fully extended.
equipped models)
2) Using a 2 to 3 mm (0.08 to 0.12 in) dia. drill,
Tightening torque: make holes in areas shown in the figure.
152±20 N·m (15.5±2.0 kg-m, 112±14 ft-lb)
3) Position aligning mark on camber adjustment
bolt with aligning mark on lower side of strut.
CAUTION:
I While holding head of adjusting bolt, tighten
self-locking nut.
I Be sure to use new self-locking nut.
Tightening torque:
152±20 N·m (15.5±2.0 kg-m, 112±14 ft-lb)
B4M1202A
4) Install brake hose at lower side of strut with
clamp.
5) Install union bolts which secure brake caliper to
brake hose.
Tightening torque:
18±3 N·m (1.8±0.3 kg-m, 13.0±2.2 ft-lb)
CAUTION:
Be sure to bleed air from brake system.
6) Install wheels.
NOTE:
Check wheel alignment and adjust if necessary.
21
4-1 [W5A0] SERVICE PROCEDURE
5. Front Stabilizer
5. Front Stabilizer
A: REMOVAL
B4M1086A
(1) Front crossmember (6) Self-locking nut Tightening torque: N·m (kg-m, ft-lb)
(2) Transverse link
T1: 25±4 (2.5±0.4, 18.1±2.9)
(3) Jack-up plate
T2: 29±5 (3.0±0.5, 21.7±3.6)
(4) Stabilizer link
T3: 32±10 (3.3±1.0, 24±7)
(5) Front stabilizer
T4: 44±6 (4.5±0.6, 32.5±4.3)
1) Jack-up the front part of the vehicle, support it 3) Remove bolts which secure stabilizer link to
with safety stands (rigid racks). front transverse link.
2) Remove bolts which secure stabilizer to cross-
member.
G4M0516
G4M0515
4) Remove jack-up plate from lower part of cross-
member.
22
SERVICE PROCEDURE [W6B0] 4-1
6. Front Crossmenber
NOTE:
I Install bushing (on front crossmember side)
while aligning it with paint mark on stabilizer.
I Ensure that bushing and stabilizer have the
same identification colors when installing.
G4M0520
23
4-1 [W6B0] SERVICE PROCEDURE
6. Front Crossmenber
24
SERVICE PROCEDURE [W7A0] 4-1
7. Rear Trailing Link
H4M1066B
(1) Trailing link (5) Housing Tightening torque: N·m (kg-m, ft-lb)
(2) Front bushing (6) Self-locking nut
T1: 98±20 (10.0±2.0, 72±14)
(3) Rear bushing
T2: 113±15 (11.5±1.5, 83±11)
(4) Bracket
G4M0523
25
4-1 [W7B1] SERVICE PROCEDURE
7. Rear Trailing Link
B: DISASSEMBLY C: INSPECTION
1. FRONT BUSHING Check trailing links for bends, corrosion or dam-
age.
Using ST, press front bushing out of place.
ST 927720000 INSTALLER & REMOVER SET
D: ASSEMBLY
To assemble, reverse the disassembly procedures.
1. FRONT BUSHING
Using ST, press bushing into trailing link.
ST 927720000 INSTALLER & REMOVER SET
CAUTION:
When installing bushing, turn ST plunger
upside down and press it until the plunger end
surface contacts the trailing link end surface.
G4M0524
2. REAR BUSHING
1) Remove housing. <Ref. to 4-2 [W2A0].>
2) Using ST, press rear bushing out of place.
ST 927730000 INSTALLER & REMOVER SET
B4M0226A
CAUTION:
Install front bushing in the proper direction, as
shown in figure.
G4M0924
G4M0525
26
SERVICE PROCEDURE [W7D2] 4-1
7. Rear Trailing Link
B4M0195A
B4M0196A
27
4-1 [W7E0] SERVICE PROCEDURE
7. Rear Trailing Link
E: INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
Always tighten rubber bushing location when
wheels are in full contact with the ground and
vehicle is at curb weight condition.
NOTE:
Check wheel alignment and adjust if necessary.
28
SERVICE PROCEDURE [W8A0] 4-1
8. Lateral Link
8. Lateral Link
A: REMOVAL
H4M1067B
(1) Crossmember (8) Bushing (B) Tightening torque: N·m (kg-m, ft-lb)
(2) Adjusting bolt (9) Washer
T1: 44±6 (4.5±0.6, 32.5±4.3)
(3) Stabilizer link (10) Cap
T2: 98±15 (10.0±1.5, 72±11)
(4) Rear lateral link (11) Trailing link
T3: 113±15 (11.5±1.5, 83±11)
(5) Bushing (C) (12) Self-locking nut
(6) Bushing (A) T4: 137±20 (14.0±2.0, 101±14)
(7) Front lateral link
1) Loosen wheel nuts. Jack-up vehicle and 6) Remove DOJ from rear differential using ST.
remove wheel. (2200 cc MT model)
2) Remove stabilizers. ST 28099PA100 DRIVE SHAFT REMOVER
3) ( Models equipped with ABS ) CAUTION:
Remove ABS sensor harness from trailing link. Do not remove circlip attached to inside of dif-
4) Remove bolts which secure lateral link assem- ferential.
bly to rear housing.
CAUTION:
Discard old self-locking nut. Replace with a
new one.
5) Remove bolts which secure trailing link assem-
bly to rear housing.
CAUTION:
Discard old self-locking nut. Replace with a
new one.
G4M0994
29
4-1 [W8B0] SERVICE PROCEDURE
8. Lateral Link
G3M0257
CAUTION:
When removing the DOJ from the rear
differential, fit tire lever to the bolt as shown in
figure so as not to damage the axle shaft
holder.
H4M1068A
G3M0045
30
SERVICE PROCEDURE [W8D0] 4-1
8. Lateral Link
D: ASSEMBLY
1) Using ST, press bushing into place.
CAUTION:
Select ST according to the type of bushings
used.
NOTE:
I Use the same ST as that used during disassem-
bly.
I If it is difficult to press 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
G4M0531
C: INSPECTION
Visually check lateral links for damage or bends.
G4M0533
31
4-1 [W8E0] SERVICE PROCEDURE
8. Lateral Link
B4M0197A
B4M0198A
32
SERVICE PROCEDURE [W9A0] 4-1
9. Rear Strut
9. Rear Strut
A: REMOVAL
H4M1274A
(1) Cap (Only Wagon model) (7) Helper Tightening torque: N·m (kg-m, ft-lb)
(2) Strut mount (8) Rubber seat lower
T1: 20±6 (2.0±0.6, 14.5±4.3)
(3) Spring seat (9) Damper strut
T2: 59±10 (6.0±1.0, 43±7)
(4) Rubber seat upper (10) Self-locking nut
T3: 196+39/−10 (20.0+4.0/−1.0,
(5) Dust cover
145+29/−7 )
(6) Coil spring
1) Depress brake pedal and secure it in that posi- 6) Jack-up vehicle, support it with safety stands
tion using a wooden block, etc. (rigid racks) and remove rear wheels.
2) Remove rear seat cushion and backrest. 7) Remove brake hose clip.
(Sedan model) 8) Models equipped with rear drum brakes:
3) Remove strut cap of quarter trim. (Wagon Disconnect brake hose from brake pipe from strut,
model) and disconnect brake pipe from drum brake.
H4M1288A
G4M0399
33
4-1 [W9B0] SERVICE PROCEDURE
9. Rear Strut
34
SERVICE PROCEDURE [W10A0] 4-1
10. Rear Crossmember
H4M1275A
(1) Crossmember (7) Front lateral link Tightening torque: N·m (kg-m, ft-lb)
(2) Floating bushing (8) Washer
T1: 44±6 (4.5±0.6, 32.5±4.3)
(3) Adjusting bolt (9) Cap
T2: 98±15 (10.0±1.5, 72±11)
(4) Stopper (10) Trailing link
T3: 113±15 (11.5±1.5, 83±11)
(5) Stabilizer link (11) Self-locking nut
(6) Rear lateral link T4: 127±20 (13.0±2.0, 94±14)
G4M0544
35
4-1 [W10B0] SERVICE PROCEDURE
10. Rear Crossmember
G4M0545
B: INSPECTION
Check removed parts for wear, damage and
cracks, and correct or replace if defective.
C: INSTALLATION
1) Install in reverse order of removal.
2) Install rear differential. <Ref. to 3-4 [W2F0].> or
<Ref. to 3-4 [W3F0].>
3) Always tighten rubber bushing location when
wheels are in full contact with the ground and
vehicle is curb weight.
NOTE:
Check wheel alignment and adjust if necessary.
36
SERVICE PROCEDURE [W11C0] 4-1
11. Rear Stabilizer
H4M1143B
(1) Rear stabilizer (5) Stabilizer link Tightening torque: N·m (kg-m, ft-lb)
(2) Stabilizer bracket (6) Rear lateral link
T1: 25±7 (2.5±0.7, 18.1±5.1)
(3) Stabilizer bushing (7) Self-locking nut
T2: 44±6 (4.5±0.6, 32.5±4.3)
(4) Clamp
G4M0519
37
4-1 [W11C0] SERVICE PROCEDURE
11. Rear Stabilizer
38
DIAGNOSTICS [K1C0] 4-1
1. Suspension
1. Suspension
A: 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 Replace.
(3) Installation of wrong strut Replace with proper parts.
(4) Installation of wrong coil spring Replace with proper parts.
C: NOISE
Possible causes Countermeasures
(1) Wear or damage of damper strut component parts Replace.
(2) Loosening of suspension link installing bolt Retighten to the specified torque.
(3) Deformation or loss of bushing Replace.
(4) Unsuitability of maximum and/or minimum length of
Replace with proper parts.
damper strut
(5) Breakage of coil spring Replace.
(6) Wear or damage of ball joint Replace.
39
4-1 DIAGNOSTICS
MEMO:
40
WHEELS AND AXLES 4-2
Page
S SPECIFICATIONS AND SERVICE DATA..........................................................2
1. Tire and Wheel Size....................................................................................2
2. Tire Inflation Pressure .................................................................................2
3. Front Drive Shaft Assembly ........................................................................3
4. Rear Drive Shaft Assembly .........................................................................3
5. Application Table .........................................................................................4
6. Wheel Balance ............................................................................................4
C COMPONENT PARTS .......................................................................................5
1. Front Axle ....................................................................................................5
2. Rear Axle.....................................................................................................6
W SERVICE PROCEDURE ...................................................................................7
1. Front Axle ....................................................................................................7
2. Rear Axle...................................................................................................12
3. Front and Rear Drive Shafts .....................................................................20
4. Full Wheel Cap..........................................................................................30
5. Steel Wheel and Tire.................................................................................31
6. Wheel Balancing .......................................................................................32
7. Installation of Wheel Assembly to Vehicle ................................................32
8. Tire Rotation ..............................................................................................33
9. “T-type” Tire ...............................................................................................33
10. Aluminum Wheel .......................................................................................34
4-2 [S100] SPECIFICATIONS AND SERVICE DATA
1. Tire and Wheel Size
G4M0208
2
SPECIFICATIONS AND SERVICE DATA [S400] 4-2
4. Rear Drive Shaft Assembly
S4M0230B
B4M0049B
3
4-2 [S500] SPECIFICATIONS AND SERVICE DATA
5. Application Table
5. Application Table
Rear drive shaft
Model Power unit Front drive shaft
5MT 4AT
79AC-RH
AWD 2200 cc BJ87L + SFJ82 79AC
79AC-LH
79AC-RH 79AC-RH
AWD 2500 cc BJ87L + SFJ82
79AC-LH 79AC-LH
6. Wheel Balance
Wheel balancing Standard Service limit
Dynamic unbalance Less than 5 g (0.18 oz)
4
COMPONENT PARTS [C100] 4-2
1. Front Axle
1. Front Axle
B4M0773B
5
4-2 [C200] COMPONENT PARTS
2. Rear Axle
2. Rear Axle
H4M1000B
(1) Circlip (2200 cc AT model) (10) Boot (DOJ) (19) Tone wheel
(2) Baffle plate (DOJ) (11) Boot (BJ) (20) Hub bolt
(3) Outer race (DOJ) (12) BJ ASSY (21) Hub
(4) Snap ring (13) Oil seal (IN. No. 2) (22) Axle nut
(5) Inner race (14) Oil seal (IN. No. 3)
(6) Ball (15) Housing Tightening torque: N·m (kg-m, ft-lb)
(7) Cage (16) Bearing T1: 13±3 (1.3±0.3, 9.4±2.2)
(8) Circlip (17) Snap ring T2: 186±20 (19±2, 137±14)
(9) Boot band (18) Oil seal (OUT)
6
SERVICE PROCEDURE [W1A0] 4-2
1. Front Axle
G4M0214
G4M0217
G4M0215
9) Remove cotter pin and castle nut which secure
6) Remove disc brake caliper from housing, and tie-rod end to housing knuckle arm.
suspend it from strut using a wire.
G4M0218
7
4-2 [W1B0] SERVICE PROCEDURE
1. Front Axle
10) Using a puller, remove tie rod ball joint from B: DISASSEMBLY
knuckle arm.
1) Using ST1, support housing and hub securely.
2) Attach ST2 to housing and drive hub out.
ST1 927060000 HUB REMOVER
ST2 927080000 HUB STAND
G4M0219
H4M1138A
ing.
If inner bearing race remains in the hub, remove it
with a suitable tool (commercially available).
CAUTION:
I Be careful not to scratch polished area of
hub.
I Be sure to install inner race on the side of
outer race from which it was removed.
G4M0221
G4M0224
G4M0222
8
SERVICE PROCEDURE [W1D0] 4-2
1. Front Axle
3) Remove disc cover from housing. 9) Using ST and a hydraulic press, drive hub bolts
out.
ST 927080000 HUB STAND
CAUTION:
Be careful not to hammer hub bolts. This may
deform hub.
G4M0225
H4M1001
G4M0227
G4M0230
8) Loosen bolts which secure tone wheel to hub.
Remove tone wheel (only vehicle equipped with 2) Using a hydraulic press, press new hub bolts
ABS). into place.
9
4-2 [W1D0] SERVICE PROCEDURE
1. Front Axle
G4M0231
G4M0234
10
SERVICE PROCEDURE [W1E0] 4-2
1. Front Axle
11) Install disc cover to housing the three bolts. 8) Install tie-rod end ball joint on housing knuckle
Tightening torque: arm.
14±4 N·m (1.4±0.4 kg-m, 10.1±2.9 ft-lb) Tightening torque:
12) Attach hub to ST1 securely. 27.0±2.5 N·m (2.75±0.25 kg-m, 19.9±1.8
13) Clean dust or foreign particles from the pol- ft-lb)
ished surface of hub.
14) Using ST2, press bearing into hub by driving
inner race.
ST1 927080000 HUB STAND
ST2 927120000 HUB INSTALLER
G4M0236
6) Install front drive shaft. <Ref. to 4-2 [W3E1].> 10) After tightening axle nut, lock it securely.
7) Connect stabilizer link.
G4M0238
11
4-2 [W2A1] SERVICE PROCEDURE
2. Rear Axle
11) Install wheel and tighten wheel nuts to speci- 2. Rear Axle
fied torque.
Tightening torque: A: REMOVAL
88±10 N·m (9±1 kg-m, 65±7 ft-lb) 1. DISC BRAKE
1) Disconnect ground cable from battery.
2) Jack-up vehicle, and remove rear wheel cap
and wheels.
CAUTION:
Be sure to loosen and retighten axle nut after
removing wheel from vehicle. Failure to follow
this rule may damage wheel bearings.
3) Unlock axle nut.
4) Remove axle nut using a socket wrench.
5) Return parking brake lever and loosen adjust-
ing nut.
B4M0050A
G4M0240
12
SERVICE PROCEDURE [W2A2] 4-2
2. Rear Axle
8) Disconnect parking brake cable end. 12) Disengage BJ from housing splines, and
remove rear drive shaft assembly. If it is hard to
remove, use STs.
ST1 926470000 AXLE SHAFT PULLER
ST2 927140000 PLATE
CAUTION:
I Be careful not to damage oil seal lip when
removing rear drive shaft.
I When rear drive shaft is to be replaced, also
replace inner oil seal with a new one.
G4M0241
G4M0247
S4M0109
S4M0110
G4M0249
2. DRUM BRAKE
1) Disconnect ground cable from battery.
2) Jack-up vehicle, and remove rear wheel cap
and wheels.
13
4-2 [W2A2] SERVICE PROCEDURE
2. Rear Axle
G4M0244
G4M0241
NOTE:
If brake drum is difficult to remove, drive it out by
installing an 8-mm bolt into bolt hole in brake drum.
S4M0109
G4M0243
14
SERVICE PROCEDURE [W2B0] 4-2
2. Rear Axle
12) Remove bolts which secure lateral link assem- 15) Remove bolts which secure rear housing to
bly to rear housing. strut, and separate the two.
CAUTION:
Discard old self-locking nut. Replace with a
new one.
G4M0249
B: DISASSEMBLY
S4M0110
1) Using ST1 and ST2, remove hub from rear
13) Disengage BJ from housing splines, and housing.
remove rear drive shaft assembly. If it is hard to ST1 927080000 HUB STAND
remove, use STs. ST2 927420000 HUB REMOVER
ST1 926470000 AXLE SHAFT PULLER
ST2 927140000 PLATE
CAUTION:
I Be careful not to damage oil seal lip when
removing rear drive shaft.
I When rear drive shaft is to be replaced, also
replace inner oil seal with a new one.
G4M0250
H4M1003
H4M1139A
15
4-2 [W2C0] SERVICE PROCEDURE
2. Rear Axle
G4M0252
H4M1002A
6) Remove tone wheel bolts and remove tone
wheel from hub (only vehicle equipped with ABS).
7) Using ST, press hub bolt out. D: ASSEMBLY
ST 927080000 HUB STAND 1) Using ST, press new hub bolt into place.
CAUTION: CAUTION:
Be careful not to hammer hub bolts. This may I Ensure hub bolt closely contacts hub.
deform hub. I Use a 12 mm (0.47 in) hole in the ST to pre-
vent hub bolt from tilting during installation.
ST 927080000 HUB STAND
G4M0228
G4M0230
16
SERVICE PROCEDURE [W2D0] 4-2
2. Rear Axle
2) Remove foreign particles (dust, rust, etc.) from 4) Using plier, install snap ring.
mating surfaces of hub and tone wheel, and install CAUTION:
tone wheel to hub (only vehicle equipped with Ensure snap ring fits in groove properly.
ABS).
CAUTION:
I Ensure tone wheel closely contacts hub.
I Be careful not to damage tone wheel teeth.
G4M0251
G4M0257
G4M0259
17
4-2 [W2E1] SERVICE PROCEDURE
2. Rear Axle
8) Using ST1 and ST2, press sub seal into place. 3) Connect rear housing assembly to lateral link
ST1 927430000 HOUSING STAND assembly.
ST2 927460000 OIL SEAL INSTALLER CAUTION:
Use a new self-locking nut.
Tightening torque:
137±20 N·m (14±2 kg-m, 101±14 ft-lb)
G4M0260
S4M0109
18
SERVICE PROCEDURE [W2E2] 4-2
2. Rear Axle
S4M0110
19
4-2 [W3A1] SERVICE PROCEDURE
3. Front and Rear Drive Shafts
8) Connect rear ABS sensor to back plate (only 3. Front and Rear Drive Shafts
vehicle equipped with ABS).
A: REMOVAL
1. FRONT DRIVE SHAFT
1) Disconnect ground cable from battery.
2) Jack-up vehicle, support it with safety stands
(rigid rocks), and remove front wheel cap and
wheels.
3) Unlock axle nut.
4) Remove axle nut using a socket wrench.
CAUTION:
H4M1139A Be sure to loosen and retighten axle nut after
removing wheel from vehicle. Failure to follow
9) Connect parking brake cable to lever. this rule may damage wheel bearings.
10) Install brake drum on rear housing assembly.
11) Bleed air from brake system. <Ref. to 4-4 5) Disconnect transverse link from housing.
[W10B0].> 6) Remove spring pin which secures transmission
12) Adjust parking brake lever stroke by turning spindle to SFJ.
adjuster. CAUTION:
13) Move brake lever back to apply brakes. While Use a new spring pin.
depressing brake pedal, tighten axle nut using a
socket wrench. Lock axle nut after tightening.
Tightening torque:
186±20 N·m (19±2 kg-m, 137±14 ft-lb)
CAUTION:
I Use a new axle nut.
I Always tighten axle nut before installing
wheel on vehicle. If wheel is installed and
comes in contact with ground when axle nut is
loose, wheel bearings may be damaged.
I Be sure to tighten axle nut to specified G4M0279
torque. Do not overtighten it as this may dam- 7) Remove front drive shaft assembly. If it is hard
age wheel bearing. to remove, use ST1 and ST2.
14) Install wheel and tighten wheel nuts to speci- ST1 926470000 AXLE SHAFT PULLER
fied torque. ST2 927140000 PLATE
Tightening torque: CAUTION:
88±10 N·m (9±1 kg-m, 65±7 ft-lb) I Be careful not to damage oil seal lip when
removing front drive shaft.
I When front drive shaft is to be replaced, also
replace inner oil seal.
G4M0216
20
SERVICE PROCEDURE [W3A2] 4-2
3. Front and Rear Drive Shafts
G4M0994
G3M0045
21
4-2 [W3B1] SERVICE PROCEDURE
3. Front and Rear Drive Shafts
10) Remove axle nut and drive shaft. If it is hard 3) Remove circlip from SFJ outer race using
to remove, use ST1 and ST2. screwdriver.
ST1 926470000 AXLE SHAFT PULLER
ST2 927140000 PLATE
CAUTION:
I Be careful not to damage oil seal lip when
removing rear drive shaft.
I When rear drive shaft is to be replaced, also
replace inner oil seal with a new one.
B4M0776
B: DISASSEMBLY
1. FRONT DRIVE SHAFT
1) Place alignment marks on shaft and outer race.
B4M0774
B4M0775A
22
SERVICE PROCEDURE [W3B2] 4-2
3. Front and Rear Drive Shafts
8) Place alignment mark on trunnion and shaft. 12) Raise boot band claws by means of screw-
driver and hammer.
B4M0778
B4M0689A
B4M0779
13) Cut and remove the boot.
CAUTION: CAUTION:
Be sure to wrap shaft splines with vinyl tape to The boot must be replaced with a new one
prevent boot from scratches. whenever it is removed.
10) Remove SFJ boot.
11) Place drive shaft in a vise between wooden
blocks.
CAUTION:
Do not place drive shaft directly in the vise; use
wooden block.
B4M0690
23
4-2 [W3C0] SERVICE PROCEDURE
3. Front and Rear Drive Shafts
2) Loosen band by means of screwdriver or pliers 9) Remove snap ring, which fixes inner race to
with care of not damaging boot. shaft, by using pliers.
10) Take out DOJ inner race.
11) Take off DOJ cage from shaft and remove DOJ
boot.
CAUTION:
Be sure to wrap shaft splines with vinyl tape to
prevent boot from scratches.
12) Remove BJ boot in the same procedure as
DOJ boot.
13) Thus, disassembly of axle is completed, but
G4M0281 BJ is unable to be disassembled.
24
SERVICE PROCEDURE [W3D1] 4-2
3. Front and Rear Drive Shafts
B4M0778
B4M1296A
6) Set large boot band in place. 11) Install snap ring to shaft.
7) Install boot projecting portion to shaft groove. CAUTION:
Confirm that the snap ring is completely fitted
in the shaft groove.
12) Fill 100 to 110 g (3.53 to 3.88 oz) of specified
grease into the interior of SFJ outer race.
13) Apply a coat of specified grease to free ring
and trunnion.
14) Align alignment marks on free ring and trun-
nion and install free ring.
B4M1297A
B4M0693B
25
4-2 [W3D2] SERVICE PROCEDURE
3. Front and Rear Drive Shafts
15) Align alignment marks on shaft and outer 22) Tap on the clip with the punch provided at the
race, and install outer race. end of ST.
ST 925091000 BAND TIGHTENING TOOL
CAUTION:
Tap to an extent that the boot underneath is not
damaged.
B4M0774
G4M0289
26
SERVICE PROCEDURE [W3D2] 4-2
3. Front and Rear Drive Shafts
3) Insert DOJ cage onto shaft. 6) Fill 80 to 90 g (2.82 to 3.17 oz) of specified
NOTE: grease into the interior of DOJ outer race.
Insert the cage with the cut-out portion facing the 7) Apply a coat of specified grease to the cage
shaft end, since the cage has an orientation. pocket and six balls.
8) Insert six balls into the cage pocket.
9) Align the outer race track and ball positions and
place in the part where shaft, inner race, cage and
balls are previously installed, and then fit outer
race.
G4M0284
G4M0285
27
4-2 [W3E1] SERVICE PROCEDURE
3. Front and Rear Drive Shafts
14) Pinch the end of band with pliers. Hold the clip E: INSTALLATION
and tighten securely.
1. FRONT DRIVE SHAFT
NOTE:
When tightening boot, exercise care so that the air 1) Insert BJ into hub splines.
within the boot is appropriate. CAUTION:
15) Tighten band by using ST. Be careful not to damage inner oil seal lip.
ST 925091000 BAND TIGHTENING TOOL 2) Using ST1 and ST2, pull drive shaft into place.
NOTE: ST1 922431000 AXLE SHAFT INSTALLER
Tighten band until it cannot be moved by hand. ST2 927390000 ADAPTER
CAUTION:
Do not hammer drive shaft when installing it.
G4M0289
G4M0290
28
SERVICE PROCEDURE [W3E2] 4-2
3. Front and Rear Drive Shafts
CAUTION: 6) Insert DOJ spline end into bore of side oil seal,
I Use a new axle nut. and remove ST.
I Always tighten axle nut before installing CAUTION:
wheel on vehicle. If wheel is installed and Do not allow DOJ splines to damage side oil
comes in contact with ground when axle nut is seal.
loose, wheel bearings may be damaged.
I Be sure to tighten axle nut to specified ST 28099PA090 SIDE OIL SEAL PROTEC-
torque. Do not overtighten it as this may dam- TOR
age wheel bearing.
8) After tightening axle nut, lock it securely.
2. REAR DRIVE SHAFT
1) Insert BJ into rear housing splines.
CAUTION:
Be careful not to damage inner oil seal lip.
2) Using ST1 and ST2, pull drive shaft into place.
ST1 922431000 AXLE SHAFT INSTALLER
G3M0049
ST2 927390000 ADAPTER
CAUTION: 7) Align DOJ and differential splines.
Do not hammer drive shaft when installing it. 8) Push housing to insert DOJ into differential.
NOTE:
Make sure DOJ is inserted properly.
H4M1094A
29
4-2 [W4A0] SERVICE PROCEDURE
4. Full Wheel Cap
H4M1140
B: INSTALLATION
Align the valve hole in the wheel cap with the valve
on the wheel and secure the wheel cap by tapping
four points by hand.
30
SERVICE PROCEDURE [W5A1] 4-2
5. Steel Wheel and Tire
I When replacing a tire, make sure to use only 3) If rim runout exceeds specifications, remove
the same size, construction and load range as tire from rim and check runout while attaching dial
originally installed. gauge to positions shown in figure.
I Avoid mixing radial, belted bias or bias tires 4) If measured runout still exceeds specifications,
on the vehicle. replace the wheel.
(1) when large crack on side wall, damage or
crack on tread is found.
(2) when the “tread wear indicator” appears as
a solid band across the tread.
G4M0297
G4M0298
31
4-2 [W600] SERVICE PROCEDURE
6. Wheel Balancing
B4M0053A
32
SERVICE PROCEDURE [W900] 4-2
9. “T-type” Tire
33
4-2 [W10A0] SERVICE PROCEDURE
10. Aluminum Wheel
B: PRECAUTIONS
Aluminum wheels are easily scratched. To main-
tain their appearance and safety, do the following:
1) Do not damage aluminum wheels during
removal, disassembly, installation, wheel
balancing, etc. After removing aluminum wheels,
place them on a rubber mat, etc.
2) While vehicle is being driven, be careful not to
ride over sharp obstacles or allow aluminum
wheels to contact the shoulder of the road.
3) When installing tire chain, be sure to install it
properly not to have a slack; otherwise it may hit
wheel while driving.
4) When washing aluminum wheel, use neutral
synthetic detergent and water. Avoid using the
cleanser including abrasive, hard brushes or an
automatic car washer.
34
Wheel Bearing
Installation Guide
MSA5P0401C
Replaces MSA5TT0001 and MSA5TT0201
© Copyright 2004
Subaru of America, Inc.
All rights reserved. This book may not be
reproduced in whole or in part without the
express permission of Subaru of America, Inc.
Continued on page 4
Notes:
Notes:
Notes:
Notes:
Note: Measure the roundness of the housing where the bearing is installed
as follows.
• Measure inner diameter “X” and “Y” at both “A” and “B” positions by
using cylinder bore gauge.
• If difference of the measurement between “X” and “Y” is more than
.020mm, replace the housing with a new one.
31. Tighten the last few turns with the breaker bar if
necessary. Installation is complete when OTC
311888 makes contact with the bearing housing.
32. Remove the tools.
36. Remove all tools from the puller bolt. Push out the
34. Thread seal installer J45697-11 with the smaller bearing stay from the center of the installed
diameter facing outward onto driver handle bearing using the head of the bolt.
J8092.
52. Stake Axle Nut. Then install the brake caliper 54. Pump the brake pedal before moving the vehicle.
mount and torque the bolts.
Legacy, Impreza and Forester 38 ± 4 ft-lb
(2) Place the hub into the press with press plates that
will provide support to the under side of the inner
race of the tapered toller bearing. Insert
28099PA040-6 onto the top of the hub. Apply
pressure with the press until the hub is removed.
(1) Assemble 28099PA040-1, 208099PA040-2 (With Align press plate bolts so they are supported
short adapter sleeve and shorter bolt) along the length of the bolt.
28099PA040-5, and J5356-4 puller bolt onto the
front hub. Insert 28099PA040-6 into the bearing
assembly. Turn puller bolt to remove bearing.
Remove tone wheel if equipped.
MSA5P0401C
Replaces MSA5TT0001 and MSA5TT0201
STEERING SYSTEM 4-3
Page
S SPECIFICATIONS AND SERVICE DATA..........................................................2
1. Steering System ..........................................................................................2
C COMPONENT PARTS .......................................................................................4
1. Steering Wheel and Column (Tilt)...............................................................4
2. Power Steering System...............................................................................5
3. Power Steering Oil Pump............................................................................7
W SERVICE PROCEDURE ...................................................................................8
1. Supplement Restraint System “Airbag” ......................................8
2. Tilt Steering Column....................................................................................8
3. Steering Gearbox (Power Steering System).............................................12
4. Control Valve (Power Steering Gearbox)..................................................22
5. Pipe Assembly (Power Steering System) .................................................29
6. Oil Pump (Power Steering System) ..........................................................33
7. Power Steering Fluid.................................................................................41
K DIAGNOSTICS.................................................................................................42
1. Power Steering..........................................................................................42
4-3 [S1A0] SPECIFICATIONS AND SERVICE DATA
1. Steering System
1. Steering System
A: SPECIFICATIONS
Minimum turning radius m (ft) 5.1 (16.7)
Steering angle (Inside-Outside) 37.4°±1.5° — 32.5°±1.5°
Whole system
Steering wheel diameter mm (in) 385 (15.16)
Overall gear ratio (Turns, lock to lock) 16.5 (3.2)
Type Rack and pinion, Integral
Gearbox Backlash 0 (Automatically adjustable)
Valve (Power steering system) Rotary valve
Type Vane pump
Oil tank Installed on pump
Output cm3 (cu in)/rev. 7.2 (0.439)
Relief pressure kPa (kg/cm2, psi) 7,355 (75, 1,067)
Pump Dropping in response to increased
(Power steering system) Hydraulic fluid control
engine revolutions
1,000 rpm: 7 (7.4, 6.2)
Hydraulic fluid (US qt, Imp qt)
3,000 rpm: 5 (5.3, 4.4)
Range of revolution rpm 500 — 7,500
Revolving direction Clockwise
Name ATF DEXRON II, IIE or III
Working fluid
Oil tank (US qt, Imp qt) 0.3 (0.3, 0.3)
(Power steering system) Capacity
Total (US qt, Imp qt) 0.7 (0.7, 0.6)
B: SERVICE DATA
Steering wheel Free play mm (in) 17 (0.67)
Inner tire & wheel 37.4°±1.5°
Turning angle
Outer tire & wheel 32.5°±1.5°
Clearance between steering
Steering shaft mm (in) 3.0 (0.118)
wheel and column cover
Sliding resistance N (kg, lb) 304 (31.0, 68.4) or less
Right-turn steer-
Rack shaft mm (in) 0.15 (0.0059) or less
ing
play in radial
Left-turn steer- Horizontal movement: 0.15 (0.0059) or less
direction mm (in)
ing Vertical movement: 0.15 (0.0059) or less
Steering gearbox In radial direc-
Input shaft mm (in) 0.18 (0.0071) or less
(Power steering system) tion
play
In axial direction mm (in) 0.1 (0.004) or less
Within 30 mm (1.18 in) from rack center in
straight ahead position: Less than 11.18
Turning resistance N (kg, lb)
(1.14, 2.51)
Maximum allowable value: 12.7 (1.3, 2.9)
Radial play mm (in) 0.4 (0.016) or less
Pulley shaft
Axial play mm (in) 0.9 (0.035) or less
Ditch deflection mm (in) 1.0 (0.039) or less
Oil pump
Pulley Resistance to
(Power steering system) N (kg, lb) 9.22 (0.94, 2.07) or less
rotation
Regular pressure kPa (kg/cm2, psi) 981 (10, 142) or less
Relief pressure kPa (kg/cm2, psi) 7,355 (75, 1,067)
At standstill with engine idling
N (kg, lb) 31.4 (3.2, 7.1) or less
Steering wheel effort on a concrete road
(Power steering system) At standstill with engine stalled
N (kg, lb) 147 (15, 33) or less
on a concrete road
2
SPECIFICATIONS AND SERVICE DATA [S1C0] 4-3
1. Steering System
C: RECOMMENDED POWER
STEERING FLUID
Recommended power steering fluid Manufacturer
B.P.
CALTEX
CASTROL
ATF DEXRON IIE or III
MOBIL
SHELL
TEXACO
3
4-3 [C100] COMPONENT PARTS
1. Steering Wheel and Column (Tilt)
S4M0304B
(1) Bushing (6) Steering wheel Tightening torque: N·m (kg-m, ft-lb)
(2) Steering shaft (7) Airbag module
T1: 1.2±0.2 (0.12±0.02, 0.9±0.1)
(3) Knee protector
T2: 3.4±1.0 (0.35±0.1, 2.5±0.7)
(4) Steering roll connector
T3: 25±5 (2.5±0.5, 18.1±3.6)
(5) Column cover
T4: 44±6 (4.5±0.6, 32.5±4.3)
4
COMPONENT PARTS [C200] 4-3
2. Power Steering System
H4M1289A
5
4-3 [C200] COMPONENT PARTS
2. Power Steering System
6
COMPONENT PARTS [C300] 4-3
3. Power Steering Oil Pump
H4M1223C
7
4-3 [W1A0] SERVICE PROCEDURE
1. Supplement Restraint System “Airbag”
1. Supplement Restraint
System “Airbag”
A: PRECAUTION
Airbag system wiring harness is routed near the
steering wheel, steering shaft and column.
WARNING:
I All Airbag system wiring harness and con-
nectors are colored yellow. Do not use electri-
cal test equipment on these circuit.
I Be careful not to damage Airbag system wir-
ing harness when servicing the steering wheel,
steering shaft and column.
H4M1290A
8
SERVICE PROCEDURE [W2B0] 4-3
2. Tilt Steering Column
G5M0332
9
4-3 [W2C1] SERVICE PROCEDURE
2. Tilt Steering Column
C: INSPECTION
1. BASIC INSPECTION
Clean the disassembled parts with a cloth, and check for wear, damage, or any other faults. If necessary,
repair or replace faulty parts.
Part name Inspection Corrective
action
I Free play
I Swinging torque
Yawing torque
Looseness
Universal
Replace if faulty.
joint
G4M0089
Standard value of universal joint free play: 0 mm (0 in)
Max. value of universal joint swinging torque: 0.3 N·m (0.03 kg-m, 0.2 ft-lb)
Replace steer-
Steering col-
ing column
umn
assembly.
H4M1309A
10
SERVICE PROCEDURE [W2E0] 4-3
2. Tilt Steering Column
11
4-3 [W3A0] SERVICE PROCEDURE
3. Steering Gearbox (Power Steering System)
B4M1310C
12
SERVICE PROCEDURE [W3A0] 4-3
3. Steering Gearbox (Power Steering System)
1) Disconnect battery minus terminal. 8) Remove lower side bolt of universal joint, then
2) Loosen front wheel nut. remove upper side bolt and lift the joint upward.
3) Lift vehicle and remove front wheels. NOTE:
4) Remove front exhaust pipe assembly. Place a mark on the joint and mating serration so
WARNING: that they can be re-installed at the original position.
Be careful, exhaust pipe is hot.
5) Using a puller, remove tie-rod end from knuckle
arm after pulling off cotter pin and removing castle
nut.
G4M0086
G4M0098
G4M0099 G4M0102
13
4-3 [W3B0] SERVICE PROCEDURE
3. Steering Gearbox (Power Steering System)
S4M0146A
S4M0147A
S4M0144A
S4M0148A
S4M0145A
14
SERVICE PROCEDURE [W3C0] 4-3
3. Steering Gearbox (Power Steering System)
9) Using a wrench [32 mm (1.26 in) width across 10) Loosen adjusting screw and remove spring
flats] or adjustable wrench, remove tie-rod. and sleeve.
CAUTION: CAUTION:
I Check ball joint for free play, and tie-rod for Replace spring and/or sleeve if damaged.
bends. Replace if necessary.
I Check dust seals used with tie-rod end ball C: INSPECTION
joint for damage or deterioration. Replace if 1) Clean all disassembled parts, and check for
necessary. wear, damage, or any other faults, then repair or
replace as necessary.
2) When disassembling, check inside of gearbox
for water. If any water is found, carefully check boot
for damage, input shaft dust seal, adjusting screw
and boot clips for poor sealing. If faulty, replace
with new parts.
S4M0149A
15
4-3 [W3C1] SERVICE PROCEDURE
3. Steering Gearbox (Power Steering System)
G4M0111
Left-turn steering:
G4M0109 Service limit
Direction
0.15 mm (0.0059 in) or less
Direction
0.15 mm (0.0059 in) or less
G4M0110
G4M0112
16
SERVICE PROCEDURE [W3D0] 4-3
3. Steering Gearbox (Power Steering System)
G4M0113
In axial direction:
G4M0115
Service limit
0.1 mm (0.004 in) or less
On condition D: ASSEMBLY
P: 20 — 49 N (2 — 5 kg, 4 — 11 lb) CAUTION:
Use only SUBARU genuine grease for gearbox.
Grease:
VALIANT GREASE M2
[Part No. 003608001, net 0.5 kg (1.1 lb)]
1) Clean all parts and tools before reassembling.
2) Apply grease to teeth of rack so that grease
applied is about as high as teeth, and also apply a
thin film of grease to sliding portion of rack shaft.
CAUTION:
G4M0114
I When moving rack to stroke end without tie-
rod attached, prevent shocks from being
applied at the end.
I Do not apply grease to threaded portion at
end of rack shaft.
I Move rack shaft to stroke end two (2) or three
(3) times to squeeze grease which accumulates
on both ends. Remove grease to prevent it
from choking air passage hole.
3) Apply grease to sleeve insertion hole.
4) Apply grease to dust seal insertion hole.
CAUTION:
Apply clean grease with clean hands. If mate-
rial having a sharp edge is used for applying
grease, oil seal at the inside might be damaged.
17
4-3 [W3D0] SERVICE PROCEDURE
3. Steering Gearbox (Power Steering System)
5) Apply grease to sliding surface of sleeve and 8) Rack and pinion backlash adjustment
spring seat, then insert sleeve into pinion housing. (1) Loosen adjusting screw.
Fit spring into sleeve screw, pack grease inside of (2) Rotate input shaft so that rack is in the
screw, then install the screw. straight ahead direction.
(3) Apply grease to sleeve.
B4M1129A
B4M1130A
6) Install lock washers and tighten left and right
tie-rods into rack ends. (4) Tighten adjusting screw by two threads.
On condition
L: Approximately 40 mm (1.57 in)
Tightening torque:
78±10 N·m (8.0±1.0 kg-m, 58±7 ft-lb)
G4M0121
G4M0662
18
SERVICE PROCEDURE [W3D0] 4-3
3. Steering Gearbox (Power Steering System)
S4M0151A
gear box.
14) Inspect gearbox as follows:
“A” Holding tie-rod end, repeat lock to lock two or
three times as quickly as possible.
“B” Holding tie-rod end, turn it slowly at a radius
one or two times as large as possible.
After all, make sure that boot is installed in the
specified position without deflation.
S4M0152A
G4M0127
19
4-3 [W3E0] SERVICE PROCEDURE
3. Steering Gearbox (Power Steering System)
15) Remove gearbox from ST. (4) Fasten the short yoke side with a spring
ST 926200000 STAND washer and bolt, then fasten the long yoke side.
16) Install four pipes on gearbox. Tightening torque:
(1) Connect pipes A and B to four pipe joints of 24±3 N·m (2.4±0.3 kg-m, 17.4±2.2 ft-lb)
gearbox. Connect upper pipe B first, and lower
pipe A.
Tightening torque:
13±3 N·m (1.3±0.3 kg-m, 9.4±2.2 ft-lb)
(2) Connect pipes C and D to gearbox.
Connect lower pipe C first, and upper pipe D
second.
Tightening torque:
15±5 N·m (1.5±0.5 kg-m, 10.8±3.6 ft-lb)
E: INSTALLATION G4M0086
1) Insert gearbox into crossmember, being careful 4) Connect tie-rod end and knuckle arm, and
not to damage gearbox boot. tighten with castle nut. Fit cotter pin into the nut
2) Tighten gearbox to crossmember bracket via and bend the pin to lock.
clamp with bolt to the specified torque. Castle nut tightening torque:
Tightening torque: Tighten to 27.0±2.5 N·m (2.75±0.25 kg-m,
59±12 N·m (6.0±1.2 kg-m, 43±9 ft-lb) 19.9±1.8 ft-lb), and tighten further within
60° until cotter pin hole is aligned with a
slot in the nut.
CAUTION:
When connecting, do not hit cap at the bottom
of tie-rod end with hammer.
G4M0102
20
SERVICE PROCEDURE [W3F0] 4-3
3. Steering Gearbox (Power Steering System)
14) Check fluid level in oil tank. 3) If steering wheel spokes are not horizontal
15) After adjusting toe-in and steering angle, when wheels are set in the straight ahead position,
tighten lock nut on tie-rod end. and error is more than 5° on the periphery of steer-
ing wheel, correctly re-install the steering wheel.
Tightening torque:
83±5 N·m (8.5±0.5 kg-m, 61.5±3.6 ft-lb)
CAUTION:
When adjusting toe-in, hold boot as shown to
prevent it from being rotated or twisted. If
twisted, straighten it.
G4M0134
F: ADJUSTMENT
1) Adjust front toe.
Standard of front toe:
IN 3 — OUT 3 mm (IN 0.12 — OUT 0.12
in)
G4M0135
G4M0133
21
4-3 [W4A0] SERVICE PROCEDURE
4. Control Valve (Power Steering Gearbox)
S4M0153A
22
SERVICE PROCEDURE [W4B2] 4-3
4. Control Valve (Power Steering Gearbox)
There are two possible causes. Take following 3) Slide dust cover out.
step first. Remove the pipe assembly B from the
valve housing, and close the circuit with ST.
ST 926420000 PLUG
Turn the steering wheel from lock to lock 30 to
40 times with the engine running, then make
comparison of the leaked portion between
immediately after and several hours after this
operation.
CAUTION:
I If leakage from “f” is noted again:
S4M0156A
The oil seal of pinion and valve assembly is
damaged. Replace pinion and valve assembly 4) Using a press remove pinion and valve assem-
with a new one. Or replace the oil seal and the bly from valve housing.
parts that are damaged during disassembly
with new ones.
I If oil stops leaking from “f”:
The oil seal of rack housing is damaged.
Replace the oil seal and the parts that are dam-
aged during disassembly with new ones.
B: DISASSEMBLY
NOTE:
This section focuses on the disassembly and reas-
sembly of control valve. For the inspection and
S4M0157A
adjustment and the service procedures for associ-
ated parts, refer to “Steering Gearbox” <Ref. to 4-3
[W3A0].> 2. RACK ASSEMBLY
1. VALVE ASSEMBLY 1) Using a sharp pointed pliers, rotate the rack
1) Remove two bolts securing valve assembly. stopper in the direction of the arrow until the end
of the circlip comes out of the stopper. Rotate the
circlip in the opposite direction and pull it out.
S4M0154
S4M0155A
23
4-3 [W4C1] SERVICE PROCEDURE
4. Control Valve (Power Steering Gearbox)
2) Pull rack assembly from cylinder side, and draw 2) Apply a coat of specified power steering fluid to
out rack bushing and rack stopper together with inner wall of valve housing.
rack assembly.
CAUTION:
Be careful not to contact rack to inner wall of
cylinder when drawing out. Any scratch on cyl-
inder inner wall will cause oil leakage.
S4M0162A
S4M0160A
S4M0159A
24
SERVICE PROCEDURE [W4C2] 4-3
4. Control Valve (Power Steering Gearbox)
4) Using ST and press, install special bearing in 2) Press out bearing together with backing washer
valve housing. using pipe of I.D. 38.5 to 39.5 mm (1.516 to 1.555
ST 34099FA120 INSTALLER & REMOVER in) and press.
SEAL CAUTION:
NOTE: Do not reuse removed bearing.
To facilitate installation, attach ball bearing to
remover and position in valve housing before
pressing it into place.
S4M0161A
25
4-3 [W4C3] SERVICE PROCEDURE
4. Control Valve (Power Steering Gearbox)
G4M0149 S4M0163A
NOTE: NOTE:
I Apply specified power steering fluid to oil seal Discard removed oil seal.
and ST3, being careful not to damage oil seal lip.
I Push oil seal until ST3 contacts housing end
face.
8) Remove ST3, and fit backing washer.
9) Force-fit ball bearing using ST3.
ST1 926370000 INSTALLER A
ST2 34099FA100 STAND BASE
ST3 927640000 INSTALLER B
G4M0150
NOTE:
Be careful not to tilt ball bearing during installation.
10) Install snap ring using snap ring pliers.
26
SERVICE PROCEDURE [W4D1] 4-3
4. Control Valve (Power Steering Gearbox)
2) Force-fit oil seal using ST. 2) Fit ST over toothed portion of rack assembly,
ST 34099FA110 INSTALLER and check for binding or unsmooth insertion. If any
CAUTION: deformation is noted on flats at the end of rack,
Be careful not to damage or scratch cylinder shape by using file, and wash with cleaning fluid.
inner wall. ST 926390001 COVER and REMOVER
NOTE:
I Apply specified power steering fluid to oil seal.
I Pay special attention not to install oil seal in
wrong direction.
I Push oil seal until the stepped portion of A con-
tacts end face of B.
G4M0154
27
4-3 [W4D2] SERVICE PROCEDURE
4. Control Valve (Power Steering Gearbox)
5) Fit ST1 and ST2 over the end of rack, and 2. VALVE ASSEMBLY
install rack bushing.
CAUTION:
ST1 926400000 GUIDE
Use only SUBARU genuine grease for gearbox.
ST2 927660000 GUIDE
Specified grease for gearbox:
CAUTION:
VALIANT GREASE M2 (Part No.
I If burrs, or nicks are found on this guide and
003608001)
rack shaft portion, remove by filing.
I Dip rack bushing in specified power steering 1) Apply specified grease to dust cover.
fluid before installing, and pay attention not to
damage O-ring and oil seal.
S4M0166A
S4M0167
S4M0155A
28
SERVICE PROCEDURE [W5A0] 4-3
5. Pipe Assembly (Power Steering System)
G4M0098
G4M0099
29
4-3 [W5B0] SERVICE PROCEDURE
5. Pipe Assembly (Power Steering System)
H4M1074A
G4M0162
B: CHECK
Check all disassembled parts for wear, damage or
5) Disconnect pipe C from pipe (on the gearbox other abnormalities. Repair or replace faulty parts
side). as required.
CAUTION:
Part name Inspection Remedy
I When disconnecting pipe C, use two
wrenches to prevent deformities. Pipe I O-ring fitting sur-
face for damage Replace with new
I Be careful to keep pipe connections free I Nut for damage one.
from foreign matter. I Pipe for damage
Clamp B I Clamps for weak
clamping force Replace with new
Clamp C
one.
Clamp E
Hose I Flared surface for
damage
I Flare nut for dam-
age
I Outer surface for
cracks Replace with new
I Outer surface for one.
wear
G4M0101
I Clip for damage
I End coupling or
adapter for degrada-
tion
30
SERVICE PROCEDURE [W5C0] 4-3
5. Pipe Assembly (Power Steering System)
H4M1074A
2) Tighten bolt A.
Tightening torque:
13±3 N·m (1.3±0.3 kg-m, 9.4±2.2 ft-lb)
3) Temporarily connect pipes C and D to pipes (on
the gearbox side).
G4M0099
G4M0165
31
4-3 [W5C0] SERVICE PROCEDURE
5. Pipe Assembly (Power Steering System)
B4M1137A
32
SERVICE PROCEDURE [W6A0] 4-3
6. Oil Pump (Power Steering System)
6. Oil Pump (Power Steering 8) Remove three bolts from the front side of oil
pump and detach the pump.
System)
A: REMOVAL
1) Remove ground cable from battery.
2) Drain the working fluid about 0.3 (0.3 US qt,
0.3 Imp qt) from oil tank.
3) Remove pulley belt cover bracket.
4) Loosen oil pump pulley nut, then remove bolts
which secure alternator.
H4M1077A
H4M1074A
33
4-3 [W6B0] SERVICE PROCEDURE
6. Oil Pump (Power Steering System)
B: CHECK
I In accordance with the following table, check all removed parts for wear and damage, and make repair
or replacement if necessary.
No. Parts Inspection Corrective action
(1) Crack, damage or oil leakage Replace oil pump with a new one.
1 Oil pump (Exterior) Measure radial play and axial play.
(2) Play of pulley shaft If any of these exceeds the service limit, replace oil
pump with a new one. <Ref. to 4-3 [W6B1].>
(1) Damage Replace it with a new one.
2 Pulley Measure V ditch deflection.
(2) Bend If it exceeds the service limit, replace pulley with a
new one. <Ref. to 4-3 [W6B1].>
3 Cap Crack or damage Replace it with a new one.
(1) Clogging with dirt Wash it.
4 Strainer
(2) Breakage Replace it with a new one.
Check resistance to rotation of pulley.
(1) Defect or burning of vane pump If it is past the service limit, replace oil pump with a
new one. <Ref. to 4-3 [W6B1].>
5 Oil pump (Interior) Oil pump emits a noise that is markedly different in
(2) Bend in the shaft or damage to tone and loudness from a sound of a new oil pump
bearing when turning with a string put around its pulley,
replace oil pump with a new one.
6 O-ring Crack or deterioration Replace it with a new one.
7 Oil tank Crack, damage or oil leakage Replace it with a new one.
8 Bracket Crack Replace it with a new one.
34
SERVICE PROCEDURE [W6B1] 4-3
6. Oil Pump (Power Steering System)
G4M0172
G4M0175
G4M0173
35
4-3 [W6C0] SERVICE PROCEDURE
6. Oil Pump (Power Steering System)
H4M1229A
H4M1230B
H4M1228A
H4M1231A
36
SERVICE PROCEDURE [W6D0] 4-3
6. Oil Pump (Power Steering System)
H4M1232A
D: INSPECTION
Perform the following inspection procedures and repair or replace defective parts.
Part name Description Remedy
1) Damage on body surfaces
2) Excessive wear on hole, into which spool valve
is inserted.
Replace with a new one together with spool valve
1. Front casing 3) Wear and damage on cartridge assembly
as selective fit is made.
mounting surface
4) Wear and damage on surfaces in contact with
shaft and oil seal
1) Damage on body surfaces
2. Rear cover Replace with a new one.
2) Wear and damage on sliding surfaces
1) Shaft bend
2) Wear and damage on surfaces in contact with
3. Shaft bushing and oil seal Replace with a new one.
3) Wear and damage on rotor mounting surfaces
4) Bearing damage
4. Side plate Wear and damage on sliding surfaces Replace with a new one.
5. Cam ring Ridge wear on sliding surfaces
6. Vane Excessive wear on nose radius and side surfaces
If damage is serious, replace with a new cartridge
1) Wear and damage on sliding surfaces assembly.
2) Ridge wear on vane sliding grooves (If light
7. Rotor leaks with vane in slit against light source)
Correct with oil stone. If damage is serious,
3) Damage resulting from snap ring removal
replace with a new cartridge assembly.
Replace with a new one together with front cas-
8. Spool valve Damage or burrs on sliding surface periphery
ing as selective fit is made.
9. Connector Damage on threads Replace with a new one.
10. Spring Damage Replace with a new one.
11. Bolts and nuts Damage on threads Replace with a new one.
37
4-3 [W6E0] SERVICE PROCEDURE
6. Oil Pump (Power Steering System)
G4M0186
H4M1235A
38
SERVICE PROCEDURE [W6E0] 4-3
6. Oil Pump (Power Steering System)
12) Using STs, press retaining ring into shaft 14) With knock pin positions aligned, install rear
groove. cover.
CAUTION: CAUTION:
Discard retaining ring and replace with a new Loosely tighten bolts in the sequence (A), (B),
one. (C), and (D) shown in figure. Then, tighten in
the same sequence.
NOTE:
Use ST2, bending its top edge slightly toward the Tightening torque:
inside. 21±3.4 N·m (2.14±0.35 kg-m, 15.5±2.5 ft-lb)
ST1 34099AC030 INSTALLER RETAINING
RING CAP
ST2 34099AC040 INSTALLER RETAINING
RING PIPE
H4M1228C
CAUTION:
Make sure the retaining ring is fit in the second
groove of the shaft.
H4M1232A
39
4-3 [W6F0] SERVICE PROCEDURE
6. Oil Pump (Power Steering System)
19) Check followings by referring to “CHECK” 3) Install oil pump, previously assembled to oil
article. tank, on bracket.
I Excessive play in pulley shaft Tightening torque:
I Ditch deflection of pulley 22±2 N·m (2.2±0.2 kg-m, 15.9±1.4 ft-lb)
I Resistance to rotation of pulley
I Measurement of generated oil pressure
F: INSTALLATION
1) Install bracket on engine.
Tightening torque:
22±2 N·m (2.2±0.2 kg-m, 15.9±1.4 ft-lb)
2) Install oil pump on oil tank as follows outside
the vehicle:
NOTE: H4M1077A
H4M1074A
40
SERVICE PROCEDURE [W7A0] 4-3
7. Power Steering Fluid
7. Power Steering Fluid (3) Grinding noise is generated from oil pump.
10) Check the fluid leakage at flare nuts after turn-
A: RECOMMENDED POWER ing steering wheel from lock to lock with engine
STEERING FLUID AND AIR running.
BLEEDING CAUTION:
I Before checking, wipe off any fluid on flare
Recommended power steering Manufacturer nuts and piping.
fluid
I In case the fluid leaks from flare nut, it is
B.P.
caused by dust (or the like) and/or damage
CALTEX between flare and tapered seat in piping.
ATF DEXRON II, IIE or III
CASTROL I So remove the flare nut, tighten again it to
MOBIL the specified torque after cleaning flare and
SHELL tapered seat. If flare or tapered seat is
TEXACO damaged, replace it with a new one.
1) Feed the specified fluid with its level being 11) Inspect fluid level on flat and level surface with
about 4 cm (1.6 in) lower than the mouth of tank. engine “OFF” by indicator of filler cap. If the level
2) Continue to turn steering wheel slowly from lock is at lower point or below, add fluid to keep the
to lock until bubbles stop appearing in the tank level in the specified range of the indicator. If at
while keeping the fluid at that level. upper point or above, drain fluid by using a syringe
3) In case air is absorbed to deliver bubbles into or the like.
piping because the fluid level is lower, leave it Fluid capacity:
about half an hour and then do the step 2) all over 0.7 (0.7 US qt, 0.6 Imp qt)
again.
4) Start, and idle the engine. (1) Check at temperature 21°C (70°F) on res-
5) Continue to turn steering wheel slowly from lock ervoir surface of oil pump, read the fluid level on
to lock again until bubbles stop appearing in the the “COLD” side.
tank while keeping the fluid at that level. It is nor- (2) Check at temperature 60°C (140°F) on res-
mal that bubbles stop appearing after three times ervoir surface of oil pump, read the fluid level on
turning of steering wheel. the “HOT” side.
6) In case bubbles do not stop appearing in the
tank, leave it about half an hour and then do the
step 5) all over again.
7) Stop the engine, and take out safety stands
after jacking up vehicle again.
Then lower the vehicle, and idle the engine.
8) Continue to turn steering wheel from lock to
lock until bubbles stop appearing and change of
the fluid level is within 3 mm (0.12 in).
9) In case the following happens, leave it about
half an hour and then do step 8) again.
H4M1007
(1) The fluid level changes over 3 mm (0.12 in).
(2) Bubbles remain on the upper surface of the
fluid.
41
4-3 [K1A0] DIAGNOSTICS
1. Power Steering
1. Power Steering
A: STEERING CONDITION
Trouble Possible cause Corrective action
1. Pulley belt
I Unequal length of pulley belts
I Adhesion of oil and grease
I Loose or damage of pulley belt
Adjust or replace.
I Poor uniformity of pulley belt cross section
I Pulley belt touches to pulley bottom
I Poor revolution of pulleys except oil pump pulley
I Poor revolution of oil pump pulley
2. Tire and rim
I Heavy steering effort in all I Improper tires out of specification
Replace or reinflate.
ranges I Improper rims out of specification
I Heavy steering effort at I Tires not properly inflated*1
stand still 3. Fluid
I Steering wheel surges when I Low fluid level
turning. I Aeration Refill, bleed air, replace or
I Dust mix instruct customer.
I Deterioration of fluid
I Poor warming-up of fluid *2
4. Idling speed
I Lower idling speed
Adjust or instruct customer.
I Excessive drop of idling speed at start or at turning steer-
ing wheel *3
5. Measure hydraulic pressure. <Ref. to 4-3 [K1B0].> Replace problem parts.
6. Measure steering effort. <Ref. to 4-3 [K1C0].> Adjust or replace.
1. Fluid line
I Folded hose Reform or replace.
I Flattened pipe
2. Tire and rim
I Flat tire
I Mix use of different tires
I Mix use of different rims Fix or replace.
I Vehicle leads to one side or I Abnormal wear of tire
the other. I Unbalance of remained grooves
I Poor return of steering I Unbalance of tire pressure
wheel to center
3. Front alignment
I Steering wheel surges when
I Improper or unbalance caster
turning. Adjust or retighten.
I Improper or unbalance toe-in
I Loose connection of suspension
4. Others
I Damaged joint assembly Replace, adjust or instruct
I Unbalanced height customer.
I One-sided weight
5. Measure steering effort. <Ref. to 4-3 [K1C0].> Adjust or replace.
*1 If tires and/or rims are wider, the load to power steering system is the more. Accordingly, in a condition, for example before fluid
warms-up, relief valve may work before maximum turning angle. In this case, steering effort may be heavy. When measured
hydraulic pressure is normal, there is no abnormal thing.
*2 In cold weather, steering effort may be heavy due to increased flow resistance of cold fluid. After warming-up engine, turn steer-
ing wheel from stop to stop several times to warm-up fluid. Then if steering effort reduces normally, there is no abnormal thing.
*3 In cold weather or with insufficient warm-up of engine, steering effort may be heavy due to excessive drop of idling when turn-
ing steering wheel. In this case, it is recommended to start the vehicle with increasing engine speed than usual. Then if steering
effort reduces normally, there is no abnormal thing.
42
DIAGNOSTICS [K1B1] 4-3
1. Power Steering
B4M1193A
43
4-3 [K1B2] DIAGNOSTICS
1. Power Steering
1) Using STs, measure relief pressure. 1) Using STs, measure working pressure.
ST1 925711000 PRESSURE GAUGE ST1 925711000 PRESSURE GAUGE
ST2 34099AC020 ADAPTER HOSE B ST2 34099AC020 ADAPTER HOSE B
ST3 34099AC010 ADAPTER HOSE A ST3 34099AC010 ADAPTER HOSE A
B4M1162B B4M1193A
44
DIAGNOSTICS [K1C0] 4-3
1. Power Steering
B4M1142A
45
4-3 [K1C0] DIAGNOSTICS
1. Power Steering
S4M0169 G4M0199
S4M0170 G4M0200
G4M0201
G4M0202
46
DIAGNOSTICS [K1C0] 4-3
1. Power Steering
G4M0205
G4M0203
Sliding resistance:
Right-turn steering;
304 N (31 kg, 68 lb) or less
G4M0204
47
4-3 [K1D0] DIAGNOSTICS
1. Power Steering
D: FLUID LEAKAGE
CAUTION:
It is likely that although one judges fluid leakage, there is actually no leakage. This is because the
fluid spilt during the last maintenance was not completely wiped off. Be sure to wipe off spilt fluid
thoroughly after maintenance.
H4M1080B
48
DIAGNOSTICS [K1E0] 4-3
1. Power Steering
E: NOISE AND VIBRATION disk rotates slightly and makes creaking noise. The
noise is generated by creaking between the disk
CAUTION: and pads. If the noise goes off when the brake is
Don’t keep the relief valve operated over 5 sec- released, there is no abnormal function in the sys-
onds at any time or inner parts of the oil pump tem.
may be damaged due to rapid increase of fluid I There may be a little vibration around the steer-
temperature. ing devices when turning steering wheel at
NOTE: standstill, even though the component parts are
I Grinding noise may be heard immediately after properly adjusted and have no defects.
the engine start in extremely cold condition. In this Hydraulic systems are likely to generate this kind
case, if the noise goes off during warm-up there is of vibration as well as working noise and fluid noise
no abnormal function in the system. This is due to because of combined conditions, i.e., road surface
the fluid characteristic in extremely cold condition. and tire surface, engine speed and turning speed
I Oil pump makes whine or growl noise slightly of steering wheel, fluid temperature and braking
due to its mechanism. Even if the noise can be condition.
heard when steering wheel is turned at stand still This phenomena does not indicate there is some
there is no abnormal function in the system pro- abnormal function in the system.
vided that the noise eliminates when the vehicle is The vibration can be known when steering wheel
running. is turned repeatedly at various speeds from slow to
I When stopping with service brake and/or park- rapid step by step with parking brake applied on
ing brake applied, power steering can be operated concrete road and in “D” range for automatic trans-
easily due to its light steering effort. If doing so, the mission vehicle.
49
4-3 [K1E0] DIAGNOSTICS
1. Power Steering
50
DIAGNOSTICS [K1F0] 4-3
1. Power Steering
F: CLEARANCE TABLE
CAUTION:
This table lists various clearances that must be
correctly adjusted to ensure normal vehicle
driving without interfering noise, or any other
faults.
Minimum allowance
Location
mm (in)
(1) Crossmember — Pipe 5 (0.20)
(2) DOJ — Shaft or joint 14 (0.55)
(3) DOJ — Valve housing 11 (0.43)
(4) Pipe — Pipe 2 (0.08)
(5) Stabilizer — Pipe 5 (0.20)
(6) Exhaust pipe — Pipe 15 (0.59)
(7) Exhaust pipe — Gearbox bolt 15 (0.59)
(8) Side frame — Hose A and B 15 (0.59)
(9) Cruise control pump — Hose A and B 15 (0.59)
(10) Pipe portion of hose A — Pipe portion of hose B 1.5 (0.059)
(11) AT cooling hose — Joint 20 (0.79)
H4M1081B
51
4-3 [K1G0] DIAGNOSTICS
1. Power Steering
G: BREAKAGE OF HOSES the hoses and their service lives are shortening
accordingly, it is necessary to perform careful
CAUTION: inspection frequently when the vehicle is used
Although surface layer materials of rubber in hot weather areas, cold weather area and/or
hoses have excellent weathering resistance,
a driving condition in which many steering
heat resistance and resistance for low tem-
operations are required in short time.
perature brittleness, they are likely to be dam-
aged chemically by brake fluid, battery Particularly continuous work of relief valve
electrolyte, engine oil and automatic transmis- over 5 seconds causes to reduce service lives
sion fluid and their service lives are to be very of the hoses, the oil pump, the fluid, etc. due to
shortened. It is very important to keep the over heat.
hoses free from before mentioned fluids and to So, avoid to keep this kind of condition when
wipe out immediately when the hoses are servicing as well as driving.
adhered with the fluids.
Since resistances for heat or low temperature
brittleness are gradually declining according to
time accumulation of hot or cold conditions for
52
BRAKES 4-4
Page
S SPECIFICATIONS AND SERVICE DATA..........................................................2
1. Brakes .........................................................................................................2
C COMPONENT PARTS .......................................................................................5
1. Front Disc Brake .........................................................................................5
2. Rear Disc Brake ..........................................................................................7
3. Rear Drum Brake ........................................................................................8
4. Master Cylinder ...........................................................................................9
5. Brake Booster............................................................................................11
6. ABS System ..............................................................................................12
7. Parking Brake............................................................................................14
W SERVICE PROCEDURE .................................................................................15
1. Front Disc Brake .......................................................................................15
2. Rear Disc Brake ........................................................................................22
3. Rear Drum Brake ......................................................................................27
4. Parking Brake (Rear Disc Brake)..............................................................32
5. Master Cylinder .........................................................................................34
6. Brake Booster............................................................................................36
7. Brake Hose................................................................................................39
8. Parking Brake Lever..................................................................................40
9. Parking Brake Cable .................................................................................41
10. Air Bleeding ...............................................................................................42
11. Brake Fluid ................................................................................................44
12. Proportioning Valve ...................................................................................45
13. ABS Sensor...............................................................................................46
14. ABS Control Module and Hydraulic Control Unit (ABSCM&H/U).............50
15. G Sensor ...................................................................................................55
16. Brake Pipe ..............................................................................57
K DIAGNOSTICS.................................................................................................58
1. Entire Brake System .................................................................................58
4-4 [S1A1] SPECIFICATIONS AND SERVICE DATA
1. Brakes
1. Brakes
A: SPECIFICATIONS
1. 2200 cc MODEL
Engine (cc) 2200
Driving system AWD
Without ABS With ABS
Type Disc (Floating type, ventilated)
Effective disc diameter mm (in) 210 (8.27)
Disc thickness × outer diameter mm (in) 24 × 260 (0.94 × 10.24)
Front brake Effective cylinder diameter mm (in) 57.15 (2.2500)
Pad dimensions
mm (in) 112.4 × 44.3 × 11.0 (4.43 × 1.744 × 0.433)
(length × width × thickness)
Clearance adjustment Automatic adjustment
Type Drum (Leading-trailing type)
Effective drum diameter mm (in) 228.6 (9)
Effective cylinder diameter mm (in) 19.05 (0.7500)
Rear brake
Lining dimensions
mm (in) 218.8 × 35.0 × 4.1 (8.61 × 1.378 × 0.161)
(length × width × thickness)
Clearance adjustment Automatic adjustment
Type Mechanical on rear brake drums
Effective drum diameter mm (in) 228.6 (9)
Parking brake Lining dimensions
mm (in) 218.8 × 35.0 × 4.1 (8.61 × 1.378 × 0.161)
(length × width × thickness)
Clearance adjustment Automatic adjustment
Type Tandem
Effective diameter mm (in) 23.81 (0.9374) 25.40 (1)
Master cylinder
Reservoir type Sealed type
Brake fluid reservoir capacity cm3 (cu in) 205 (12.51)
Type Vacuum suspended
Brake booster 180 + 205
Effective diameter mm (in) 230 (9.06)
(7.09 + 8.07)
Split point kPa (kg/cm2, psi) 2,942 (30.0, 427)
Proportioning valve
Reducing ratio 0.4
Brake line Dual circuit system
ABS — STD
2
SPECIFICATIONS AND SERVICE DATA [S1A2] 4-4
1. Brakes
2. 2500 cc MODEL
Engine (cc) 2500
Driving system AWD
With ABS
Type Disc (Floating type, ventilated)
Effective disc diameter mm (in) 228 (8.98)
Disc thickness × Outer diameter mm (in) 24 × 277 (0.94 × 10.91)
Front brake Effective cylinder diameter mm (in) 42.8 (1.685) × 2
Pad dimensions
mm (in) 112.3 × 50.0 × 11.0 (4.42 × 1.969 × 0.433)
(length × width × thickness)
Clearance adjustment Automatic adjustment
Type Disc (Floating type)
Effective disc diameter mm (in) 230 (9.06)
Disc thickness × Outer diameter mm (in) 10 × 266 (0.39 × 10.47)
Rear brake Effective cylinder diameter mm (in) 38.1 (1.500)
Pad dimensions
mm (in) 92.4 × 33.7 × 10.0 (3.638 × 1.327 × 0.394)
(length × width × thickness)
Clearance adjustment Automatic adjustment
Type Mechanical on rear brakes, drum in disc
Effective drum diameter mm (in) 170 (6.69)
Parking brake Lining dimensions
mm (in) 162.6 × 30.0 × 3.2 (6.40 × 1.181 × 0.126)
(length × width × thickness)
Clearance adjustment Manual adjustment
Type Tandem
Effective diameter mm (in) 25.40 (1)
Master cylinder
Reservoir type Sealed type
Brake fluid reservoir capacity cm3 (cu in) 205 (12.51)
Type Vacuum suspended
Brake booster
Effective diameter mm (in) 180 + 205 (7.09 + 8.07)
Split point kPa (kg/cm2, psi) 2,942 (30.0, 427)
Proportioning valve
Reducing ratio 0.4
Brake line Dual circuit system
ABS STD
3
4-4 [S1B0] SPECIFICATIONS AND SERVICE DATA
1. Brakes
B: SERVICE DATA
ITEM STANDARD SERVICE LIMIT
Pad thickness
17 mm (0.67 in) 7.5 mm (0.295 in)
(including back metal)
Front brake
Disc thickness 24 mm (0.94 in) 22 mm (0.87 in)
Disc runout — 0.075 mm (0.0030 in)
Pad thickness
15 mm (0.59 in) 6.5 mm (0.256 in)
(including back metal)
Rear brake (Disc type)
Disc thickness 10 mm (0.39 in) 8.5 mm (0.335 in)
Disc runout — 0.10 mm (0.0039 in)
Inside diameter 228.6 mm (9 in) 230.6 mm (9.08 in)
Rear brake (Drum type)
Lining thickness 4.1 mm (0.161 in) 1.5 mm (0.059 in)
Rear brake (Disc type park- Inside diameter 170 mm (6.69 in) 171 mm (6.73 in)
ing) Lining thickness 3.2 mm (0.126 in) 1.5 mm (0.059 in)
Parking brake Lever stroke 7 to 8 notches/196 N (20 kg,44 lb)
4
COMPONENT PARTS [C1A0] 4-4
1. Front Disc Brake
B4M1208C
(1) Caliper body (9) Support Tightening torque: N·m (kg-m, ft-lb)
(2) Air bleeder screw (10) Pad clip
T1: 8±1 (0.8±0.1, 5.8±0.7)
(3) Guide pin (Green) (11) Outer shim
T2: 18±5 (1.8±0.5, 13.0±3.6)
(4) Pin boot (12) Inner shim
T3: 37±5 (3.8±0.5, 27.5±3.6)
(5) Piston seal (13) Pad (Outside)
(6) Piston (14) Pad (Inside) T4: 78±10 (8.0±1.0, 58±7)
(7) Piston boot (15) Disc rotor
(8) Lock pin (Yellow) (16) Disc cover
5
4-4 [C1B0] COMPONENT PARTS
1. Front Disc Brake
B: 2500 cc MODEL
B4M1151C
(1) Caliper body (9) Lock pin (Yellow) (17) Disc cover
(2) Air bleeder screw (10) Support
(3) Guide pin (Green) (11) Pad clip Tightening torque: N·m (kg-m, ft-lb)
(4) Pin boot (12) Outer shim T1: 8±1 (0.8±0.1, 5.8±0.7)
(5) Piston seal (13) Inner shim T2: 18±5 (1.8±0.5, 13.0±3.6)
(6) Piston (14) Pad (Outside) T3: 37±5 (3.8±0.5, 27.5±3.6)
(7) Piston boot (15) Pad (Inside) T4: 78±10 (8.0±1.0, 58±7)
(8) Boot ring (16) Disc rotor
6
COMPONENT PARTS [C200] 4-4
2. Rear Disc Brake
H4M1355A
(1) Caliper body (14) Shim (27) Primary shoe return spring
(2) Air bleeder screw (15) Shoe hold-down pin (28) Adjusting spring
(3) Guide pin (Green) (16) Cover (29) Adjuster
(4) Pin boot (17) Back plate (30) Shoe hold-down cup
(5) Piston seal (18) Retainer (31) Shoe hold-down spring
(6) Piston (19) Spring washer (32) Disc rotor
(7) Piston boot (20) Parking brake lever
(8) Boot ring (21) Parking brake shoe (Secondary) Tightening torque: N·m (kg-m, ft-lb)
(9) Lock pin (Yellow) (22) Parking brake shoe (Primary) T1: 8±1 (0.8±0.1, 5.8±0.7)
(10) Support (23) Strut T2: 39±5 (4.0±0.5, 28.9±3.6)
(11) Pad clip (24) Strut shoe spring T3: 52±6 (5.3±0.6, 38.3±4.3)
(12) Inner pad (25) Shoe guide plate
(13) Outer pad (26) Secondary shoe return spring
7
4-4 [C300] COMPONENT PARTS
3. Rear Drum Brake
B4M1120A
(1) Air bleeder cap (11) Upper shoe return spring (21) Lower shoe return spring
(2) Air bleeder screw (12) Retainer (22) Adjusting spring
(3) Boot (13) Washer (23) Drum
(4) Piston (14) Parking brake lever (24) Plug
(5) Cup (15) Brake shoe (Trailing)
(6) Spring (16) Brake shoe (Leading) Tightening torque: N·m (kg-m, ft-lb)
(7) Wheel cylinder body (17) Shoe hold-down spring T1: 8±1 (0.8±0.1, 5.8±0.7)
(8) Pin (18) Cup T2: 10±2 (1.0±0.2, 7.2±1.4)
(9) Plug (19) Adjusting lever T3: 52±6 (5.3±0.6, 38.3±4.3)
(10) Back plate (20) Adjuster
8
COMPONENT PARTS [C4A0] 4-4
4. Master Cylinder
4. Master Cylinder
A: WITH ABS VEHICLES
B4M1440A
9
4-4 [C4B0] COMPONENT PARTS
4. Master Cylinder
H4M1354A
10
COMPONENT PARTS [C5B0] 4-4
5. Brake Booster
5. Brake Booster
A: MODELS WITH ABS
B4M1121A
B4M1122A
11
4-4 [C6A0] COMPONENT PARTS
6. ABS System
6. ABS System
A: SENSOR
B4M1441A
(1) G sensor (5) Front ABS sensor LH Tightening torque: N·m (kg-m, ft-lb)
(2) Rear ABS sensor RH (6) Front ABS sensor RH
T1: 7.4±2.0 (0.75±0.2, 5.4±1.4)
(3) ABS spacer
T2: 32±10 (3.3±1.0, 24±7)
(4) Rear ABS sensor LH
12
COMPONENT PARTS [C6B0] 4-4
6. ABS System
B4M1220B
(1) Stud bolt (6) Front-RH outlet Tightening torque: N·m (kg-m, ft-lb)
(2) Damper (7) Primary inlet
T1: 18±5 (1.8±0.5, 13.0±3.6)
(3) ABS control module and hydrau- (8) Rear-LH outlet
T2: 29±7 (3.0±0.7, 21.7±5.1)
lic control unit (9) Rear-RH outlet
T3: 32±10 (3.3±1.0, 24±7)
(4) Front-LH outlet (10) Bracket
(5) Secondary inlet
13
4-4 [C700] COMPONENT PARTS
7. Parking Brake
7. Parking Brake
B4M0705B
(1) Parking brake lever (7) Clamp Tightening torque: N·m (kg-m, ft-lb)
(2) Parking brake switch (8) Parking brake cable RH
T1: 5.9±1.5 (0.60±0.15, 4.3±1.1)
(3) Lock nut (9) Cable guide
T2: 18±5 (1.8±0.5, 13.0±3.6)
(4) Adjusting nut (10) Clamp (Rear disc brake model
T3: 32±10 (3.3±1.0, 24±7)
(5) Equalizer only)
(6) Bracket (11) Parking brake cable LH
14
SERVICE PROCEDURE [W1A2] 4-4
1. Front Disc Brake
1. Front Disc Brake 5) Apply thin coat of PBC GREASE (Part No.
003607000) to the frictional portion between pad
A: ON-CAR SERVICE and pad clip.
1. PAD
1) Remove lock pin.
2) Raise caliper body.
3) Remove pad.
B4M1169A
B4M1168A
15
4-4 [W1B0] SERVICE PROCEDURE
1. Front Disc Brake
G4M0365
NOTE:
Make sure that micrometer is set 5 mm (0.20 in)
inward of rotor outer perimeter. B4M1192A
G4M0365
B4M1170
6) Clean mud and foreign particles from caliper
body assembly and support.
2) Remove bolt securing lock pin to caliper body.
B4M1171
16
SERVICE PROCEDURE [W1C1] 4-4
1. Front Disc Brake
C: DISASSEMBLY
1. EXCEPT 2500 cc MODEL
B4M1208D
(1) Caliper body (9) Support Tightening torque: N·m (kg-m, ft-lb)
(2) Air bleeder screw (10) Pad clip
T1: 8±1 (0.8±0.1, 5.8±0.7)
(3) Guide pin (Green) (11) Outer shim
T2: 18±5 (1.8±0.5, 13.0±3.6)
(4) Pin boot (12) Inner shim
T3: 37±5 (3.8±0.5, 27.5±3.6)
(5) Piston seal (13) Pad (Outside)
(6) Piston (14) Pad (Inside) T4: 78±10 (8.0±1.0, 58±7)
(7) Piston boot (15) Disc rotor
(8) Lock pin (Yellow) (16) Disc cover
17
4-4 [W1C1] SERVICE PROCEDURE
1. Front Disc Brake
1) Clean mud and foreign particles from caliper 4) Remove piston seal from caliper body cylinder.
body assembly and support.
CAUTION:
Be careful not to allow foreign particles to enter
inlet (at brake hose connector).
2) Gradually supply compressed air via caliper
body brake hose to force piston out.
CAUTION:
I Place a wooden block as shown in Figure to
prevent damage to piston.
I Do not apply excessively high-pressure. B4M1173A
B4M1174A
18
SERVICE PROCEDURE [W1C2] 4-4
1. Front Disc Brake
2. 2500 cc MODEL
B4M1151D
(1) Caliper body (9) Lock pin (Yellow) (17) Disc cover
(2) Air bleeder screw (10) Support
(3) Guide pin (Green) (11) Pad clip Tightening torque: N·m (kg-m, ft-lb)
(4) Pin boot (12) Outer shim T1: 8±1 (0.8±0.1, 5.8±0.7)
(5) Piston seal (13) Inner shim T2: 18±5 (1.8±0.5, 13.0±3.6)
(6) Piston (14) Pad (Outside) T3: 37±5 (3.8±0.5, 27.5±3.6)
(7) Piston boot (15) Pad (Inside) T4: 78±10 (8.0±1.0, 58±7)
(8) Boot ring (16) Disc rotor
19
4-4 [W1D0] SERVICE PROCEDURE
1. Front Disc Brake
B4M1175A
B4M0072A
B4M1172A
20
SERVICE PROCEDURE [W1E2] 4-4
1. Front Disc Brake
7) Apply a coat of specified grease to lock pin and 5) Apply a coat of specified grease to boot and fit
guide pin outer surface, cylinder inner surface, and in groove on ends of cylinder and piston.
boot grooves. Grease:
Grease: NIGLUBE RX-2 (Part No. 003606000)
NIGLUBE RX-2 (Part No. 003606000) To facilitate installation, fit boot starting with piston
end.
B4M1176A
G4M0373
8) Install lock and guide pin boot on support.
6) Position boot in grooves on cylinder and piston.
2. 2500 cc MODEL 7) Install boot ring. Be careful not scratch boot.
1) Clean caliper body interior using brake fluid. 8) Apply a coat of specified grease to lock pin and
2) Apply a coat of brake fluid to piston seal and fit guide pin, outer surface, cylinder inner surface,
piston seal in groove on caliper body. and boot grooves.
3) Apply a coat of brake fluid to the entire inner Grease:
surface of cylinder and outer surface of piston. NIGLUBE RX-2 (Part No. 003606000)
4) Insert piston into cylinder.
CAUTION:
Do not force piston into cylinder.
B4M1176A
21
4-4 [W1F0] SERVICE PROCEDURE
2. Rear Disc Brake
S4M0116
B4M1169A
22
SERVICE PROCEDURE [W2A2] 4-4
2. Rear Disc Brake
G4M0382
G4M0383
23
4-4 [W2B0] SERVICE PROCEDURE
2. Rear Disc Brake
B: REMOVAL
H4M1356A
1) Lift-up vehicle and remove wheels. 4) Raise caliper body and move it toward vehicle
2) Disconnect brake hose from caliper body center to separate it from support.
assembly. 5) Remove support from back plate.
CAUTION: NOTE:
Do not allow brake fluid to come in contact with Remove support only when replacing it or the rotor.
vehicle body; wipe off completely if spilled. It need not be removed when servicing caliper
body assembly.
6) Clean mud and foreign particles from caliper
body assembly and support.
CAUTION:
Be careful not to allow foreign particles to enter
inlet (at brake hose connector).
S4M0119
24
SERVICE PROCEDURE [W2E0] 4-4
2. Rear Disc Brake
S4M0122A
D: INSPECTION
1) Repair or replace faulty parts.
2) Check caliper body and piston for uneven wear,
damage or rust.
3) Check rubber parts for damage or deterioration.
E: ASSEMBLY
1) Clean caliper body interior using brake fluid.
S4M0121A 2) Apply a coat of brake fluid to piston seal and fit
piston seal in groove on caliper body.
3) Gradually supply compressed air via inlet of
3) Apply a coat of brake fluid to the entire inner
caliper body to force piston out.
surface of cylinder and outer surface of piston.
CAUTION: 4) Insert piston into cylinder.
I Place a wooden block as shown in Figure to
CAUTION:
prevent damage to piston.
Do not force piston into cylinder.
I Do not apply excessively high-pressure.
5) Apply a coat of specified grease to boot and fit
in groove on ends of cylinder and piston.
Grease
NIGLUBE RX-2 (Part No. 003606000)
6) Install the piston boot to the caliper body, and
attach boot ring.
B4M1174A
G4M0373
25
4-4 [W2F0] SERVICE PROCEDURE
2. Rear Disc Brake
26
SERVICE PROCEDURE [W3A1] 4-4
3. Rear Drum Brake
B4M0075B
(1) Air bleeder cap (11) Upper shoe return spring (21) Lower shoe return spring
(2) Air bleeder screw (12) Retainer (22) Adjusting spring
(3) Boot (13) Washer (23) Plug
(4) Piston (14) Parking brake lever
(5) Cup (15) Brake shoe (Trailing) Tightening torque: N·m (kg-m, ft-lb)
(6) Spring (16) Brake shoe (Leading) T1: 8±1 (0.8±0.1, 5.8±0.7)
(7) Wheel cylinder body (17) Shoe hold-down spring T2: 10±2 (1.0±0.2, 7.2±1.4)
(8) Pin (18) Cup T3: 52±6 (5.3±0.6, 38.3±4.3)
(9) Plug (19) Adjusting lever
(10) Back plate (20) Adjuster
1. BRAKE DRUM AND SHOE 3) Remove brake drum from brake assembly.
1) Loosen wheel nuts, jack-up vehicle, support it
with rigid racks, and remove wheel.
2) Release parking brake.
G4M0393
27
4-4 [W3A1] SERVICE PROCEDURE
3. Rear Drum Brake
G4M0242
G4M0397
4) Hold hold-down pin by securing rear of back 8) Disconnect parking brake cable from parking
plate with your hand. lever.
9) Remove the following.
G4M0395
G4M0396
28
SERVICE PROCEDURE [W3C0] 4-4
3. Rear Drum Brake
G4M0399
B4M1126A
5) Remove hub. <Ref. to 4-2 [W2B0].>
6) Remove the bolts installing back plate, and
then, remove brake assembly. C: INSPECTION
1) If the inside surface of brake drum is streaked,
correct the surface. And, if it is unevenly worn,
taperingly streaked, or the outside surface of brake
drum is damaged, correct or replace it.
2) Measure the drum inner diameter.
Drum inner diameter: “L”
Standard: 228.6 mm (9 in)
Service limit: 230.6 mm (9.08 in)
G4M0400
3. WHEEL CYLINDER
1) Remove brake drum and shoes.
2) Unscrew brake pipe flare nut; and disconnect
brake pipe.
3) Remove the bolts installing wheel cylinder on
back plate, and remove it.
G4M0403
29
4-4 [W3D1] SERVICE PROCEDURE
3. Rear Drum Brake
CAUTION:
While assembling, be careful to prevent any
metal chip, dust or dirt from entering the wheel
cylinder.
G4M0404
30
SERVICE PROCEDURE [W3E3] 4-4
3. Rear Drum Brake
G4M0409
G4M0400
G4M0408
31
4-4 [W4A0] SERVICE PROCEDURE
4. Parking Brake (Rear Disc Brake)
B4M1127A
(1) Back plate (8) Strut (15) Shoe hold down spring
(2) Retainer (9) Shoe guide plate (16) Shoe hold down pin
(3) Spring washer (10) Primary return spring (17) Adjusting hole cover
(4) Lever (11) Secondary return spring
(5) Parking brake shoe (Primary) (12) Adjusting spring Tightening torque: N·m(kg-m, ft-lb)
(6) Parking brake show (Secondary) (13) Adjuster T: 52±6 (5.3±0.6, 38.3±4.3)
(7) Strut spring (14) Shoe hold-down cup
1) Remove the two mounting bolts to the disc 4) Remove shoe return spring from parking brake
brake assembly and remove the disc brake assem- assembly.
bly. 5) Remove front shoe hold down spring and pin
with pliers.
6) Remove strut and strut spring.
7) Remove adjuster assembly from parking brake
assembly.
8) Remove brake shoe.
9) Remove rear shoe hold-down spring and pin
with pliers.
G4M0412
32
SERVICE PROCEDURE [W4C0] 4-4
4. Parking Brake (Rear Disc Brake)
B: INSPECTION
1) Measure brake disc inside diameter. If the disc
is scored or worn, replace the brake disc.
Disc inside diameter: G4M0414
Standard
170 mm (6.69 in) NOTE:
Service limit Ensure that shoe return spring is installed as
171 mm (6.73 in) shown in Figure.
2) Measure the lining thickness. If it exceeds the
limit, replace shoe assembly.
Lining thickness:
Standard
3.2 mm (0.126 in)
Service limit
1.5 mm (0.059 in)
CAUTION:
Replace the brake shoes on the right and left
brake assembly at the same time. G4M0415
33
4-4 [W4D1] SERVICE PROCEDURE
5. Master Cylinder
B4M1446A
B4M0050A
4) Tighten lock nut. 2) Remove cylinder pin with magnetic pick-up tool
5) Install console box lid. while pushing in primary piston.
Lever stroke:
7 to 8 notches when pulled with a force
of 196 N (20 kg, 44 lb)
Tightening torque (Lock nut):
5.9±1.5 N·m (0.60±0.15 kg-m, 4.3±1.1 ft-lb)
B4M1447A
34
SERVICE PROCEDURE [W5E0] 4-4
5. Master Cylinder
B4M1449
CAUTION:
I Do not disassemble the piston assembly;
otherwise, the spring set value may be
changed.
I Use brake fluid or methanol to wash inside
wall of cylinder, pistons and piston cups. Be
careful not to damage parts when washing. If B4M1450A
methanol is used for washing, do not dip rub-
ber parts, such as piston cups, in it for more 6) Install pin with drift pins which secures reservoir
than 30 seconds; otherwise, they may become tank to master cylinder.
swelled.
E: INSTALLATION
C: INSPECTION To install the master cylinder to the body, reverse
If any damage, deformation, wear, swelling, rust, the sequence of removal procedure.
and other faults are found on the primary piston Tightening torque:
assembly, secondary piston assembly, supply Master cylinder mounting nut
valve stopper, or gasket, replace the faulty part. 14±4 N·m (1.4±0.4 kg-m, 10.1±2.9 ft-lb)
CAUTION: Piping flare nut
I The primary and secondary pistons must be 15+3/−2 N·m (1.5+0.3/−0.2 kg-m, 10.8+2.2/−1.4
replaced as complete assemblies. ft-lb)
I The service limit of the clearance between CAUTION:
each piston and the master cylinder inner dia. Be sure to use recommended brake fluid.
is 0.11 mm (0.0043 in).
I When handling parts, be extremely careful
not to damage or scratch the parts, or let any
foreign matter get on them.
35
4-4 [W6A0] SERVICE PROCEDURE
6. Brake Booster
G4M0913
G4M0425
36
SERVICE PROCEDURE [W6D2] 4-4
6. Brake Booster
3) Connect vacuum hose to brake booster. 10) Bleed air from brake system.
Tightening torque (Air bleeder screw):
8±1 N·m (0.8±0.1 kg-m, 5.8±0.7 ft-lb)
11) Conduct road tests to ensure brakes do not
drag.
G4M0744
B4M0617B
37
4-4 [W6D3] SERVICE PROCEDURE
6. Brake Booster
G4M0746
G4M0747
38
SERVICE PROCEDURE [W7B1] 4-4
7. Brake Hose
B4M1170
39
4-4 [W7B2] SERVICE PROCEDURE
8. Parking Brake Lever
7) While holding hexagonal part of brake hose fit- 8. Parking Brake Lever
ting with a wrench, tighten flare nut to the specified
torque. A: REPLACEMENT
Torque (Brake pipe flare nut): 1) Remove console box from front floor.
14.7+3/−2 N·m (1.5+0.3/−0.2 kg-m, 10.8+2.2/ 2) Disconnect electric connector for parking brake
−1.4 ft-lb) switch.
8) Bleed air from the brake system. 3) Loosen parking brake adjuster, and remove
inner cable end from equalizer.
2. REAR BRAKE HOSE 4) Remove parking brake lever.
5) Install parking brake lever in the reverse order
1) Pass brake hose through the hole of bracket,
of removal.
and lightly tighten flare nut to connect brake pipe.
2) Insert clamp upward to fix brake hose. Tightening torque (Lever installing bolt and
3) Perform the same procedures as before men- nut):
tioned in steps 7) and 8). 18±5 N·m (1.8±0.5 kg-m, 13.0±3.6 ft-lb)
6) Adjust parking brake lever by turning adjusting
nut until parking brake lever stroke is set at 7 to 8
notches with operating force of 196 N (20 kg, 44
lb).
7) Tighten lock nut.
Tightening torque (Lock nut):
5.9±1.5 N·m (0.60±0.15 kg-m, 4.3±1.1 ft-lb)
B4M0050A
40
SERVICE PROCEDURE [W9A0] 4-4
9. Parking Brake Cable
B4M0070B
(1) Parking brake lever (7) Clamp Tightening torque: N·m (kg-m, ft-lb)
(2) Parking brake switch (8) Parking brake cable RH
T1: 5.9±1.5 (0.60±0.15, 4.3±1.1)
(3) Lock nut (9) Cable guide
T2: 18±5 (1.8±0.5, 13.0±3.6)
(4) Adjusting nut (10) Clamp (Rear disc brake model
T3: 32±10 (3.3±1.0, 24±7)
(5) Equalizer only)
(6) Bracket (11) Parking brake cable LH
B4M0078A
41
4-4 [W10A0] SERVICE PROCEDURE
10. Air Bleeding
11) Remove bolt and clamp from rear floor. 10. Air Bleeding
A: GENERAL RULES FOR
EFFECTIVE BLEEDING
1) Start with the brakes (wheels) connecting to the
secondary chamber of the master cylinder.
2) The time interval between two brake pedal
operations (from the time when the pedal is
released to the time when it is depressed another
time) shall be approximately 3 seconds.
G4M0433
3) The air bleeder on each brake shall be released
for 1 to 2 seconds.
12) Detach grommet from rear floor.
13) Remove cable assembly from cabin by forc- B: BLEEDING PROCEDURE
ibly pulling it backward.
14) Detach parking brake cable from cable guide CAUTION:
at rear trailing link. I The FMVSS No. 116, fresh DOT3 or 4 brake
15) Install parking brake assembly in the reverse fluid must be used.
order of removal. I Cover bleeder with waste cloth, when loos-
ening it, to prevent brake fluid from being
NOTE:
splashed over surrounding parts.
I Be sure to pass cable through cable guide inside
the tunnel. I Avoid mixing different brands of brake fluid
I Be sure to adjust the shoe clearance. (Rear disc to prevent degrading the quality of the fluid.
brake only) <Ref. to 4-4 [W4D1].> I Be careful not to allow dirt or dust to get into
the reservoir tank.
16) Adjust parking brake lever by turning adjusting
nut until parking brake lever stroke is set at 7 to 8 NOTE:
notches with operating force of 196 N (20 kg, 44 I During bleeding operation, keep the brake
lb). reserve tank filled with brake fluid to eliminate entry
17) Tighten lock nut. of air.
I Brake pedal operating must be very slow.
Tightening torque (Lock nut):
I For convenience and safety, it is advisable to
5.9±1.5 N·m (0.60±0.15 kg-m, 4.3±1.1 ft-lb)
have two men working.
1) Make sure that there is no leak from joints and
connections of the brake system.
B4M0050A
42
SERVICE PROCEDURE [W10B0] 4-4
10. Air Bleeding
2) Fit one end of vinyl tube into the air bleeder and 7) Check the pedal stroke.
put the other end into a brake fluid container. While the engine is idling, depress the brake pedal
with a 490 N (50 kg, 110 lb) load and measure the
distance between the brake pedal and steering
wheel. With the brake pedal released, measure the
distance between the pedal and steering wheel
again. The difference between the two measure-
ments must be more than specified.
H4M1084
G4M0436
43
4-4 [W11A0] SERVICE PROCEDURE
11. Brake Fluid
11. Brake Fluid 5) Install one end of a vinyl tube onto the air
bleeder and insert the other end of the tube into a
A: REPLACEMENT container to collect the brake fluid.
CAUTION:
I To always maintain the brake fluid
characteristics, replace the brake fluid accord-
ing to maintenance schedule or earlier than
that when used in severe condition.
I The FMVSS No. 116, fresh DOT3 or 4 brake
fluid must be used.
I Cover bleeder with waste cloth, when loos-
ening it, to prevent brake fluid from being
splashed over surrounding parts.
I Avoid mixing different brands of brake fluid H4M1084
fluid
6) Instruct your co-worker to depress the brake
pedal slowly two or three times and then hold it
depressed.
7) Loosen bleeder screw approximately 1/4 turn
until a small amount of brake fluid drains into
container, and then quickly tighten screw.
8) Repeat again from the two former procedures
above until there are no air bubbles in drained
brake fluid and new fluid flows through vinyl tube.
NOTE:
Add brake fluid as necessary while performing the
air bleed operation, in order to prevent the tank
from running short of brake fluid.
9) After completing the bleeding operation, hold
brake pedal depressed and tighten screw and
install bleeder cap.
44
SERVICE PROCEDURE [W12B0] 4-4
12. Proportioning Valve
B4M1198A
B: REMOVAL
B4M1177A
B4M1197A
45
4-4 [W12C0] SERVICE PROCEDURE
13. ABS Sensor
B4M1181A
B4M1183A
46
SERVICE PROCEDURE [W13B2] 4-4
13. ABS Sensor
6) Remove front drive shaft and housing and hub 2) Measure ABS sensor resistance.
assembly. <Ref. to 4-2 [W1A0].> CAUTION:
7) Remove tone wheel while removing hub from If resistance is outside the standard value,
housing and hub assembly. <Ref. to 4-2 [W1B0].> replace ABS sensor with new one.
CAUTION: NOTE:
Be careful not to damage teeth faces of tone Check ABS sensor cable for discontinuity. If
wheel during removal. necessary, replace with a new one.
ABS sensor Terminal No. Standard
Front - LH 1 and 2
Front - RH 1 and 2
1.0±0.2 kΩ
Rear - LH 1 and 2
Rear - RH 1 and 2
G4M0444
B4M1184A
47
4-4 [W13B3] SERVICE PROCEDURE
13. ABS Sensor
B4M1442A
B4M1183A B4M1182A
3) Install front drive shaft to hub spline. <Ref. to 3) Install rear drive shaft to rear housing and rear
4-2 [W1E0].> differential spindle. <Ref. to 4-2 [W2E0].>
48
SERVICE PROCEDURE [W13C2] 4-4
13. ABS Sensor
G4M0453
49
4-4 [W14A0] SERVICE PROCEDURE
14. ABS Control Module and Hydraulic Control Unit (ABSCM&H/U)
B4M1220B
(1) Stud bolt (6) Front-RH outlet Tightening torque: N·m (kg-m, ft-lb)
(2) Damper (7) Primary inlet
T1: 18±5 (1.8±0.5, 13.0±3.6)
(3) ABS control module and hydrau- (8) Rear-LH outlet
T2: 29±7 (3.0±0.7, 21.7±5.1)
lic control unit (9) Rear-RH outlet
T3: 32±10 (3.3±1.0, 24±7)
(4) Front-LH outlet (10) Bracket
(5) Secondary inlet
1) Disconnect ground cable from battery. 4) Pull on the lock of the ABSCM&H/U connector
2) Remove air intake duct from engine compart- to remove it.
ment to facilitate removal of ABSCM&H/U.
3) Use an air-gun to get rid of water around the
ABSCM&H/U.
CAUTION:
The contact will be insufficient if the terminal
gets wet.
B4M1224A
50
SERVICE PROCEDURE [W14C1] 4-4
14. ABS Control Module and Hydraulic Control Unit (ABSCM&H/U)
B4M1222 B4M0633A
51
4-4 [W14C2] SERVICE PROCEDURE
14. ABS Control Module and Hydraulic Control Unit (ABSCM&H/U)
9) Remove air bleeder screws from the RL and RR 5) Perform ABS sequence control. <Ref. to 4-4
caliper bodies. [W14D1].> or <Ref. to 4-4 [W14D2].>
10) Connect the air bleeder screws to the FL and 6) Hydraulic unit begins to work; and check the
FR caliper bodies. following working sequence.
11) Connect two pressure gauges to the RL and (1) The FL wheel performs decompression,
RR caliper bodies. holding, and compression in sequence, and
12) Bleed air from the pressure gauges and the FL subsequently the FR wheel repeats the cycle.
and FR caliper bodies. (2) The RR wheel performs decompression,
13) Perform ABS sequence control. holding, and compression in sequence, and
<Ref. to 4-4 [W14D0].> subsequently the RL wheel repeats the cycle.
14) When the hydraulic unit begins to work, at first 7) Read values indicated on the brake tester and
the RR side performs decompression, holding, and check if the fluctuation of values, when decom-
pressed and compressed, meet the standard val-
compression, and then the RL side performs
ues.
decompression, holding, and compression.
15) Read values indicated on the pressure Front wheel Rear wheel
gauges and check if they meet the standard value. 981 N 981 N
16) After checking, remove the pressure gauges Initial value
(100 kg, 221 lb) (100 kg, 221 lb)
from caliper bodies. When 490 N 490 N
17) Connect the air bleeder screws to RL and RR decom- (50 kg, 110 lb) (50 kg, 110 lb)
caliper bodies. pressed or less or less
18) Bleed air from brake line. When
981 N 981 N
(100 kg, 221 lb) (100 kg, 221 lb)
compressed
2. CHECKING THE HYDRAULIC UNIT ABS or more or more
OPERATION WITH BRAKE TESTER
8) After checking, also check if any irregular brake
1) In the case of AWD AT vehicles, install a spare pedal tightness is felt.
fuse with the FWD connector in the main fuse box
to simulate FWD vehicles.
S4M0127A
G4M0464
52
SERVICE PROCEDURE [W14D3] 4-4
14. ABS Control Module and Hydraulic Control Unit (ABSCM&H/U)
53
4-4 [W14D4] SERVICE PROCEDURE
14. ABS Control Module and Hydraulic Control Unit (ABSCM&H/U)
B4M1001A
54
SERVICE PROCEDURE [W15B1] 4-4
15. G Sensor
S4M0128
H4M1146
55
4-4 [W15B2] SERVICE PROCEDURE
15. G Sensor
H4M1147A
56
SERVICE PROCEDURE [W16B0] 4-4
16. Brake Pipe
57
BRAKES 4-4
Page
T DIAGNOSTICS ...............................................................................2
1. Supplemental Restraint System “Airbag”....................................................2
2. Pre-inspection..............................................................................................2
3. Electrical Components Location..................................................................4
4. Schematic....................................................................................................6
5. Control Module I/O Signal...........................................................................8
6. Diagnostics Chart for On-board Diagnosis System ..................................11
7. Diagnostics Chart for ABS Warning Light Circuit and Diagnosis Circuit
Failure........................................................................................................18
8. Diagnostics Chart with Trouble Code by ABS Warning Light...................29
9. Select Monitor Function Mode ..................................................................76
10. Diagnostics Chart with Select Monitor ......................................................78
11. General Diagnostic Table ........................................................................162
4-4 [T100] BRAKES
1. Supplemental Restraint System “Airbag”
2
BRAKES [T2B1] 4-4
2. Pre-inspection
B: ELECTRICAL INSPECTION
1. WARNING LIGHT ILLUMINATION PATTERN
B4M0781A
3
4-4 [T300] BRAKES
3. Electrical Components Location
H4M1303A
(1) ABS control module and hydrau- (5) Data link connector (for Subaru (8) ABS sensor
lic control unit (ABSCM&H/U) select monitor) (9) Wheel cylinder
(2) Proportioning valve (6) Transmission control module (10) G sensor
(3) Diagnosis connector (only AT vehicle) (11) Brake switch
(4) ABS warning light (7) Tone wheel (12) Master cylinder
4
BRAKES [T300] 4-4
3. Electrical Components Location
B4M1226B H4M1304A
S4M0055A
B4M0231E S4M0056A
B4M0646E
5
4-4 [T400] BRAKES
4. Schematic
4. Schematic
S4M0057A
(1) ABS control module and hydrau- (9) Front right outlet solenoid valve (17) ABS warning light
lic control unit (ABSCM&H/U) (10) Rear left inlet solenoid valve (18) Stop light switch
(2) ABS control module area (11) Rear left outlet solenoid valve (19) Stop light
(3) Valve relay (12) Rear right inlet solenoid valve (20) G sensor
(4) Motor relay (13) Rear right outlet solenoid valve (21) Front left ABS sensor
(5) Motor (14) Transmission control module (22) Front right ABS sensor
(6) Front left inlet solenoid valve (only AT model) (23) Rear left ABS sensor
(7) Front left outlet solenoid valve (15) Diagnosis connector (24) Rear right ABS sensor
(8) Front right inlet solenoid valve (16) Data link connector
6
BRAKES [T400] 4-4
4. Schematic
MEMO:
7
4-4 [T5A0] BRAKES
5. Control Module I/O Signal
B4M1228A
NOTE:
I The terminal numbers in the ABS control mod-
ule and hydraulic control unit connector are as
shown in the figure.
I When the connector is removed from the
ABSCM&H/U, the connector switch closes the cir-
cuit between terminal No. 21 and No. 23. The ABS
warning light illuminates.
8
BRAKES [T5A0] 4-4
5. Control Module I/O Signal
9
4-4 [T5B0] BRAKES
5. Control Module I/O Signal
B4M1229B
10
BRAKES [T6A0] 4-4
6. Diagnostics Chart for On-board Diagnosis System
S4M0179A
CAUTION:
Remove foreign matter (dust, water, etc.) from the ABSCM&H/U connector during removal and
installation.
NOTE:
I To check harness for broken wires or short circuits, shake it while holding it or the connector.
I When ABS warning light illuminates, read and record trouble code indicated by ABS warning light.
11
4-4 [T6B0] BRAKES
6. Diagnostics Chart for On-board Diagnosis System
12
BRAKES [T6B0] 4-4
6. Diagnostics Chart for On-board Diagnosis System
Behavior of vehicle a) Directional stability cannot be obtained or steering arm refuses to work when applying brakes :
l Yes / l No
I When : l Vehicle turns to right
l Vehicle turns to left
l Spins
l Others :
b) Directional stability cannot be obtained or steering arm refuses to work when accelerating :
l Yes / l No
I When : l Vehicle turns to right
l Vehicle turns to left
l Spins
l Others :
c) Brakes are out of order : l Yes / l No
I What : l Braking distance is long
l Brakes lock or drag
l Pedal stroke is long
l Pedal sticks
l Others :
d) Poor acceleration : l Yes / l No
I What : l Fails to accelerate
l Engine stalls
l Others :
e) Occurrence of vibration : l Yes / l No
I Where
I What kind :
f) Occurrence of abnormal noise : l Yes / l No
I Where
I What kind :
g) Occurrence of other phenomena : l Yes / l No
I What kind :
3. CONDITIONS UNDER WHICH TROUBLE OCCURS
13
4-4 [T6C0] BRAKES
6. Diagnostics Chart for On-board Diagnosis System
C: INSPECTION MODE
Reproduce the condition under which the problem
has occurred as much as possible.
Drive the vehicle at a speed more than 40 km/h (25
MPH) for at least one minute.
D: TROUBLE CODES
When on-board diagnosis of the ABS control mod-
ule detects a problem, the information (up to a
maximum of three) will be stored in the EEP ROM
as a trouble code. When there are more than three,
the most recent three will be stored. (Stored codes
will stay in memory until they are cleared.)
14
BRAKES [T6D1] 4-4
6. Diagnostics Chart for On-board Diagnosis System
B4M0082D
6) After the start code (11) is shown, the trouble codes will be shown in order of the last information first.
These repeat for a maximum of 5 minutes.
NOTE:
When there are no trouble codes in memory, only the start code (11) is shown.
B4M0232A
15
4-4 [T6D2] BRAKES
6. Diagnostics Chart for On-board Diagnosis System
2. CLEARING MEMORY
1) After calling up a trouble code, disconnect diag-
nosis connector terminal 6 from diagnosis terminal.
B4M0082D
2) Repeat 3 times within approx. 12 seconds; connecting and disconnecting terminal 6 and diagnosis ter-
minal for at least 0.2 seconds each time.
B4M0233E
NOTE:
After diagnostics is completed, make sure to clear
memory. Make sure only start code (11) is shown
after memory is cleared.
16
BRAKES [T6D2] 4-4
6. Diagnostics Chart for On-board Diagnosis System
MEMO:
17
4-4 [T7A0] BRAKES
7. Diagnostics Chart for ABS Warning Light Circuit and Diagnosis Circuit Failure
H4M1351
18
BRAKES [T7A5] 4-4
7. Diagnostics Chart for ABS Warning Light Circuit and Diagnosis Circuit Failure
7A1 : CHECK IF OTHER WARNING LIGHTS 7A4 : CHECK BATTERY SHORT OF ABS
TURN ON. WARNING LIGHT HARNESS.
H4M1292A
H4M1292A
19
4-4 [T7A6] BRAKES
7. Diagnostics Chart for ABS Warning Light Circuit and Diagnosis Circuit Failure
B4M1243A
H4M1293A
: Is the resistance less than 0.5 Ω?
: Is the voltage less than 3 V? : Go to step 7A9.
: Go to step 7A7. : Repair ABSCM&H/U ground harness.
: Repair wiring harness.
7A9 : CHECK WIRING HARNESS.
7A7 : CHECK BATTERY SHORT OF ABS
WARNING LIGHT HARNESS. Measure resistance between connector (F2) and
chassis ground.
1) Turn ignition switch to ON. Connector & terminal
2) Measure voltage between connector (F2) and (F2) No. 8 — Chassis ground:
chassis ground.
Connector & terminal
(F2) No. 8 (+) — Chassis ground (−):
H4M1294A
20
BRAKES [T7A10] 4-4
7. Diagnostics Chart for ABS Warning Light Circuit and Diagnosis Circuit Failure
21
4-4 [T7B0] BRAKES
7. Diagnostics Chart for ABS Warning Light Circuit and Diagnosis Circuit Failure
H4M1351
22
BRAKES [T7B4] 4-4
7. Diagnostics Chart for ABS Warning Light Circuit and Diagnosis Circuit Failure
B4M0430
23
4-4 [T7B5] BRAKES
7. Diagnostics Chart for ABS Warning Light Circuit and Diagnosis Circuit Failure
24
BRAKES [T7B12] 4-4
7. Diagnostics Chart for ABS Warning Light Circuit and Diagnosis Circuit Failure
H4M1294A
H4M1294A
25
4-4 [T7C0] BRAKES
7. Diagnostics Chart for ABS Warning Light Circuit and Diagnosis Circuit Failure
H4M1351
26
BRAKES [T7C3] 4-4
7. Diagnostics Chart for ABS Warning Light Circuit and Diagnosis Circuit Failure
B4M0800A
B4M1233A
27
4-4 [T7C3] BRAKES
7. Diagnostics Chart for ABS Warning Light Circuit and Diagnosis Circuit Failure
MEMO:
28
BRAKES [T8A0] 4-4
8. Diagnostics Chart with Trouble Code by ABS Warning Light
29
4-4 [T8B0] BRAKES
8. Diagnostics Chart with Trouble Code by ABS Warning Light
H4M1295
30
BRAKES [T8E3] 4-4
8. Diagnostics Chart with Trouble Code by ABS Warning Light
B4M0806 B4M0807
: Is the resistance between 0.8 and 1.2 : Is the voltage less than 1 V?
kΩ? : Go to step 8E3.
: Go to step 8E2. : Replace ABS sensor.
: Replace ABS sensor.
8E3 : CHECK BATTERY SHORT OF ABS
SENSOR.
B4M0807
31
4-4 [T8E4] BRAKES
8. Diagnostics Chart with Trouble Code by ABS Warning Light
B4M1239A
B4M1240A
: Is the resistance between 0.8 and 1.2
kΩ? : Is the voltage less than 1 V?
: Go to step 8E5. : Go to step 8E6.
: Repair harness/connector between : Repair harness between ABSCM&H/U
ABSCM&H/U and ABS sensor. and ABS sensor.
32
BRAKES [T8E9] 4-4
8. Diagnostics Chart with Trouble Code by ABS Warning Light
B4M1240A
G4M0700
: Is the voltage less than 1 V?
: Go to step 8E7.
: Repair harness between ABSCM&H/U
and ABS sensor.
Tightening torque:
32±10 N·m (3.3±1.0 kg-m, 24±7 ft-lb)
G4M0701
: Are the ABS sensor installation bolts
tightened securely?
Front wheel Rear wheel
: Go to step 8E8. Specifications 0.9 — 1.4 mm 0.7 — 1.2 mm
: Tighten ABS sensor installation bolts (0.035 — 0.055 in) (0.028 — 0.047 in)
securely.
: Is the gap within the specifications?
: Go to step 8E10.
: Adjust the gap.
NOTE:
Adjust the gap using spacers (Part No.
26755AA000). If spacers cannot correct the gap,
replace worn sensor or worn tone wheel.
33
4-4 [T8E10] BRAKES
8. Diagnostics Chart with Trouble Code by ABS Warning Light
B4M1241A
34
BRAKES [T8E15] 4-4
8. Diagnostics Chart with Trouble Code by ABS Warning Light
35
4-4 [T8F0] BRAKES
8. Diagnostics Chart with Trouble Code by ABS Warning Light
H4M1295
36
BRAKES [T8I4] 4-4
8. Diagnostics Chart with Trouble Code by ABS Warning Light
8I1 : CHECK INSTALLATION OF ABS SEN- 8I3 : CHECK ABS SENSOR GAP.
SOR.
Measure tone wheel to pole piece gap over entire
Tightening torque: perimeter of the wheel.
32±10 N·m (3.3±1.0 kg-m, 24±7 ft-lb)
: Are the ABS sensor installation bolts
tightened securely?
: Go to step 8I2.
: Tighten ABS sensor installation bolts
securely.
Tightening torque:
13±3 N·m (1.3±0.3 kg-m, 9±2.2 ft-lb)
: Are the tone wheel installation bolts
tightened securely?
: Go to step 8I3.
: Tighten tone wheel installation bolts
securely.
G4M0701
: Is an oscilloscope available?
: Go to step 8I5.
: Go to step 8I6.
37
4-4 [T8I5] BRAKES
8. Diagnostics Chart with Trouble Code by ABS Warning Light
H4M1296A
38
BRAKES [T8I10] 4-4
8. Diagnostics Chart with Trouble Code by ABS Warning Light
8I9 : CHECK RESISTANCE OF ABS SEN- 8I10 : CHECK GROUND SHORT OF ABS
SOR. SENSOR.
1) Turn ignition switch OFF. Measure resistance between ABS sensor and
2) Disconnect connector from ABS sensor. chassis ground.
3) Measure resistance between ABS sensor con- Terminal
nector terminals. Front RH No. 1 — Chassis ground:
Terminal Front LH No. 1 — Chassis ground:
Front RH No. 1 — No. 2: Rear RH No. 1 — Chassis ground:
Front LH No. 1 — No. 2: Rear LH No. 1 — Chassis ground:
Rear RH No. 1 — No. 2:
Rear LH No. 1 — No. 2:
B4M0818
39
4-4 [T8I11] BRAKES
8. Diagnostics Chart with Trouble Code by ABS Warning Light
B4M1239A
B4M1241A
: Is the resistance between 0.8 and 1.2
kΩ? : Is the resistance more than 1 MΩ?
: Go to step 8I12. : Go to step 8I13.
: Repair harness/connector between : Repair harness/connector between
ABSCM&H/U and ABS sensor. ABSCM&H/U and ABS sensor.
B4M1243A
40
BRAKES [T8I19] 4-4
8. Diagnostics Chart with Trouble Code by ABS Warning Light
41
4-4 [T8J0] BRAKES
8. Diagnostics Chart with Trouble Code by ABS Warning Light
J: TROUBLE CODE 29
— ABNORMAL ABS SENSOR SIGNAL (ANY ONE OF FOUR) —
DIAGNOSIS:
I Faulty ABS sensor signal (noise, irregular signal, etc.)
I Faulty tone wheel
I Wheels turning freely for a long time
TROUBLE SYMPTOM:
I ABS does not operate.
WIRING DIAGRAM:
H4M1295
42
BRAKES [T8J7] 4-4
8. Diagnostics Chart with Trouble Code by ABS Warning Light
43
4-4 [T8J8] BRAKES
8. Diagnostics Chart with Trouble Code by ABS Warning Light
44
BRAKES [T8J14] 4-4
8. Diagnostics Chart with Trouble Code by ABS Warning Light
MEMO:
45
4-4 [T8K0] BRAKES
8. Diagnostics Chart with Trouble Code by ABS Warning Light
H4M1305
46
BRAKES [T8N5] 4-4
8. Diagnostics Chart with Trouble Code by ABS Warning Light
B4M1243A
47
4-4 [T8O0] BRAKES
8. Diagnostics Chart with Trouble Code by ABS Warning Light
H4M1305
48
BRAKES [T8R5] 4-4
8. Diagnostics Chart with Trouble Code by ABS Warning Light
B4M1243A
49
4-4 [T8S0] BRAKES
8. Diagnostics Chart with Trouble Code by ABS Warning Light
S: TROUBLE CODE 41
— ABNORMAL ABS CONTROL MODULE —
DIAGNOSIS:
I Faulty ABSCM&H/U
TROUBLE SYMPTOM:
I ABS does not operate.
WIRING DIAGRAM:
B4M1246
50
BRAKES [T8S6] 4-4
8. Diagnostics Chart with Trouble Code by ABS Warning Light
8S2 : CHECK POOR CONTACT IN CON- : Are other trouble codes being out-
NECTORS. put?
: Proceed with the diagnosis correspond-
ing to the trouble code.
: Is there poor contact in connectors
between battery, ignition switch and : A temporary poor contact.
ABSCM&H/U? <Ref. to FOREWORD
[T3C1].>
: Repair connector.
: Go to step 8S3.
51
4-4 [T8T0] BRAKES
8. Diagnostics Chart with Trouble Code by ABS Warning Light
T: TROUBLE CODE 42
— SOURCE VOLTAGE IS ABNORMAL. —
DIAGNOSIS:
I Power source voltage of the ABSCM&H/U is low or high.
TROUBLE SYMPTOM:
I ABS does not operate.
WIRING DIAGRAM:
H4M1305
52
BRAKES [T8T4] 4-4
8. Diagnostics Chart with Trouble Code by ABS Warning Light
B4M0430
B4M1234A
: Is the voltage between 10 V and 17 V?
: Go to step 8T2. : Is the voltage between 10 V and 17 V?
: Repair generator. : Go to step 8T4.
: Repair harness connector between
8T2 : CHECK BATTERY TERMINAL. battery, ignition switch and
ABSCM&H/U.
B4M1243A
53
4-4 [T8T5] BRAKES
8. Diagnostics Chart with Trouble Code by ABS Warning Light
54
BRAKES [T8T7] 4-4
8. Diagnostics Chart with Trouble Code by ABS Warning Light
MEMO:
55
4-4 [T8U0] BRAKES
8. Diagnostics Chart with Trouble Code by ABS Warning Light
U: TROUBLE CODE 44
— A COMBINATION OF AT CONTROL ABNORMAL —
DIAGNOSIS:
I Combination of AT control faults
TROUBLE SYMPTOM:
I ABS does not operate.
WIRING DIAGRAM:
H4M1352
56
BRAKES [T8U4] 4-4
8. Diagnostics Chart with Trouble Code by ABS Warning Light
Check specifications of the mark to the Measure voltage between ABSCM&H/U connector
ABSCM&H/U. and chassis ground.
Connector & terminal
(F49) No. 3 (+) — Chassis ground (−):
B4M1248A
B4M1250A
57
4-4 [T8U5] BRAKES
8. Diagnostics Chart with Trouble Code by ABS Warning Light
B4M1252A
H4M1353A
: Is the voltage between 10 V and 15 V?
: Is the voltage between 10 V and 15 V? : Go to step 8U8.
: Go to step 8U7. : Repair harness/connector between
: Go to step 8U6. TCM and ABSCM&H/U.
58
BRAKES [T8U10] 4-4
8. Diagnostics Chart with Trouble Code by ABS Warning Light
59
4-4 [T8V0] BRAKES
8. Diagnostics Chart with Trouble Code by ABS Warning Light
V: TROUBLE CODE 51
— ABNORMAL VALVE RELAY —
DIAGNOSIS:
I Faulty valve relay
TROUBLE SYMPTOM:
I ABS does not operate.
WIRING DIAGRAM:
H4M1299
60
BRAKES [T8V5] 4-4
8. Diagnostics Chart with Trouble Code by ABS Warning Light
B4M1272A
B4M1243A
61
4-4 [T8V6] BRAKES
8. Diagnostics Chart with Trouble Code by ABS Warning Light
62
BRAKES [T8V6] 4-4
8. Diagnostics Chart with Trouble Code by ABS Warning Light
MEMO:
63
4-4 [T8W0] BRAKES
8. Diagnostics Chart with Trouble Code by ABS Warning Light
W: TROUBLE CODE 52
— ABNORMAL MOTOR AND/OR MOTOR RELAY —
DIAGNOSIS:
I Faulty motor
I Faulty motor relay
I Faulty harness connector
TROUBLE SYMPTOM:
I ABS does not operate.
WIRING DIAGRAM:
H4M1300
64
BRAKES [T8W4] 4-4
8. Diagnostics Chart with Trouble Code by ABS Warning Light
B4M1234A
B4M1243A
65
4-4 [T8W5] BRAKES
8. Diagnostics Chart with Trouble Code by ABS Warning Light
66
BRAKES [T8W8] 4-4
8. Diagnostics Chart with Trouble Code by ABS Warning Light
MEMO:
67
4-4 [T8X0] BRAKES
8. Diagnostics Chart with Trouble Code by ABS Warning Light
X: TROUBLE CODE 54
— ABNORMAL STOP LIGHT SWITCH —
DIAGNOSIS:
I Faulty stop light switch
TROUBLE SYMPTOM:
I ABS does not operate.
WIRING DIAGRAM:
S4M0071
68
BRAKES [T8X5] 4-4
8. Diagnostics Chart with Trouble Code by ABS Warning Light
B4M1259A
69
4-4 [T8Y0] BRAKES
8. Diagnostics Chart with Trouble Code by ABS Warning Light
Y: TROUBLE CODE 56
— ABNORMAL G SENSOR OUTPUT VOLTAGE —
DIAGNOSIS:
I Faulty G sensor output voltage
TROUBLE SYMPTOM:
I ABS does not operate.
WIRING DIAGRAM:
H4M1301
70
BRAKES [T8Y3] 4-4
8. Diagnostics Chart with Trouble Code by ABS Warning Light
8Y1 : CHECK ALL FOUR WHEELS FOR 8Y3 : CHECK INPUT VOLTAGE OF G SEN-
FREE TURNING. SOR.
: Have the wheels been turned freely 1) Turn ignition switch to OFF.
such as when the vehicle is lifted up, 2) Remove console box.
or operated on a rolling road? 3) Disconnect G sensor from body. (Do not dis-
: The ABS is normal. Erase the trouble connect connector.)
code. 4) Turn ignition switch to ON.
5) Measure voltage between G sensor connector
: Go to step 8Y2.
terminals.
B4M0911C
71
4-4 [T8Y4] BRAKES
8. Diagnostics Chart with Trouble Code by ABS Warning Light
8Y4 : CHECK OPEN CIRCUIT IN G SEN- 8Y6 : CHECK BATTERY SHORT OF HAR-
SOR OUTPUT HARNESS AND NESS.
GROUND HARNESS.
Measure voltage between ABSCM&H/U connector
1) Turn ignition switch to OFF. and chassis ground.
2) Disconnect connector from ABSCM&H/U.
Connector & terminal
3) Measure resistance between ABSCM&H/U
(F49) No. 6 (+) — Chassis ground (−):
connector terminals.
Connector & terminal
(F49) No. 30 — No. 28:
B4M1263A
B4M1263A
72
BRAKES [T8Y9] 4-4
8. Diagnostics Chart with Trouble Code by ABS Warning Light
B4M1264A
H4M1146
73
4-4 [T8Y10] BRAKES
8. Diagnostics Chart with Trouble Code by ABS Warning Light
H4M1148A
74
BRAKES [T8Y14] 4-4
8. Diagnostics Chart with Trouble Code by ABS Warning Light
MEMO:
75
4-4 [T900] BRAKES
9. Select Monitor Function Mode
76
BRAKES [T9A6] 4-4
9. Select Monitor Function Mode
77
4-4 [T10A0] BRAKES
10. Diagnostics Chart with Select Monitor
S4M0180B
CAUTION:
Remove foreign matter (dust, water, etc.) from the ABSCM&H/U connector during removal and
installation.
NOTE:
I To check harness for broken wires or short circuits, shake it while holding it or the connector.
I Check list for interview. <Ref. to 4-4 [T6B0].>
78
BRAKES [T10B0] 4-4
10. Diagnostics Chart with Select Monitor
NOTE:
High µ means high friction coefficient against road
surface.
79
4-4 [T10C0] BRAKES
10. Diagnostics Chart with Select Monitor
H4M1302
80
BRAKES [T10C6] 4-4
10. Diagnostics Chart with Select Monitor
B4M0430
81
4-4 [T10C7] BRAKES
10. Diagnostics Chart with Select Monitor
B4M1243A
S4M0075A
82
BRAKES [T10C9] 4-4
10. Diagnostics Chart with Select Monitor
MEMO:
83
4-4 [T10D0] BRAKES
10. Diagnostics Chart with Select Monitor
D: NO TROUBLE CODE
— ALTHOUGH NO TROUBLE CODE APPEARS ON THE SELECT MONITOR
DISPLAY, THE ABS WARNING LIGHT REMAINS ON. —
DIAGNOSIS:
I ABS warning light circuit is shorted.
TROUBLE SYMPTOM:
I ABS warning light remains on.
I NO TROUBLE CODE displayed on the select monitor.
NOTE:
When the ABS warning light is OFF and “NO TROUBLE CODE” is displayed on the select monitor, the
system is in normal condition.
WIRING DIAGRAM:
H4M1351
84
BRAKES [T10D4] 4-4
10. Diagnostics Chart with Select Monitor
H4M1294A
85
4-4 [T10D5] BRAKES
10. Diagnostics Chart with Select Monitor
H4M1294A
86
BRAKES [T10D6] 4-4
10. Diagnostics Chart with Select Monitor
MEMO:
87
4-4 [T10E0] BRAKES
10. Diagnostics Chart with Select Monitor
88
BRAKES [T10H0] 4-4
10. Diagnostics Chart with Select Monitor
WIRING DIAGRAM:
H4M1295
89
4-4 [T10H1] BRAKES
10. Diagnostics Chart with Select Monitor
10H1 : CHECK OUTPUT OF ABS SENSOR 10H4 : CHECK ABS SENSOR GAP.
USING SELECT MONITOR.
Measure tone wheel-to-pole piece gap over entire
1) Select “Current data display & Save” on the perimeter of the wheel.
select monitor.
2) Read the ABS sensor output corresponding to
the faulty system in the select monitor data display
mode.
: Does the speed indicated on the dis-
play change in response to the
speedometer reading during
acceleration/deceleration when the
steering wheel is in the straight-
ahead position?
G4M0700
: Go to step 10H2.
: Go to step 10H9.
Tightening torque:
32±10 N·m (3.3±1.0 kg-m, 24±7 ft-lb)
: Are the ABS sensor installation bolts
tightened securely?
G4M0701
: Go to step 10H3.
: Tighten ABS sensor installation bolts
securely. Front wheel Rear wheel
Specifications 0.9 — 1.4 mm 0.7 — 1.2 mm
(0.035 — 0.055 in) (0.028 — 0.047 in)
10H3 : CHECK INSTALLATION OF TONE
WHEEL. : Is the gap within the specifications?
: Go to step 10H5.
Tightening torque: : Adjust the gap.
13±3 N·m (1.3±0.3 kg-m, 9±2.2 ft-lb) NOTE:
: Are the tone wheel installation bolts Adjust the gap using spacers (Part No.
tightened securely? 26755AA000). If spacers cannot correct the gap,
: Go to step 10H4. replace worn sensor or worn tone wheel.
: Tighten tone wheel installation bolts
10H5 : CHECK HUB RUNOUT.
securely.
90
BRAKES [T10H9] 4-4
10. Diagnostics Chart with Select Monitor
10H8 : CHECK ANY OTHER TROUBLE : Is the resistance between 0.8 and 1.2
CODES APPEARANCE. kΩ?
: Go to step 10H10.
: Are other trouble codes being out- : Replace ABS sensor.
put?
: Proceed with the diagnosis correspond-
ing to the trouble code.
: A temporary poor contact.
NOTE:
Check harness and connectors between
ABSCM&H/U and ABS sensor.
91
4-4 [T10H10] BRAKES
10. Diagnostics Chart with Select Monitor
B4M0807
: Go to step 10H11.
: Is the resistance between 0.8 and 1.2
: Replace ABS sensor.
kΩ?
: Go to step 10H13.
10H11 : CHECK BATTERY SHORT OF ABS
SENSOR. : Repair harness/connector between
ABSCM&H/U and ABS sensor.
1) Turn ignition switch to ON.
2) Measure voltage between ABS sensor and
chassis ground.
Terminal
Front RH No. 1 (+) — Chassis ground (−):
Front LH No. 1 (+) — Chassis ground (−):
Rear RH No. 1 (+) — Chassis ground (−):
Rear LH No. 1 (+) — Chassis ground (−):
B4M0807
92
BRAKES [T10H15] 4-4
10. Diagnostics Chart with Select Monitor
10H13 : CHECK BATTERY SHORT OF HAR- 10H14 : CHECK BATTERY SHORT OF HAR-
NESS. NESS.
B4M1240A
B4M1240A
: Is the voltage less than 1 V?
: Go to step 10H14. : Is the voltage less than 1 V?
: Repair harness between ABSCM&H/U : Go to step 10H15.
and ABS sensor. : Repair harness between ABSCM&H/U
and ABS sensor.
Tightening torque:
32±10 N·m (3.3±1.0 kg-m, 24±7 ft-lb)
: Are the ABS sensor installation bolts
tightened securely?
: Go to step 10H16.
: Tighten ABS sensor installation bolts
securely.
93
4-4 [T10H16] BRAKES
10. Diagnostics Chart with Select Monitor
G4M0700
B4M0818
G4M0701
94
BRAKES [T10H23] 4-4
10. Diagnostics Chart with Select Monitor
B4M1241A
95
4-4 [T10I0] BRAKES
10. Diagnostics Chart with Select Monitor
H4M1295
96
BRAKES [T10L7] 4-4
10. Diagnostics Chart with Select Monitor
97
4-4 [T10L8] BRAKES
10. Diagnostics Chart with Select Monitor
Tightening torque:
13±3 N·m (1.3±0.3 kg-m, 9±2.2 ft-lb)
: Are the tone wheel installation bolts
tightened securely?
: Go to step 10L10.
: Tighten tone wheel installation bolts
securely.
G4M0701
: Is an oscilloscope available?
: Go to step 10L12.
: Go to step 10L13.
98
BRAKES [T10L15] 4-4
10. Diagnostics Chart with Select Monitor
H4M1296A
99
4-4 [T10L16] BRAKES
10. Diagnostics Chart with Select Monitor
1) Turn ignition switch OFF. Measure resistance between ABS sensor and
2) Disconnect connector from ABS sensor. chassis ground.
3) Measure resistance between ABS sensor con- Terminal
nector terminals. Front RH No. 1 — Chassis ground:
Terminal Front LH No. 1 — Chassis ground:
Front RH No. 1 — No. 2: Rear RH No. 1 — Chassis ground:
Front LH No. 1 — No. 2: Rear LH No. 1 — Chassis ground:
Rear RH No. 1 — No. 2:
Rear LH No. 1 — No. 2:
B4M0818
100
BRAKES [T10L20] 4-4
10. Diagnostics Chart with Select Monitor
B4M1239A
B4M1241A
: Is the resistance between 0.8 and 1.2
kΩ? : Is the resistance more than 1 MΩ?
: Go to step 10L19. : Go to step 10L20.
: Repair harness/connector between : Repair harness/connector between
ABSCM&H/U and ABS sensor. ABSCM&H/U and ABS sensor.
B4M1243A
101
4-4 [T10L21] BRAKES
10. Diagnostics Chart with Select Monitor
102
BRAKES [T10L26] 4-4
10. Diagnostics Chart with Select Monitor
MEMO:
103
4-4 [T10M0] BRAKES
10. Diagnostics Chart with Select Monitor
H4M1295
104
BRAKES [T10M7] 4-4
10. Diagnostics Chart with Select Monitor
105
4-4 [T10M8] BRAKES
10. Diagnostics Chart with Select Monitor
106
BRAKES [T10M14] 4-4
10. Diagnostics Chart with Select Monitor
MEMO:
107
4-4 [T10N0] BRAKES
10. Diagnostics Chart with Select Monitor
H4M1305
108
BRAKES [T10Q5] 4-4
10. Diagnostics Chart with Select Monitor
B4M1243A
109
4-4 [T10R0] BRAKES
10. Diagnostics Chart with Select Monitor
H4M1305
110
BRAKES [T10U5] 4-4
10. Diagnostics Chart with Select Monitor
B4M1243A
111
4-4 [T10V0] BRAKES
10. Diagnostics Chart with Select Monitor
B4M1246
112
BRAKES [T10V6] 4-4
10. Diagnostics Chart with Select Monitor
113
4-4 [T10W0] BRAKES
10. Diagnostics Chart with Select Monitor
H4M1305
114
BRAKES [T10W4] 4-4
10. Diagnostics Chart with Select Monitor
B4M0430
B4M1234A
: Is the voltage between 10 V and 15 V?
: Go to step 10W2. : Is the voltage between 10 V and 15 V?
: Repair generator. : Go to step 10W4.
: Repair harness connector between
10W2 : CHECK BATTERY TERMINAL. battery, ignition switch and
ABSCM&H/U.
B4M1243A
115
4-4 [T10W5] BRAKES
10. Diagnostics Chart with Select Monitor
116
BRAKES [T10W7] 4-4
10. Diagnostics Chart with Select Monitor
MEMO:
117
4-4 [T10X0] BRAKES
10. Diagnostics Chart with Select Monitor
H4M1305
118
BRAKES [T10X4] 4-4
10. Diagnostics Chart with Select Monitor
B4M0430
B4M1234A
: Is the voltage between 10 V and 17 V?
: Go to step 10X2. : Is the voltage between 10 V and 17 V?
: Repair generator. : Go to step 10X4.
: Repair harness connector between
10X2 : CHECK BATTERY TERMINAL. battery, ignition switch and
ABSCM&H/U.
B4M1243A
119
4-4 [T10X5] BRAKES
10. Diagnostics Chart with Select Monitor
120
BRAKES [T10X7] 4-4
10. Diagnostics Chart with Select Monitor
MEMO:
121
4-4 [T10Y0] BRAKES
10. Diagnostics Chart with Select Monitor
H4M1352
122
BRAKES [T10Y4] 4-4
10. Diagnostics Chart with Select Monitor
B4M1248A
Mark Model
C5 AWD AT H4M1353A
C6 AWD MT
: Is the voltage between 10 V and 15 V?
: Is an ABSCM&H/U for AT model
installed on a MT model? : Go to step 10Y5.
: Replace ABSCM&H/U. : Go to step 10Y4.
: Go to step 10Y2.
10Y4 : CHECK AT.
10Y2 : CHECK GROUND SHORT OF HAR-
NESS. : Is the AT functioning normally?
: Replace TCM.
1) Turn ignition switch to OFF. : Repair AT.
2) Disconnect two connectors from TCM.
3) Disconnect connector from ABSCM&H/U.
4) Measure resistance between ABSCM&H/U
connector and chassis ground.
Connector & terminal
(F49) No. 3 — Chassis ground:
B4M1249A
123
4-4 [T10Y5] BRAKES
10. Diagnostics Chart with Select Monitor
10Y5 : CHECK OPEN CIRCUIT OF HAR- 10Y8 : CHECK ANY OTHER TROUBLE
NESS. CODES APPEARANCE.
Measure voltage between ABSCM&H/U connector : Are other trouble codes being out-
and chassis ground. put?
Connector & terminal : Proceed with the diagnosis correspond-
(F49) No. 3 (+) — Chassis ground (−): ing to the trouble code.
(F49) No. 31 (+) — Chassis ground (−): : A temporary poor contact.
B4M1252A
124
BRAKES [T10Y8] 4-4
10. Diagnostics Chart with Select Monitor
MEMO:
125
4-4 [T10Z0] BRAKES
10. Diagnostics Chart with Select Monitor
H4M1298
126
BRAKES [T10Z5] 4-4
10. Diagnostics Chart with Select Monitor
10Z1 : CHECK BATTERY SHORT OF HAR- 10Z3 : CHECK OPEN CIRCUIT OF HAR-
NESS. NESS.
B4M1250A B4M1252A
10Z2 : CHECK BATTERY SHORT OF HAR- 10Z4 : CHECK POOR CONTACT IN CON-
NESS. NECTORS.
127
4-4 [T10Z6] BRAKES
10. Diagnostics Chart with Select Monitor
128
BRAKES [T10Z6] 4-4
10. Diagnostics Chart with Select Monitor
MEMO:
129
4-4 [T10AA0] BRAKES
10. Diagnostics Chart with Select Monitor
H4M1299
130
BRAKES [T10AA5] 4-4
10. Diagnostics Chart with Select Monitor
B4M1243A
131
4-4 [T10AB0] BRAKES
10. Diagnostics Chart with Select Monitor
H4M1299
132
BRAKES [T10AB4] 4-4
10. Diagnostics Chart with Select Monitor
Measure resistance between ABSCM&H/U termi- : Are other trouble codes being out-
nals. put?
Terminals : Proceed with the diagnosis correspond-
No. 23 (+) — No. 24 (−): ing to the trouble code.
: A temporary poor contact.
B4M1272A
133
4-4 [T10AC0] BRAKES
10. Diagnostics Chart with Select Monitor
H4M1300
134
BRAKES [T10AC6] 4-4
10. Diagnostics Chart with Select Monitor
135
4-4 [T10AD0] BRAKES
10. Diagnostics Chart with Select Monitor
H4M1300
136
BRAKES [T10AD5] 4-4
10. Diagnostics Chart with Select Monitor
137
4-4 [T10AE0] BRAKES
10. Diagnostics Chart with Select Monitor
H4M1300
138
BRAKES [T10AE4] 4-4
10. Diagnostics Chart with Select Monitor
B4M1234A
B4M1243A
139
4-4 [T10AE5] BRAKES
10. Diagnostics Chart with Select Monitor
140
BRAKES [T10AE8] 4-4
10. Diagnostics Chart with Select Monitor
MEMO:
141
4-4 [T10AF0] BRAKES
10. Diagnostics Chart with Select Monitor
S4M0071
142
BRAKES [T10AF6] 4-4
10. Diagnostics Chart with Select Monitor
10AF1 : CHECK OUTPUT OF STOP LIGHT 10AF4 : CHECK OPEN CIRCUIT IN HAR-
SWITCH USING SELECT MONI- NESS.
TOR.
1) Turn ignition switch to OFF.
1) Select “Current data display & Save” on the 2) Disconnect connector from ABSCM&H/U.
select monitor. 3) Depress brake pedal.
2) Release the brake pedal. 4) Measure voltage between ABSCM&H/U con-
3) Read the stop light switch output in the select nector and chassis ground.
monitor data display.
Connector & terminal
: Is the reading indicated on monitor (F49) No. 2 — Chassis ground:
display less than 1.5 V?
: Go to step 10AF2.
: Go to step 10AF3.
10AF3 : CHECK IF STOP LIGHTS COME 10AF5 : CHECK POOR CONTACT IN CON-
ON. NECTORS.
143
4-4 [T10AF7] BRAKES
10. Diagnostics Chart with Select Monitor
144
BRAKES [T10AF7] 4-4
10. Diagnostics Chart with Select Monitor
MEMO:
145
4-4 [T10AG0] BRAKES
10. Diagnostics Chart with Select Monitor
H4M1301
146
BRAKES [T10AG8] 4-4
10. Diagnostics Chart with Select Monitor
B4M1248A
: Are other trouble codes being out-
put?
Mark Model
: Proceed with the diagnosis correspond-
C5 AWD AT
ing to the trouble code.
C6 AWD MT
: A temporary poor contact.
: Is an ABSCM for AWD model installed
on a FWD model? 10AG6 : CHECK FREEZE FRAME DATA.
: Replace ABSCM&H/U.
CAUTION: 1) Select “Freeze frame data” on the select moni-
Be sure to turn ignition switch to OFF when tor.
removing ABSCM&H/U. 2) Read front right wheel speed on the select
: Go to step 10AG2. monitor display.
: Is the front right wheel speed on
10AG2 : CHECK OUTPUT OF G SENSOR monitor display 0 km?
USING SELECT MONITOR.
: Go to step 10AG7.
: Go to step 10AG15.
1) Select “Current data display & Save” on the
select monitor.
2) Read the G sensor output in select monitor data 10AG7 : CHECK FREEZE FRAME DATA.
display.
: Is the G sensor output on the monitor Read front left wheel speed on the select monitor
display between 2.1 and 2.5 V when display.
the G sensor is in horizontal posi- : Is the front left wheel speed on moni-
tion? tor display 0 km?
: Go to step 10AG3. : Go to step 10AG8.
: Go to step 10AG6. : Go to step 10AG15.
10AG3 : CHECK POOR CONTACT IN CON- 10AG8 : CHECK FREEZE FRAME DATA.
NECTORS.
Read rear right wheel speed on the select monitor
: Is there poor contact in connector display.
between ABSCM&H/U and G sensor?
<Ref. to FOREWORD [T3C1].> : Is the rear right wheel speed on moni-
tor display 0 km?
: Repair connector.
: Go to step 10AG9.
: Go to step 10AG4.
: Go to step 10AG15.
147
4-4 [T10AG9] BRAKES
10. Diagnostics Chart with Select Monitor
Read G sensor output on the select monitor dis- 1) Connect all connectors.
play. 2) Erase the memory.
3) Perform inspection mode.
: Is the G sensor output on monitor 4) Read out the trouble code.
display more than 3.65 V?
: Is the same trouble code as in the
: Go to step 10AG11. current diagnosis still being output?
: Go to step 10AG15. : Replace ABSCM&H/U.
: Go to step 10AG14.
10AG11 : CHECK OPEN CIRCUIT IN G
SENSOR OUTPUT HARNESS
AND GROUND HARNESS. 10AG14 : CHECK ANY OTHER TROUBLE
CODES APPEARANCE.
1) Turn ignition switch to OFF.
2) Disconnect connector from ABSCM&H/U. : Are other trouble codes being out-
3) Measure resistance between ABSCM&H/U put?
connector terminals. : Proceed with the diagnosis correspond-
ing to the trouble code.
Connector & terminal
(F49) No. 30 — No. 28: : A temporary poor contact.
B4M1261A
148
BRAKES [T10AG17] 4-4
10. Diagnostics Chart with Select Monitor
B4M1261A
B4M1262A
149
4-4 [T10AG18] BRAKES
10. Diagnostics Chart with Select Monitor
H4M1147A
H4M1148A
150
BRAKES [T10AG23] 4-4
10. Diagnostics Chart with Select Monitor
Turn ignition switch to OFF. : Are other trouble codes being out-
: Is there poor contact in connector put?
between ABSCM&H/U and G sensor? : Proceed with the diagnosis correspond-
<Ref. to FOREWORD [T3C1].> ing to the trouble code.
: Repair connector. : A temporary poor contact.
: Go to step 10AG22.
151
4-4 [T10AH0] BRAKES
10. Diagnostics Chart with Select Monitor
H4M1301
152
BRAKES [T10AH5] 4-4
10. Diagnostics Chart with Select Monitor
1) Select “Current data display & Save” on the 1) Turn ignition switch to ON.
select monitor. 2) Measure voltage between ABSCM&H/U con-
2) Read G sensor output on the select monitor nector and chassis ground.
display. Connector & terminal
: Is the G sensor output on monitor (F49) No. 6 (+) — Chassis ground (−):
display between 2.1 and 2.5 V when
the G sensor is in horizontal posi-
tion?
: Replace ABSCM&H/U.
: Go to step 10AH2.
B4M1263A
1) Turn ignition switch to OFF.
2) Remove console box.
: Is the voltage less than 1 V?
3) Disconnect connector from G sensor.
4) Disconnect connector from ABSCM&H/U. : Go to step 10AH4.
5) Measure voltage between ABSCM&H/U con- : Repair harness between G sensor and
nector and chassis ground. ABSCM&H/U.
Connector & terminal
(F49) No. 6 (+) — Chassis ground (−): 10AH4 : CHECK ABSCM&H/U.
153
4-4 [T10AI0] BRAKES
10. Diagnostics Chart with Select Monitor
H4M1301
154
BRAKES [T10AI6] 4-4
10. Diagnostics Chart with Select Monitor
155
4-4 [T10AI7] BRAKES
10. Diagnostics Chart with Select Monitor
H4M1147A
H4M1146
H4M1148A
156
BRAKES [T10AI11] 4-4
10. Diagnostics Chart with Select Monitor
157
4-4 [T10AJ0] BRAKES
10. Diagnostics Chart with Select Monitor
H4M1301
158
BRAKES [T10AJ7] 4-4
10. Diagnostics Chart with Select Monitor
10AJ1 : CHECK ALL FOUR WHEELS FOR 10AJ4 : CHECK OUTPUT OF G SENSOR
FREE TURNING. USING SELECT MONITOR.
: Have the wheels been turned freely Read the select monitor display.
such as when the vehicle is lifted up,
or operated on a rolling road?
: The ABS is normal. Erase the trouble
code.
: Go to step 10AJ2.
159
4-4 [T10AJ8] BRAKES
10. Diagnostics Chart with Select Monitor
B4M1261A
S4M0074F
: Is the resistance between 4.3 and 4.9
kΩ?
: Go to step 10AJ9.
: Repair harness/connector between G
sensor and ABSCM&H/U.
H4M1146
160
BRAKES [T10AJ13] 4-4
10. Diagnostics Chart with Select Monitor
Measure voltage between G sensor connector ter- 1) Turn ignition switch to OFF.
minals. 2) Connect all connectors.
3) Erase the memory.
Connector & terminal 4) Perform inspection mode.
(R70) No. 2 (+) — No. 1 (−): 5) Read out the trouble code.
: Is the same trouble code as in the
current diagnosis still being output?
: Replace ABSCM&H/U.
: Go to step 10AJ13.
H4M1147A
: Are other trouble codes being out-
put?
: Is the voltage between 3.7 and 4.1 V : Proceed with the diagnosis correspond-
when G sensor is inclined forwards ing to the trouble code.
to 90°? : A temporary poor contact.
: Go to step 10AJ11.
: Replace G sensor.
H4M1148A
161
4-4 [T11A0] BRAKES
11. General Diagnostic Table
162
BRAKES [T11B1] 4-4
11. General Diagnostic Table
163
4-4 BRAKES
MEMO:
164
4-4 [K100] DIAGNOSTICS
1. Entire Brake System
58
DIAGNOSTICS [K100] 4-4
1. Entire Brake System
59
4-4 DIAGNOSTICS
MEMO:
60
PEDAL SYSTEM AND CONTROL
CABLES 4-5
Page
S SPECIFICATIONS AND SERVICE DATA..........................................................2
1. Pedal System ..............................................................................................2
C COMPONENT PARTS .......................................................................................3
1. Pedal ...........................................................................................................3
W SERVICE PROCEDURE ...................................................................................6
1. Pedal ...........................................................................................................6
2. Clutch Cable..............................................................................................13
3. Accelerator Cable......................................................................................14
K DIAGNOSTICS.................................................................................................16
1. Pedal System and Control Cables............................................................16
4-5 [S100] SPECIFICATIONS AND SERVICE DATA
1. Pedal System
1. Pedal System
1 — 3 mm (0.04 — 0.12 in) [Depress brake pedal pad
Brake pedal Free play
with a force of less than 10 N (1 kg, 2 lb).]
Except 2500 cc model: 10 — 20 mm (0.39 — 0.79 in)
Free play At clutch pedal pad
2500 cc model: 4 — 13 mm (0.16 — 0.51 in)
Clutch pedal
Except 2500 cc model: 140 — 145 mm (5.51 — 5.71 in)
Full stroke At clutch pedal pad
2500 cc model: 130 — 135 mm (5.12 — 5.31 in)
Free play At pedal pad 1 — 4 mm (0.04 — 0.16 in)
Accelerator pedal
Stroke At pedal pad 50 — 55 mm (1.97 — 2.17 in)
2
COMPONENT PARTS [C1A1] 4-5
1. Pedal
1. Pedal
A: MT MODEL
1. 2200 cc MODEL
H4M1135B
(1) Accelerator pedal (14) Pedal bracket (27) Clutch cable clamp
(2) Bushing (15) Stop light switch (28) Clutch cable
(3) Holder (16) Brake pedal (29) Mass damper
(4) Accelerator bracket (17) Spacer (30) Clutch switch (Starter interlock)
(5) Stopper (18) Snap pin
(6) Clip (19) Brake pedal pad Tightening torque: N·m (kg-m, ft-lb)
(7) Accelerator spring (20) Clevis pin T1: 5.9±1.5 (0.60±0.15, 4.3±1.1)
(8) Accelerator pedal spring (21) Brake pedal spring T2: 8±2 (0.8±0.2, 5.8±1.4)
(9) Spring pin (22) Washer T3: 18±5 (1.8±0.5, 13.0±3.6)
(10) Accelerator pedal pad (23) Clutch pedal pad T4: 29±7 (3.0±0.7, 21.7±5.1)
(11) Accelerator stopper (24) Clutch pedal
(12) Clip (25) Bushing assist
(13) Accelerator plate (26) Spring assist
3
4-5 [C1A2] COMPONENT PARTS
1. Pedal
2. 2500 cc MODEL
S4M0134A
(1) Holder (16) Brake pedal spring (31) Clutch switch (Starter interlock)
(2) Accelerator bracket (17) Clutch pedal pad (32) Clutch switch (With cruise con-
(3) Stopper (18) Clutch pedal trol)
(4) Bushing (19) Bushing C (33) Stop light switch
(5) Clip (20) Clutch clevis pin (34) Pedal bracket
(6) Accelerator spring (21) Assist rod A (35) Clutch master cylinder bracket
(7) Accelerator pedal spring (22) Clip (36) Lever
(8) Accelerator pedal (23) Assist spring (37) Lock wire
(9) Spring pin (24) Assist bushing
(10) Accelerator pedal pad (25) Assist rod B Tightening torque: N·m (kg-m, ft-lb)
(11) Accelerator stopper (26) Rod S T1: 8±2 (0.8±0.2, 5.8±1.4)
(12) Snap pin (27) Spring S T2: 18±5 (1.8±0.5, 13.0±3.6)
(13) Brake pedal pad (28) Bushing S
(14) Brake pedal (29) O-ring
(15) Clevis pin (30) Clip
4
COMPONENT PARTS [C1B0] 4-5
1. Pedal
B: AT MODEL
H4M1136B
5
4-5 [W1A1] SERVICE PROCEDURE
1. Pedal
G4M0318
B4M0366B
Pedal height: Y
158 mm (6.22 in)
(1) Stop light switch
Pedal stroke: A
(2) Mat
140 — 145 mm (5.51 — 5.71 in)
(3) Toe board
(4) Brake booster operating rod
B4M0617F
6
SERVICE PROCEDURE [W1A3] 4-5
1. Pedal
B4M1115A
B4M1116A
7
4-5 [W1A4] SERVICE PROCEDURE
1. Pedal
B4M1191A
G4M0335
G4M0321
8
SERVICE PROCEDURE [W1B4] 4-5
1. Pedal
9
4-5 [W1C1] SERVICE PROCEDURE
1. Pedal
G4M0333
G4M0326
G4M0327
10
SERVICE PROCEDURE [W1E0] 4-5
1. Pedal
D: ASSEMBLY E: INSTALLATION
1. BRAKE AND CLUTCH PEDAL 1) Installation is in the reverse order of removal
procedures.
1) Attach stop light switch, etc. to pedal bracket
temporarily. CAUTION:
2) Clean inside of bores of clutch pedal and brake I Be careful not to bend clutch cable too
pedal, apply grease, and set bushings into bores. much.
3) Align bores of pedal bracket, clutch pedal and I Never fail to cover outer cable end with boot.
brake pedal, attach brake pedal return spring and I Be careful not to kink accelerator cable.
clutch pedal effort reducing spring, and then install I Make sure that holder and casing cap are
pedal bolt. securely connected.
NOTE:
Clean up inside of bushings and apply grease
before installing spacer.
Tightening torque:
T2: 29±7 N·m (3.0±0.7 kg-m, 21.7±5.1 ft-lb)
B4M0159B
4) Set brake pedal position by adjusting position of 2) Adjust clutch pedal (2500 cc model) <Ref. to
stop light switch. 4-5 [W1F1].>
3) Adjustment after pedal installation <Ref. to 4-5
Pedal position: L [W1A0].>
125.9 mm (4.96 in)
Tightening torque:
T1: 8±2 N·m (0.8±0.2 kg-m, 5.8±1.4 ft-lb)
2. ACCELERATOR PEDAL
Clean and apply grease to spacer and inside bore
of accelerator pedal. Install accelerator pedal onto
pedal bracket.
11
4-5 [W1F1] SERVICE PROCEDURE
1. Pedal
B4M1191A
B4M1190A
B4M1189A
12
SERVICE PROCEDURE [W2B0] 4-5
2. Clutch Cable
B4M0160A
G4M0332
13
4-5 [W3A0] SERVICE PROCEDURE
3. Accelerator Cable
3. Accelerator Cable
A: REMOVAL
H4M1349A
1) Disconnect accelerator cable from connector 7) Working inside engine compartment, remove
inside engine compartment first. cable connection by turning toe board clockwise.
2) Remove lock nut from accelerator cable
bracket.
3) Separate accelerator cable from bracket, then
unlock inner cable.
G4M0335
B4M1185B
14
SERVICE PROCEDURE [W3B0] 4-5
3. Accelerator Cable
B4M0159B
15
4-5 [K100] DIAGNOSTICS
1. Pedal System and Control Cables
16
HEATER AND VENTILATOR 4-6
Page
S SPECIFICATIONS AND SERVICE DATA..........................................................2
1. Specifications ..............................................................................................2
C COMPONENT PARTS .......................................................................................3
1. Heater Unit ..................................................................................................3
2. Intake Unit ...................................................................................................4
3. Control Unit .................................................................................................5
W SERVICE PROCEDURE ...................................................................................6
1. Precaution ...................................................................................................6
2. Heater Unit ..................................................................................................6
3. Blower Motor Assembly...............................................................................7
4. Control Unit .................................................................................................7
4-6 [S1A0] SPECIFICATIONS AND SERVICE DATA
1. Specifications
1. Specifications
A: HEATER SYSTEM
Item Specifications Condition
Heating capacity 4.652 kW (4,000 kcal/h, I Mode selector switch : HEAT
15,872 BTU/h) or more I Temperature control switch : FULL HOT
I Temperature difference between : 65°C (149°F)
hot water and inlet air
I Hot water flow rate : 360 (95.1
US gal, 79.2 Imp gal)/h
Air flow rate 270 m3 (9,534 cu ft)/h Heat mode (FRESH), FULL HOT at 12.5 V
Max air flow rate 480 m3 (16,949 cu ft)/h I Temperature control switch : FULL COLD
I Blower fan speed : 4th position
I Mode selector lever : RECIRC
Heater core size (height x 192.4 x 152.0 x 25.0 x 1.8 —
length x width x thickness) mm (7.57 x 5.98 x 0.984 x
0.071 in)
Blower motor Type Magnet motor 200 W or less at 12 V
Fan type and Sirocco fan type 150 x 75 mm —
size (diameter x (5.91 x 2.95 in)
width)
2
COMPONENT PARTS [C100] 4-6
1. Heater Unit
1. Heater Unit
H4M1045B
3
4-6 [C200] COMPONENT PARTS
2. Intake Unit
2. Intake Unit
H4M1046B
(1) Intake unit case lower (6) Lever (A) Tightening torque: N·m (kg-m, ft-lb)
(2) Lever (B) (7) Link
T: 7.35±1.96
(3) Intake unit case upper (8) Rod (0.750±0.200, 5.421±1.446)
(4) Door (A) (9) Blower motor ASSY
(5) Door (B) (10) Aspirator pipe
4
COMPONENT PARTS [C300] 4-6
3. Control Unit
3. Control Unit
H4M1047B
(1) Temperature control cable (6) Harness ASSY (11) A/C switch knob
(2) Recirc control cable (7) Bulb (12) Control lever knob
(3) Clip (8) A/C switch ASSY (13) Plate
(4) Grommet (9) Mode control cable (14) Base unit
(5) Blower switch ASSY (10) Control dial knob
5
4-6 [W1A0] SERVICE PROCEDURE
1. Precaution
G4M0554
6
SERVICE PROCEDURE [W4A0] 4-6
4. Control Unit
G5M0276
H4M1260A
H4M1049A
7
4-6 [W4B1] SERVICE PROCEDURE
4. Control Unit
H4M1050
NOTE:
Before installing control unit, set temperature con-
trol switch to “FULL HOT” and mode selector
switch to “DEF” position and recirc switch to
“FRESH” position.
B: INSPECTION
1. FAN SWITCH
Check continuity between terminals at each switch
position.
H4M1052
C: ADJUSTMENT
1) Operate temperature control switch to “FULL
COLD” and mode selector switch to “VENT” posi-
tion and recirc switch to “RECIRC” position.
2) Install control cable to lever. While pushing
outer cable, secure control cable with clip.
H5M1280A
H4M1053A
H4M1051
8
AIR CONDITIONING SYSTEM 4-7
Page
S SPECIFICATIONS ..............................................................................................2
1. Specifications ..............................................................................................2
C COMPONENT PARTS .......................................................................................3
1. Air Conditioning System..............................................................................3
2. Intake Unit with Evaporator.........................................................................4
3. Compressor .................................................................................................5
W SERVICE PROCEDURE ...................................................................................6
1. Safety Precautions ......................................................................................6
2. Basic Information.........................................................................................7
3. Tools and Equipment...................................................................................8
4. O-ring Connections....................................................................................11
5. Refrigerant Service Procedure..................................................................13
6. Discharge the System ...............................................................................14
7. Evacuating and Charging..........................................................................14
8. Leak Testing ..............................................................................................18
9. Lubrication .................................................................................................20
10. Performance Test ......................................................................................21
11. Compressor ...............................................................................................21
12. Condenser .................................................................................................25
13. Receiver Drier ...........................................................................................26
14. Intake Unit with Evaporator.......................................................................26
15. Condenser Fan Assembly .........................................................................28
16. Flexible Hose.............................................................................................28
17. Relay and Fuse .........................................................................................29
18. Pressure Switch (Dual Switch)..................................................................31
K DIAGNOSTICS.................................................................................................32
1. Air Conditioning System Diagnosis...........................................................32
2. Performance Test Diagnosis .....................................................................33
3. Blower Motor Diagnosis ............................................................................36
4. Compressor Diagnosis ..............................................................................37
5. Compressor Clutch Diagnosis...................................................................38
6. Radiator Fan (Main Fan) Diagnosis..........................................................39
7. Condenser Fan (Sub Fan) Diagnosis (I)...................................................40
8. Condenser Fan (Sub Fan) Diagnosis (II)..................................................41
4-7 [S100] SPECIFICATIONS
1. Specifications
1. Specifications
Item Specifications
Type of air conditioner Reheat air-mix type
5.234 kW
Cooling capacity
(4,500 kcal/h, 17,856 BTU/h)
HFC-134a (CH2FCF3)
Refrigerant
[0.6±0.05 kg (1.3±0.11 lb)]
Type 5-vane rotary, fix volume (CR-14)
Compressor Discharge 144 cm3 (8.79 cu in)/rev
Max. permissible speed 7,000 rpm
Type Dry, single-disc type
Power consumption 47 W
Magnet clutch Type of belt V-Ribbed 4 PK
Pulley dia. (effective dia.) 125 mm (4.92 in)
Pulley ratio 1.064
Type Corrugated fin (Multi-flow)
Core face area 0.211 m2 (2.27 sq ft)
Condenser
Core thickness 19 mm (0.75 in)
Radiation area 5.76 m2 (62 sq ft)
Receiver drier Effective inner capacity 250 cm3 (15.26 cu in)
Expansion valve Type Internal equalizing
Type Single tank
Evaporator 74 × 222 × 235 mm
Dimensions (W × H × T)
(2.91 × 8.74 × 9.25 in)
Fan type Sirocco fan
Blower fan Outer diameter × width 140 × 75 mm (5.51 × 2.95 in)
Power consumption 200 W at 12 V
Motor type Magnet
Condenser fan (Sub fan) Power consumption 70 W at 12 V
Fan outer diameter 320 mm (12.60 in)
Motor type Magnet
Radiator fan (Main fan) Power consumption 70 W at 12 V
Fan outer diameter 320 mm (12.60 in)
850±100 rpm
Idling speed (A/C ON) MPFI model
(700±100 rpm “D” range in AT model)
176±29
Low-pressure switch oper- ON → OFF
(1.80±0.30, 25.5±4.3)
ating pressure
186+39/−25
Dual switch kPa (kg/cm2, psi) OFF → ON +0.4
(1.90 /−0.25, 27.0+5.7/−3.6 )
(Pressure switch)
High-pressure switch oper- ON → OFF 2,746±98 (28±1, 398±14)
ating pressure
kPa (kg/cm2, psi) DIFF 588±196 (6±2, 85±28)
Compressor relief valve blow-out pressure kPa (kg/cm2, psi) 3,727±196 (38±2.0, 540±28)
G4M0938
150±5°C (302±9°F)
Compressor thermocut temperature
Diff. −3±5°C (27±9°F)
2
COMPONENT PARTS [C100] 4-7
1. Air Conditioning System
H4M1057C
(1) A/C cut relay (9) Fuse Tightening torque: N·m (kg-m, ft-lb)
(2) FICD (1800 cc model) (10) Hose (High-pressure)
T1: 7.4±2.0 (0.75±0.2, 5.4±1.4)
(3) Receiver drier bracket (11) Compressor
T2: 18±5 (1.8±0.5, 13±3.6)
(4) Pipe (Receiver drier — C/unit) (12) Condenser
T3: 15±5 (1.5±0.5, 11±3.6)
(5) Receiver drier (13) Radiator bracket
(6) Cooling unit (14) Pipe (Condenser — Receiver T4: 25±5 (2.5±0.5, 18±3.6)
(7) Hose (Low-pressure) drier)
(8) A/C relay
3
4-7 [C200] COMPONENT PARTS
2. Intake Unit with Evaporator
H4M1058B
(1) Evaporator (6) Drain hose Tightening torque: N·m (kg-m, ft-lb)
(2) Insulator (7) Intake unit case lower
T1: 4±1 (0.4±0.1, 2.9±0.7)
(3) Block expansion valve (8) Mount bracket
T2: 7.4±2.0 (0.75±0.2, 5.4±1.4)
(4) Thermo control amplifier (9) Resistor
(5) Intake unit case upper
4
COMPONENT PARTS [C300] 4-7
3. Compressor
3. Compressor
H4M1027B
(1) Alternator (7) Condenser fan motor ASSY Tightening torque: N·m (kg-m, ft-lb)
(2) Alternator bracket nut (8) Idler pulley ASSY
T1: 5±1.5 (0.5±0.15, 3.6±1.1)
(3) Compressor belt cover (9) Compressor bracket upper
T2: 7.4±2 (0.75±0.2, 5.4±1.4)
(4) Bracket
T3: 23±3 (2.3±0.3, 17±2.2)
(5) Compressor bracket lower
(6) Compressor T4: 23.0±3 (2.35±0.3, 17.0±2.2)
T5: 28.9±4.4 (2.95±0.45, 21.3±3.3)
T6: 35±4 (3.6±0.4, 26±2.9)
5
4-7 [W1A0] SERVICE PROCEDURE
1. Safety Precautions
1. Safety Precautions
A: HFC-134a AIR CONDITIONING
SYSTEM
Component parts of the cooling system,
refrigerant, compressor oil, and other parts are not
the same for the HFC- 134a system and the older
CFC-12 system. Do not interchange parts or liquid.
Vehicles with HFC-134a air conditioning systems,
use only HFC-134a parts that are indicated on a
label attached to the vehicle. Before performing
any maintenance, verify the type of air conditioning
system installed in the vehicle.
H4M1065A
6
SERVICE PROCEDURE [W200] 4-7
2. Basic Information
G4M0979
7
4-7 [W300] SERVICE PROCEDURE
3. Tools and Equipment
3. Tools and Equipment pressor oil is mixed, poor lubrication will result
and the compressor itself may be destroyed. In
The following section provides information about order to help prevent mixing HFC-134a and
the tools and equipment that will be necessary to CFC-12 parts and liquid, the tool and screw
properly service the A/C system. type and the type of service valves used are
Since equipment may vary slightly depending on different. The gas leak detectors for the HFC-
the manufacturer, it is important to always read and 134a and CFC-12 systems must also not be
follow the manufacturer’s instructions. interchanged.
CAUTION:
When working on vehicles with the HFC-134a HFC-134a CFC-12
system, only use HFC-134a specified tools and Tool & screw type Millimeter size Inch size
parts. Do not mix with CFC-12 tools and parts. Valve type Quick joint type Screw-in type
If HFC-134a and CFC-12 refrigerant or com-
G4M0571
I APPLICATOR BOTTLE
G4M0572
I MANIFOLD GAUGE SET
G4M0573
8
SERVICE PROCEDURE [W300] 4-7
3. Tools and Equipment
G4M0574
I SYRINGE
A graduated plastic SYRINGE will be needed to add oil back into the
system. The syringe can be found at a pharmacy or drug store.
G4M0575
I VACUUM PUMP
G4M0576
I CAN TAP
A CAN TAP for the 397 g (14 oz) can is available from an auto sup-
ply store.
G4M0577
9
4-7 [W300] SERVICE PROCEDURE
3. Tools and Equipment
G4M0578
I ELECTRONIC LEAK DETECTOR
G4M0579
I WEIGHT SCALE
G4M0580
10
SERVICE PROCEDURE [W4C0] 4-7
4. O-ring Connections
G4M0583
G4M0581
G4M0582
11
4-7 [W4D0] SERVICE PROCEDURE
4. O-ring Connections
G4M0584
12
SERVICE PROCEDURE [W5A0] 4-7
5. Refrigerant Service Procedure
H4M1261A
13
4-7 [W600] SERVICE PROCEDURE
6. Discharge the System
G4M0585
G4M0596
14
SERVICE PROCEDURE [W7B0] 4-7
7. Evacuating and Charging
6) Slowly open the low-pressure manifold valve. 4) Note the low side gauge reading.
G4M0597 G4M0600
7) When the low-pressure gauge reaches approxi- 5) After 5 minutes, re-check the low-pressure
mately 66.43 kPa (498.3 mmHg, 19.62 inHg), gauge reading.
slowly open the high- pressure manifold valve. If the vacuum level has changed more than 4 kPa
8) Maintain a minimum vacuum level of 100.56 (25 mmHg, 1 inHg), perform an HFC-134a leak
kPa (754.4 mmHg, 29.70 inHg) for a minimum of test.
15 minutes on a new system or 30 minutes for an If the vacuum reading is about the same as noted
in-service system. in step 4), continue on to next step.
NOTE: 6) Carefully attach the can tap to the refrigerant
The gauge will read 4 kPa (25 mmHg, 1 inHg) less can by following the can tap manufacturer’s
for every 304.8 m (1,000 ft) above sea level. instructions.
G4M0980
G4M0598
G4M0599
15
4-7 [W7C0] SERVICE PROCEDURE
7. Evacuating and Charging
G4M0603
G4M0605
2) Open the valve on the HFC-134a source.
3) Loosen the center hose connection at the mani-
fold and allow the HFC-134a to escape for no more F: ADD ADDITIONAL CANS
than two or three seconds, then quickly retighten If the HFC-134a source is exhausted, first close
the hose fitting at the manifold. the high- pressure manifold valve, second, close
the can tap valve, then slowly purge the refrigerant
D: INITIAL CHARGING THROUGH from the service hose by loosening the fitting at the
THE HIGH SIDE can tap.
1) Connect a tachometer to the engine. G: COMPLETE CHARGING
2) With the engine off, start charging by slowly
opening the high-pressure manifold valve. THROUGH THE LOW SIDE
NOTE: 1) Verify that the high-pressure manifold valve is
The initial charge rate can be increased by closed (should have already been closed).
immersing the can in lukewarm [below 38°C 2) Verify that the low-pressure manifold valve is
(100°F)] water for a short time. closed (should have already been closed).
G4M0606
G4M0604
16
SERVICE PROCEDURE [W7J0] 4-7
7. Evacuating and Charging
5) Quickly turn the A/C switch on-off-on-off a few I: COMPLETE ALL SYSTEM
times to prevent initial compressor damage due to CHECKS
“load shock.” Finish this operation with the A/C
switch in the ON position. 1) Evaluate the system performance. <Ref. to 4-7
[K200].>
2) Perform leak detection test. <Ref. to 4-7
[W800].>
CAUTION:
Always perform leak checking in an environ-
ment free of refrigerant pollution.
Do not disconnect the high- or low-pressure
hoses from the vehicle before leak checking.
J: DISCONNECT THE MANIFOLD
G4M0607
GAUGE SET
Remove the high- or low-pressure hoses from the
6) Raise engine rpm to approximately 1,500 rpm. service ports and install the service port caps.
H: CHARGE THE SYSTEM
1) With the refrigerant source connected and the
service hose purged, slowly open the low-pressure
manifold valve, while checking the low-pressure
gauge reading.
CAUTION:
The refrigerant source must be positioned for
vapor (valve up).
G4M0608
17
4-7 [W8A0] SERVICE PROCEDURE
8. Leak Testing
G4M0609
18
SERVICE PROCEDURE [W8A6] 4-7
8. Leak Testing
I Check the area where the two parts of the fitting 2) Check the area.
join each other. (1) Check the area where the fitting joins the
tube.
G4M0613
G4M0615
I Check the area where the nut meets the tube.
(2) Check the area where the two parts of the
fitting join each other.
(3) Check the area where the nut joins the tube.
G4M0614
19
4-7 [W8A7] SERVICE PROCEDURE
9. Lubrication
20
SERVICE PROCEDURE [W11B0] 4-7
11. Compressor
B4M0091
B: REMOVAL
1) Disconnect ground cable from battery.
21
4-7 [W11B0] SERVICE PROCEDURE
11. Compressor
2) Discharge refrigerant using refrigerant recovery 4) Compressor belt cover and generator belt
system. <Ref. to 4-7 [W600].> cover:
(1) Fully close low-pressure valve of manifold Remove bolts which secure belt covers.
gauge.
(2) Connect low-pressure charging hose of
manifold gauge to low-pressure service valve.
(3) Open low-pressure manifold gauge valve
slightly, and slowly discharge refrigerant from
system.
CAUTION:
Do not allow refrigerant to rush out. Otherwise,
compressor oil will be discharged along with
refrigerant.
B4M0090
B4M0760A
G4M0626
B4M0761C
7) Disconnect alternator harness.
G4M0627
22
SERVICE PROCEDURE [W11C0] 4-7
11. Compressor
G4M0628
G4M0634
G4M0630
23
4-7 [W11C0] SERVICE PROCEDURE
11. Compressor
B4M1098A
B4M0761C
24
SERVICE PROCEDURE [W12B0] 4-7
12. Condenser
H4M1059
B: INSPECTION
1) Make sure the condenser fins are free from
dust and insects. If the fins are clogged, clean by
blowing air or water through them.
NOTE:
To prevent dust and water from getting into the
condenser, this work must be done when the con-
H4M1262A denser is installed in an actual vehicle.
6) Remove the two bolts which secure condenser. 2) Check the condenser to see if it shows any sign
While lifting condenser, remove it through space of oil. If oil ooze or gas leak occur from the
between radiator and radiator panel. condenser, replace it with a new one.
G4M0638
25
4-7 [W13A0] SERVICE PROCEDURE
13. Receiver Drier
G4M0641
H4M1263A
G5M0276
H4M1060
26
SERVICE PROCEDURE [W14B0] 4-7
14. Intake Unit with Evaporator
H4M1061A
H4M1064A
2) Remove some screws then separate intake unit 8) Reassemble the intake unit in the reverse order
case. of disassembly.
3) Remove thermistor from clip with the evapora-
tor. NOTE:
Confirm that the O-ring is inserted in the specified
position.
H4M1062A
H4M1063A
27
4-7 [W15A0] SERVICE PROCEDURE
15. Condenser Fan Assembly
G4M0647
28
SERVICE PROCEDURE [W17A0] 4-7
17. Relay and Fuse
H4M1131A
G4M0648
G4M0650
29
4-7 [W17B0] SERVICE PROCEDURE
17. Relay and Fuse
B: INSPECTION
1) Check conduction with a circuit tester (ohm
range) according to the following table in figure.
G4M0651
G4M0652
G4M0653
30
SERVICE PROCEDURE [W18A0] 4-7
18. Pressure Switch (Dual Switch)
18. Pressure Switch (Dual 1) Remove cap from high-pressure line service
valve, and connect gauge manifold to service
Switch) valve.
A: INSPECTION 2) Disconnect pressure switch harness connector,
and check pressure switch for proper ON-OFF
NOTE: operation. Use a circuit tester.
Pressure switch is attached to receiver dryer. It has
two built-in switches.
G4M0654
31
4-7 [K100] DIAGNOSTICS
1. Air Conditioning System Diagnosis
H4M1265A
32
DIAGNOSTICS [K200] 4-7
2. Performance Test Diagnosis
G4M0673
ALMOST NO REFRIGERANT No cooling action. Serious refrigerant Stop compressor
leak. immediately.
1. Leak test.
2. Discharge system.
3. Repair leak(s).
4. Replace receiver
drier if necessary.
5. Check oil level.
6. Evacuate and
recharge system.
G4M0674
FAULTY EXPANSION VALVE Slight cooling. Expansion valve If valve inlet reveals
Sweating or frosted restricts refrigerant sweat or frost:
expansion valve inlet. flow. 1. Discharge system.
I Expansion valve is 2. Remove valve and
clogged. clean it. Replace it if
I Expansion valve is necessary.
inoperative. 3. Evacuate system.
I Valve stuck closed. 4. Charge system.
Thermal bulb has lost If valve does not oper-
charge. ate:
1. Discharge system.
2. Replace valve.
3. Evacuate and
G4M0675 charge system.
33
4-7 [K200] DIAGNOSTICS
2. Performance Test Diagnosis
G4M0676
G4M0677
AIR IN SYSTEM Insufficient cooling. Air mixed with refriger- 1. Discharge system.
ant in system. 2. Replace receiver
drier.
3. Evacuate and
charge system.
G4M0678
MOISTURE IN SYSTEM After operation for a Drier is saturated with 1. Discharge system.
while, pressure on moisture. Moisture has 2. Replace receiver
suction side may show frozen at expansion drier (twice if neces-
vacuum pressure valve. Refrigerant flow sary).
reading. During this is restricted. 3. Evacuate system
condition, discharge completely (Repeat 30
air will be warm. As minute evacuating
warning of this, read- three times.).
ing shows 39 kPa (0.4 4. Recharge system.
kg/cm2, 6 psi) vibra-
tion.
G4M0679
34
DIAGNOSTICS [K200] 4-7
2. Performance Test Diagnosis
G4M0681
FAULTY COMPRESSOR Insufficient cooling. Internal problem in 1. Discharge system.
compressor, or dam- 2. Remove and check
aged gasket and compressor.
valve. 3. Repair or replace
compressor.
4. Check oil level.
5. Replace receiver
drier.
6. Evacuate and
charge system.
G4M0682
35
4-7 [K300] DIAGNOSTICS
3. Blower Motor Diagnosis
H4M1266A
36
DIAGNOSTICS [K400] 4-7
4. Compressor Diagnosis
4. Compressor Diagnosis
H4M1267A
37
4-7 [K500] DIAGNOSTICS
5. Compressor Clutch Diagnosis
H4M1268A
38
DIAGNOSTICS [K600] 4-7
6. Radiator Fan (Main Fan) Diagnosis
H4M1269A
39
4-7 [K700] DIAGNOSTICS
7. Condenser Fan (Sub Fan) Diagnosis (I)
H4M1270A
40
DIAGNOSTICS [K800] 4-7
8. Condenser Fan (Sub Fan) Diagnosis (II)
H4M1271A
41
4-7 DIAGNOSTICS
MEMO:
42
BODY AND EXTERIOR 5-1
Page
S SPECIFICATIONS AND SERVICE DATA..........................................................2
1. Precaution ...................................................................................................2
2. Body Datum Points .....................................................................................3
3. Datum Dimensions ....................................................................................20
4. Datum Points and Dimensions Concerning On-Board Aiming
Adjustment.................................................................................................28
C COMPONENT PARTS .....................................................................................29
1. Front Hood and Hood Lock.......................................................................29
2. Trunk Lid ...................................................................................................30
3. Front Bumper ............................................................................................31
4. Rear Bumper .............................................................................................32
5. Sunroof ......................................................................................................33
6. Steering Support Beam.............................................................................34
7. Guard Pipe ................................................................................................35
W SERVICE PROCEDURE .................................................................................36
1. Hood ..........................................................................................................36
2. Trunk Lid ...................................................................................................37
3. Fuel Flap ...................................................................................................39
4. Front Bumper ............................................................................................39
5. Rear Bumper .............................................................................................40
6. Coating Method for PP Bumper................................................................42
7. Repair Instructions for Colored PP Bumper .............................................43
8. Side Protector............................................................................................47
9. Front Fender..............................................................................................48
10. Mud Guard and Rear Arch Protector ........................................................49
11. Cowl Panel ................................................................................................49
12. Molding and Retainer ................................................................................50
13. Front Grille.................................................................................................50
14. Sunroof ......................................................................................................51
15. Rear Spoiler ..............................................................................................54
16. Hood Duct .................................................................................................54
K DIAGNOSTICS.................................................................................................55
1. Sunroof ......................................................................................................55
5-1 [S1A0] SPECIFICATIONS AND SERVICE DATA
1. Precaution
1. Precaution
A: SUPPLEMENTAL RESTRAINT
SYSTEM “AIRBAG”
Airbag system wiring harness is routed on and
along body panels.
CAUTION:
I All Airbag system wiring harness and connec-
tors are colored yellow. Do not use electrical test
equipment on these circuit.
I Be careful not to damage Airbag system wiring
harness when repairing the body panel.
2
SPECIFICATIONS AND SERVICE DATA [S2A1] 5-1
2. Body Datum Points
H5M0815A
3
5-1 [S2A1] SPECIFICATIONS AND SERVICE DATA
2. Body Datum Points
(1) Radiator panel (UPR) repair bolt (10) Hood hinge attaching bolt hole (20) Center pillar gauge hole 10 mm
hole M8 (Right) M8 (Symmetrical) (0.39 in) dia. (Symmetrical)
(2) Radiator panel (UPR) repair bolt (11) Cowl panel mounting hole 5 mm (21) Belt anchor attaching bolt hole
hole M8 (Left) (0.20 in) dia. (Located in center (Symmetrical)
(3) Fender attaching bolt hole M6 of vehicle.) (22) Wax coat hole, 20 mm (0.79 in)
(Symmetrical) (12) Front rail (Inner) mirror attaching dia. (Symmetrical)
(4) Headlight attaching bolt hole M6 bolt hole 8 mm (0.31 in) dia. (23) Rear door switch attaching hole
(Symmetrical) (13) Fender attaching bolt hole M6 20 mm (0.79 in) dia. (Symmetri-
(5) Radiator panel side gauge hole (Symmetrical) cal)
24 mm (0.94 in) dia. (Symmetri- (14) Front pillar gauge hole 20 mm (24) Retainer attaching square hole 7
cal) (0.79 in) dia. (Symmetrical) mm (0.28 in) (Symmetrical)
(6) Front bumper mounting hole 14 (15) Wax coat hole, 20 mm (0.79 in) (25) Spare tire attaching bolt hole M8
x 17 mm (0.55 x 0.67 in) dia. dia. (Symmetrical) (26) Air draw hole 7 mm (0.28 in) dia.
(Symmetrical) (16) Retainer attaching square hole 7 (Symmetrical)
(7) Front crossmember attaching mm (0.28 in) (Symmetrical) (60) Fender attaching bolt hole M6
bolt hole 12.4 mm (0.488 in) dia. (17) Sun visor attaching hole 20 mm (Symmetrical)
(Symmetrical) (0.79 in) dia. (Symmetrical) (64) Door switch attaching hole 20
(8) Fender attaching bolt hole M6 (18) Retainer attaching square hole 7 mm (0.79 in) dia. (Symmetrical)
(Symmetrical) mm (0.28 in) (Symmetrical) (67) Front glass attaching hole Right
(9) Front strut mounting hole 10 mm (19) Retainer attaching square hole 7 6.5 mm (0.256 in) dia. Left 6.5 x
(0.39 in) dia. (Symmetrical) mm (0.28 in) (Symmetrical) 10 mm (0.256 x 0.39 in) dia.
4
SPECIFICATIONS AND SERVICE DATA [S2A2] 5-1
2. Body Datum Points
2. COUPE
H5M0712B
5
5-1 [S2A2] SPECIFICATIONS AND SERVICE DATA
2. Body Datum Points
(1) Radiator panel (UPR) repair bolt (11) Cowl panel mounting hole 5 mm (70) Door switch attaching hole 13.5
hole M8 (Right) (0.20 in) dia. (Located in center mm (0.531 in) dia. (Symmetrical)
(2) Radiator panel (UPR) repair bolt of vehicle.) (71) Retainer attaching square hole 8
hole M8 (Left) (12) Front rail (Inner) mirror attaching mm (0.31 in). (Symmetrical)
(3) Fender attaching bolt hole M6 bolt hole 8 mm (0.31 in) dia. (72) Rear quarter glass attaching
(Symmetrical) (13) Fender attaching bolt hole M6 hole 8 mm (0.31 in) dia. (Sym-
(4) Headlight attaching bolt hole M6 (Symmetrical) metrical)
(Symmetrical) (14) Front pillar gauge hole 20 mm (73) Rear quarter glass attaching
(5) Radiator panel side gauge hole (0.79 in) dia. (Symmetrical) hole 7 mm (0.28 in) dia. (Sym-
24 mm (0.94 in) dia. (Symmetri- (16) Retainer attaching square hole 7 metrical)
cal) mm (0.28 in) (Symmetrical) (74) Rear quarter glass attaching
(6) Front bumper mounting hole 14 (17) Sun visor attaching hole 20 mm hole 8 x 5.5 mm (0.31 x 0.217
x 17 mm (0.55 x 0.67 in) dia. (0.79 in) dia. (Symmetrical) in) dia. (Symmetrical)
(Symmetrical) (25) Spare tire attaching bolt hole M8 (75) Retainer attaching square hole 8
(7) Front crossmember attaching (26) Air draw hole 7 mm (0.28 in) dia. mm (0.31 in). (Symmetrical)
bolt hole 12.4 mm (0.488 in) dia. (Symmetrical) (76) Seat belt anchor attaching bolt
(Symmetrical) (60) Fender attaching bolt hole M6 hole 16 mm (0.63 in) dia. (Sym-
(8) Fender attaching bolt hole M6 (Symmetrical) metrical)
(Symmetrical) (67) Front glass attaching hole Right
(9) Front strut mounting hole 10 mm 6.5 mm (0.256 in) dia. Left 6.5 x
(0.39 in) dia. (Symmetrical) 10 mm (0.256 x 0.39 in) dia.
(10) Hood hinge attaching bolt hole (69) Wax coat hole 20 mm (0.79 in)
M8 (Symmetrical) dia. (Symmetrical)
6
SPECIFICATIONS AND SERVICE DATA [S2B1] 5-1
2. Body Datum Points
H5M0816A
7
5-1 [S2B1] SPECIFICATIONS AND SERVICE DATA
2. Body Datum Points
(27) Rear pillar (Inner) gauge hole 8 (33) Rear skirt (UPR) cutout (Repair (39) Steering support beam attaching
mm (0.31 in) dia. (Symmetrical) locator) bolt hole M8 (Symmetrical)
(28) Rear roof trim attaching hole 8 (34) Rear skirt gauge hole 20 mm (40) Front pillar (Inner) gauge hole 10
mm (0.31 in) dia. (Symmetrical) (0.79 in) dia. (Symmetrical) mm (0.39 in) dia. (Symmetrical)
(29) Rear quarter trim attaching hole (35) Rear combination light mounting (41) Floor mat attaching clip hole 8
8 mm (0.31 in) dia. (Symmetri- hole 9 mm (0.35 in) dia. (Sym- mm (0.31 in) dia. (Symmetrical)
cal) metrical) (66) Rear panel (Center) repair loca-
(30) Seat belt anchor attaching bolt (36) Rear quarter bumper side gauge tor (Located in center of vehicle.)
hole (Symmetrical) hole 20 mm (0.79 in) dia. (Left) (68) Rear glass attaching hole
(31) Reinforcement (Rear panel rear) (37) Rear quarter bumper side gauge (Right): 6.5 mm (0.256 in) dia.
repair locator (Located in center hole 20 mm (0.79 in) dia. (Right) (Left): 6.5 x 10 mm (0.256 x 0.39
of vehicle) (38) Instrument panel attaching in) dia.
(32) Rear corner patch at flange square hole 22 x 34.5 mm (0.87
(Symmetrical) x 1.358 in) (Right)
8
SPECIFICATIONS AND SERVICE DATA [S2B2] 5-1
2. Body Datum Points
2. WAGON
H5M0817A
(42) Rear quarter glass attaching (46) Rear strut mounting hole 10 mm (61) Side rail (Inner) gauge hole 8
hole 8 mm (0.31 in) dia. (Sym- (0.39 in) dia. (Symmetrical) mm (0.31 in) dia. (Symmetrical)
metrical) (47) Rear gate stay attaching bolt (62) Rear quarter trim attaching hole
(43) Roof rail attaching hole 10 mm hole M8 (Symmetrical) 8 mm (0.31 in) dia. (Symmetri-
(0.39 in) dia. (Symmetrical) (48) Child seat anchor attaching bolt cal)
(44) Rear quarter glass attaching hole (63) Rear quarter harness attaching
hole 8 x 15 mm (0.31 x 0.59 in) (49) Rear combination light mounting clip hole 7 mm (0.28 in) dia.
dia. (Symmetrical) hole 10 mm (0.39 in) dia. (Sym- (Symmetrical)
(45) Rear roof trim attaching hole 8 metrical) (65) Seat belt anchor attaching bolt
mm (0.31 in) dia. (Symmetrical) hole (Symmetrical)
9
5-1 [S2C0] SPECIFICATIONS AND SERVICE DATA
2. Body Datum Points
C: UNDER BODY
H5M0818A
(50) Radiator panel (LWR) frame (53) Front suspension attaching bolt (57) Rear differential attaching bolt
gauge hole 15 mm (0.59 in) dia. hole M14 hole M12 (Symmetrical)
(Symmetrical) (54) Side frame gauge hole 20 mm (58) Rear suspension attaching bolt
(51) Front side frame gauge hole 20 (0.79 in) dia. (Symmetrical) hole M12 (Symmetrical)
mm (0.79 in) dia. (Symmetrical) (55) Transmission mount attaching (59) Rear side frame gauge hole 15
(52) Front crossmember attaching bolt hole M10 (Symmetrical) mm (0.59 in) dia. (Symmetrical)
hole 12.4 mm (0.488 in) dia. (56) Side frame gauge hole 15 mm
(Symmetrical) (0.59 in) dia. (Symmetrical)
10
SPECIFICATIONS AND SERVICE DATA [S2D0] 5-1
2. Body Datum Points
H5M0819A H5M0823A
H5M0820A
H5M0824A
H5M0825A
H5M0821A
H5M0822A H5M0826A
11
5-1 [S2D0] SPECIFICATIONS AND SERVICE DATA
2. Body Datum Points
H5M0827A H5M0831A
H5M0828A
H5M0832A
H5M0833A
H5M0829A
H5M0830A
H5M0834A
12
SPECIFICATIONS AND SERVICE DATA [S2D0] 5-1
2. Body Datum Points
H5M0835A
H5M0839A
H5M0836A H5M0840A
H5M0841A
H5M0837A
H5M0842A
H5M0838A
13
5-1 [S2D0] SPECIFICATIONS AND SERVICE DATA
2. Body Datum Points
H5M0847A
H5M0843A
H5M0848A
H5M0844A
H5M0845A
H5M0849A
H5M0846A H5M0850A
14
SPECIFICATIONS AND SERVICE DATA [S2D0] 5-1
2. Body Datum Points
H5M0851A
H5M0855A
H5M0852A H5M0856A
H5M0857A
H5M0853A
H5M0854A H5M0858A
15
5-1 [S2D0] SPECIFICATIONS AND SERVICE DATA
2. Body Datum Points
H5M0859A
H5M0863A
H5M0860A H5M0864A
H5M0861A H5M0865A
H5M0866A
H5M0862A
16
SPECIFICATIONS AND SERVICE DATA [S2D0] 5-1
2. Body Datum Points
H5M0871A
H5M0867A
H5M0868A
H5M0872A
H5M0869A
H5M0873A
H5M0870A H5M0874A
17
5-1 [S2D0] SPECIFICATIONS AND SERVICE DATA
2. Body Datum Points
H5M0875A
H5M0879A
H5M0876A H5M0880A
H5M0881A
H5M0670B
H5M0878A H5M0882A
18
SPECIFICATIONS AND SERVICE DATA [S2D0] 5-1
2. Body Datum Points
H5M0883A H5M0887A
H5M0888A
H5M0884A
H5M0885A
H5M0889A
H5M0886A
19
5-1 [S300] SPECIFICATIONS AND SERVICE DATA
3. Datum Dimensions
G5M0122
A: FRONT STRUCTURE
H5M0890A
Unit: mm (in)
Point to point Dimension Point to point Dimension
(11) to (9) R 525 (20.67) (10) R to (10) L 1,382 (54.41)
(11) to (9) L 525 (20.67) (3) R to (3) L 1,336 (52.60)
(11) to (6) R 988 (38.90) (5) R to (5) L 942 (37.09)
(11) to (6) L 988 (38.90) (5) R to (4) R 1,174 (46.22)
(11) to (3) R 990 (38.98) (5) L to (4) L 1,174 (46.22)
(11) to (3) L 990 (38.98) (4) R to (4) L 1,269 (49.96)
(10) R to (3) R 829 (32.64) (60) R to (13) R 1,113 (43.82)
(10) L to (3) L 829 (32.64) (60) L to (13) L 1,113 (43.82)
(10) R to (8) R 567 (22.32) (60) R to (14) R 1,076 (42.36)
(10) L to (8) L 567 (22.32) (60) L to (14) L 1,076 (42.36)
(8) R to (3) R 264 (10.39) (1) to (11) 882 (34.72)
(8) L to (3) L 264 (10.39) (2) to (11) 913 (35.94)
20
SPECIFICATIONS AND SERVICE DATA [S3B0] 5-1
3. Datum Dimensions
B: CENTER STRUCTURE
H5M0891A
21
5-1 [S3C1] SPECIFICATIONS AND SERVICE DATA
3. Datum Dimensions
H5M0892A
Unit: mm (in)
Point to point Dimension Point to point Dimension
(14) to (18) 1,495 (58.86) (19) to (23) 912 (35.91)
(13) to (64) 947 (37.28) (20) to (36) L* 1,462 (57.56)
(16) to (64) 976 (38.43) (20) R to (37) R* 1,481 (58.31)
(20) to (23) 803 (31.61) (62) to (43) * 377 (14.84)
(20) to (24) 829 (32.64) (42) to (44) * 847 (33.35)
*: Wagon only
22
SPECIFICATIONS AND SERVICE DATA [S3C2] 5-1
3. Datum Dimensions
2. COUPE
H5M0713B
Unit: mm (in)
Point to point Dimension Point to point Dimension
(14) to (71) 1,576 (62.05) (72) to (74) 778 (30.63)
(13) to (70) 1,251 (49.25) (73) to (75) 512 (20.16)
(16) to (70) 997 (39.25) (70) to (36) L 1,295 (50.98)
(13) to (69) 1,063 (41.85) (70) to (37) R 1,243 (48.94)
23
5-1 [S3D0] SPECIFICATIONS AND SERVICE DATA
3. Datum Dimensions
H5M0893A
Unit: mm (in)
Point to point Dimension Point to point Dimension
(11) to (12) 989 (38.94) (66) to (28) L 714 (28.11)
(67) R to (67) L 1,012 (39.84) (66) to (68) R 856 (33.70)
(11) to (67) R 1,116 (43.94) (66) to (68) L 856 (33.70)
(11) to (67) L 1,116 (43.94) (68) R to (68) L 1,012 (39.84)
(66) to (28) R 714 (28.11)
24
SPECIFICATIONS AND SERVICE DATA [S3E0] 5-1
3. Datum Dimensions
H5M0894A
Unit: mm (in)
Point to point Dimension Point to point Dimension
(31) to (32) R 575 (22.64) (35) R to (35) L 1,364 (53.70)
(31) to (32) L 575 (22.64) (45) R to (48) 988 (38.90)
(31) to (26) R 812 (31.97) (45) L to (48) 988 (38.90)
(31) to (26) L 812 (31.97) (45) R to (47) R 926 (36.46)
(31) to (33) 522 (20.55) (45) L to (47) L 926 (36.46)
(31) to (35) R 794 (31.26) (47) R to (47) L 1,043 (41.06)
(31) to (35) L 794 (31.26) (49) R to (49) L 1,355 (52.56)
(34) R to (34)L 890 (35.04) (34) R to (34) L 890 (35.04)
25
5-1 [S3F0] SPECIFICATIONS AND SERVICE DATA
3. Datum Dimensions
F: COMPARTMENT
H5M0895A
Unit: mm (in)
Point to point Dimension Point to point Dimension Point to point Dimension
(30) R to (30) L 1,197 (47.13) (41) to (15) R 1,140 (44.88) (41) to (30) L* 1,168 (45.98)
(21) R to (21) L 1,061 (41.77) (41) to (15) L 1,140 (44.88) (41) to (28) R* 1,050 (41.34)
(15) R to (15) L 1,453 (57.20) (41) to (22) R 733 (28.86) (41) to (28) L* 1,050 (41.34)
(22) R to (22) L 1,453 (57.20) (41) to (22) L 733 (28.86) (41) to (21) R 1,038 (40.87)
(39) R to (39) L 1,388 (54.65) (41) to (12) 1,156 (45.51) (41) to (21) L 1,038 (40.87)
(40) R to (40) L 1,401 (55.16) (41) to (27) R 1,085 (42.72) (41) to (17) R 1,208 (47.56)
(41) to (38) 1,527 (60.12) (41) to (27) L 1,085 (42.72) (41) to (17) L 1,208 (47.56)
(41) to (39) R 1,524 (60.00) (41) to (26) R 1,568 (61.73) (41) to (33) * 1,569 (61.77)
(41) to (39) L 1,524 (60.00) (41) to (26) L 1,568 (61.73) (76) R to (76) 1,212 (47.72)
L✩
(41) to (40) R 1,756 (69.13) (41) to (25) 1,184 (46.61)
(41) to (40) L 1,756 (69.13) (41) to (30) R* 1,168 (45.98)
*: Sedan only ✩ : Coupe only
26
SPECIFICATIONS AND SERVICE DATA [S3G0] 5-1
3. Datum Dimensions
G: LUGGAGE ROOM
H5M0896A
Unit: mm (in)
Point to point Dimension Point to point Dimension
(41) to (65) R 1,122 (44.17) (41) to (43) R 1,237 (48.70)
(41) to (65) L 1,122 (44.17) (41) to (43) L 1,237 (48.70)
(41) to (45) R 1,225 (48.23) (48) to (46) R 971 (38.23)
(41) to (45) L 1,225 (48.23) (48) to (46) L 971 (38.23)
(41) to (48) 1,446 (56.93) (65) R to (65) L 1,235 (48.62)
27
5-1 [S400] SPECIFICATIONS AND SERVICE DATA
4. Datum Points and Dimensions Concerning On-Board Aiming Adjustment
H5M0898A
Unit: mm (in)
Point to point Dimension Point to point Dimension
(11) to (A) L 993 (39.09) (11) to (B) L 1,048 (41.26)
(11) to (A) R 993 (39.09) (11) to (B) R 1,048 (41.26)
28
COMPONENT PARTS [C100] 5-1
1. Front Hood and Hood Lock
H5M0671B
(1) Front hood (7) Hood lock ASSY Tightening torque: N·m (kg-m, ft-lb)
(2) Hinge (RH, LH) (8) Striker
T1: 14±9 (1.4±0.9, 10.1±6.5)
(3) Hood hinge cover (RH, LH) (9) Front hood stay
T2: 32±1 (3.3±0.1, 23.9±0.7)
(4) Lever ASSY (10) Seal (Front hood) SD
(5) Cable (11) Seal (Front hood) CTR
(6) Stopper
29
5-1 [C200] COMPONENT PARTS
2. Trunk Lid
2. Trunk Lid
H5M0900A
(1) Torsion bar (5) Trunk lid lock ASSY Tightening torque: N·m (kg-m, ft-lb)
(2) Trunk lid (6) Striker
T1: 14±4 (1.4±0.4, 10.1±2.9)
(3) Weatherstrip (7) Hinge ASSY
T2: 18±5 (1.8±0.5, 13.0±3.6)
(4) Rod
30
COMPONENT PARTS [C300] 5-1
3. Front Bumper
3. Front Bumper
H5M0938A
(1) Plate (5) Front beam (Except USA 2500 (9) Bumper face (USA 2500 cc)
(2) Bumper face (Except USA 2500 cc)
cc) (6) Bracket (Side) Tightening torque: N·m (kg-m, ft-lb)
(3) Spacer (7) Holder upper T: 93±25 (9.5±2.5, 69±18)
(4) E/A form bumper (8) Front beam (USA 2500 cc)
31
5-1 [C400] COMPONENT PARTS
4. Rear Bumper
4. Rear Bumper
H5M0715B
(1) Holder upper (4) E/A from bumper Tightening torque: N·m (kg-m, ft-lb)
(2) Bumper beam (5) Plate
T: 93±25 (9.5±2.5, 69±18)
(3) Bracket (Side) (6) Bumper surface
32
COMPONENT PARTS [C500] 5-1
5. Sunroof
5. Sunroof
H5M0901A
33
5-1 [C600] COMPONENT PARTS
6. Steering Support Beam
H5M0902A
34
COMPONENT PARTS [C700] 5-1
7. Guard Pipe
7. Guard Pipe
B5M0371C
35
5-1 [W1A0] SERVICE PROCEDURE
1. Hood
G5M0137
G5M0139
G5M0141
5) Installation is in the reverse order of removal.
B: POINTS TO CHECK
2. HOOD LOCK
1) Check striker for bending or abnormal wear.
1) Open front hood and remove front grille. 2) Check safety lever for improper movement.
36
SERVICE PROCEDURE [W2A3] 5-1
2. Trunk Lid
3) Check other levers and spring for rust formation 2. Trunk Lid
and unsmooth movement.
A: REMOVAL AND INSTALLATION
1. TRUNK LID
1) Open trunk lid.
2) Remove trunk lid mounting bolts and detach
trunk lid from hinges.
G5M0140
C: ADJUSTMENT
1) Fore-aft and left-right adjustments Loosen
striker mounting bolts and adjust fore-and-aft posi-
tion of striker. G5M0144
CAUTION:
3) Installation is in the reverse order of removal.
Do not adjust striker position using the lock.
Doing so may result in a misaligned front grille. 2. TORSION BAR
1) Open trunk lid. Remove torsion bars from hinge
links using ST.
ST 927780000 REMOVER
CAUTION:
Be careful because torsion bar quickly swings
back when released.
G5M0145
37
5-1 [W2A4] SERVICE PROCEDURE
2. Trunk Lid
2) Remove bolts which hold lock assembly and 7) Disconnect cable from striker.
remove lock assembly. NOTE:
NOTE: Be careful not to bend or break cable.
I Always remove rear skirt trim panel beforehand,
if so equipped.
I Be careful not to bend opener cable.
G5M0147
G5M0148
38
SERVICE PROCEDURE [W4A0] 5-1
4. Front Bumper
G5M0150
H5M0717
G5M0151
39
5-1 [W5A1] SERVICE PROCEDURE
5. Rear Bumper
G5M0156
G5M0160
G5M0157
G5M0162
G5M0158
40
SERVICE PROCEDURE [W5A2] 5-1
5. Rear Bumper
6) Installation is in the reverse order of removal. 6) Installation is in the reverse order of removal.
CAUTION: CAUTION:
I Be extremely careful to prevent scratches on I Be extremely careful to prevent scratches on
bumper face as it is made of resin. bumper face as it is made of resin.
I Be careful not to scratch the body when I Be careful not to scratch the body when
removing or installing bumper. removing or installing bumper.
NOTE: NOTE:
To facilitate installation of rear bumper, attach hook To facilitate installation of rear bumper, attach hook
(located at stay) to body panel. (located at stay) to body panel.
G5M0163
G5M0163
2. WAGON
1) Open rear gate and rear quarter trim lid.
2) Disconnect license plate light connector.
3) Remove bolts from side of bumper.
4) Remove bolts from bumper stays.
5) Remove bumper assembly.
41
5-1 [W6A0] SERVICE PROCEDURE
6. Coating Method for PP Bumper
G5M0164
2 Masking Mask specified part (black base) with masking tape. Use masking tape for PP
(example, Nichiban No. 533, etc.).
3 Degreasing, cleaning Clean all parts to be painted with white gasoline, normal alcohol, etc. to remove dirt,
oil, fat, etc.
4 Primer paint Apply primer one to all parts to be painted, using air gun. Use primer (clear).
5 Drying Dry at normal temperature [10 to 15 min. at 20°C (68°F)]. In half-dried condition, PP
primer paint is dissolved by solvent, e.g. thinner, etc. Therefore, if dust or dirt must be
removed, use ordinary alcohol, etc.
6 Top coat paint (I) Solid color Metallic color
Use section (block) paint for top coat. Use section (block) paint for top coat.
I Paint in use (for each color): I Paint in use (for each color):
Solid paint Metallic paint
Hardener PB Hardener PB
Thinner T-301 Thinner T-306
I Mixing ratio: Main agent vs. hardener = I Mixing ratio: Main agent vs. hardener
4:1 = 10:1
I Viscosity: 10 — 13 sec/20°C (68°F) I Viscosity: 10 — 13 sec/20°C (68°F)
I Film thickness: 35 — 45µ I Film thickness: 15 — 20µ
I Spraying pressure: 245 — 343 kPa (2.5 I Spraying pressure: 245 — 343 kPa
— 3.5 kg/cm2, 36 — 50 psi) (2.5 — 3.5 kg/cm2, 36 — 50 psi)
7 Drying Not required. Dry at normal temperature [10 min. or
more at 20°C (68°F)]. In half-dried
condition, avoid dust, dirt.
8 Top coat paint (II) Not required. Apply a clear coat to parts with top coat
paint (I), three times, at 5 — 7 minute
intervals.
I Paint in use
Metallic paint
Hardener PB
Thinner T-301
I Mixing ratio: Clear vs. hardener = 6:1
I Viscosity: 14 — 16 sec/20°C (68°F)
I Film thickness: 25 — 30µ
I Spraying pressure: 245 — 343 kPa
(2.5 — 3.5 kg/cm2, 36 — 50 psi)
9 Drying 60°C (140°F), 60 min. or 80°C (176°F), 30 min. If higher than 80°C (176°F), PP may
be deformed. Keep maximum temperature of 80°C (176°F).
10 Inspection Paint check.
11 Masking removal Remove masking in process No. 2.
42
SERVICE PROCEDURE [W7C0] 5-1
7. Repair Instructions for Colored PP Bumper
G5M0164
4 Surface preparation Remove dust, oil, etc. from areas to be repaired and surrounding areas, using a
suitable solvent (NRM No. 900 Precleno, white gasoline, or alcohol).
43
5-1 [W7C0] SERVICE PROCEDURE
7. Repair Instructions for Colored PP Bumper
G5M0165
6 Sanding (I) Grind beveled surface with sandpaper (#40 to #60) to smooth finish.
7 Cleaning Clean the sanded surface with the same solvent as used in Process No. 4.
8 Temporary welding Grind the side just opposite the beveled area with sandpaper (#40 to #60) and
clean using a solvent. Temporarily spot-weld the side, using a PP welding rod and
heater gun.
G5M0166
NOTE:
I Do not melt welding rod until it flows out. This results in reduced strength.
I Leave the welded spot unattended until it cools completely.
9 Welding Using a heater gun and PP welding rod, weld the beveled spot while melting the rod
and damaged area.
G5M0167
NOTE:
I Melt the sections indicated by hatched area.
I Do not melt welding rod until it flows out, in order to provide strength.
I Always keep the heater gun 1 to 2 cm (0.4 to 0.8 in) away from the welding spot.
I Leave the welded spot unattended until it cools completely.
44
SERVICE PROCEDURE [W7C0] 5-1
7. Repair Instructions for Colored PP Bumper
G5M0168
Sand the welded spot smooth with #240 sand paper.
11 Masking Mask the black substrate section using masking tape.
Recommended masking tape: Nichiban No. 533 or equivalent
12 Cleaning/ degreasing Completely clean the entire coated area, using solvent similar to that used in Pro-
cess No. 4.
13 Primer coating Apply a coat of primer to the repaired surface and its surrounding areas. Mask
these areas, if necessary.
Recommended primer: Mp/ 364 PP Primer
NOTE:
Be sure to apply one coat of primer at a spraying pressure of 245 to 343 kPa (2.5
to 3.5 kg/cm2, 36 to 50 psi) with a spray gun.
14 Leave unattended. Leave the repaired area unattended at 20°C (68°F) for 10 to 15 minutes until primer
is half-dry.
NOTE:
If dirt or dust comes in contact with the coated area, wipe it off with a cloth damp-
ended with alcohol. (Do not use thinner since the coated area tends to melt.)
15 Primer surfacer coating Apply a coat of primer surfacer to the repaired area two or three times at an interval
of 3 to 5 minutes.
Recommended surfacer:
I UPS 300 Flex Primer
I No. 303 UPS 300 Exclusive hardener
I NPS 725 Exclusive Reducer (thinner)
I Mixing ratio: 2 : 1 (UPS 300: No. 303)
I Viscosity: 12 — 14 sec/20°C (68°F)
I Coated film thickness: 40 — 50µ
16 Drying Allow the coated surface to dry for 60 minutes at 20°C (68°F) [or 30 minutes at
60°C (140°F)].
17 Sanding (III) Sand the coated surface and its surrounding areas using #400 sandpaper and
water.
18 Cleaning/ degreasing Same as Process No. 12.
19 Top coat (I) Solid color Metallic color
Use a “block” coating method. Use a “block” coating method.
I Recommended paint: I Recommended paint:
Suncryl (SC) Suncryl (SC)
No. 307 Flex Hardener No. 307 Flex Hardener
SC Reducer (thinner) SC Reducer (thinner)
I Mixing ratio: 3 : 1 I Mixing ratio: 3 : 1
(Suncryl: No. 307) (Suncryl: No. 307)
I Viscosity: 11 — 13 sec/20°C I Viscosity: 11 — 13 sec/20°C (68°F)
(68°F) I Coated film thickness: 20 — 30µ
I Coated film thickness: 40 — 50µ I Spraying thickness: 245 — 343 kPa
I Spraying thickness: 245 — 343 (2.5 — 3.5 kg/cm2, 36 — 50 psi)
kPa
(2.5 — 3.5 kg/cm2, 36 — 50 psi)
45
5-1 [W7C0] SERVICE PROCEDURE
7. Repair Instructions for Colored PP Bumper
46
SERVICE PROCEDURE [W8A0] 5-1
8. Side Protector
H5M0718A
G5M0170
2) Type C:
Protector is attached to body with clips.
Remove door inner trim, and detach protector by
pushing clip pawl from inside.
3) Type D:
Protector is attached to body with clips.
While holding end of protector by hand, force pro-
tector out.
G5M0171
47
5-1 [W9A0] SERVICE PROCEDURE
9. Front Fender
G5M0175
G5M0174
G5M0176
G5M0115
48
SERVICE PROCEDURE [W11A0] 5-1
11. Cowl Panel
G5M0544
G5M0177
5) Installation is in the reverse order of removal.
NOTE:
3) Installation is in the reverse order of removal.
Install middle clip and other clips in that order.
CAUTION:
Only use new nuts and clips.
2. REAR ARCH PROTECTOR
1) Remove clip and screws.
G5M0545
G5M0178
49
5-1 [W12A0] SERVICE PROCEDURE
12. Molding and Retainer
G5M0181
H5M0719A
3) Installation is in the reverse order of removal.
NOTE: 2) Installation is in the reverse order of removal.
Insert clips onto hooks, then fasten with screws. NOTE:
Attach all clips to grille. Align them with clip hole in
body and push them into place.
G5M0182
50
SERVICE PROCEDURE [W14A3] 5-1
14. Sunroof
A: REMOVAL
1. SUNROOF PANEL
1) Open sunroof approx. 1/3.
2) Remove clips attached to front side of sunroof
trim by pulling trim from inside of compartment.
G5M0188
G5M0186
4) Detach trim.
G5M0190
G5M0193
51
5-1 [W14B0] SERVICE PROCEDURE
14. Sunroof
G5M0194
G5M0195
G5M0196
G5M0197
52
SERVICE PROCEDURE [W14B0] 5-1
14. Sunroof
G5M0201
G5M0205
Difference in height between roof panel and
sunroof panel: 9) Install roof trim.
0±1.0 mm (0±0.039 in) 10) Install garnish.
NOTE:
Place garnish joint at rear center of body.
G5M0202
7) Tighten bolts.
G5M0204
53
5-1 [W15A1] SERVICE PROCEDURE
15. Rear Spoiler
G5M0616
G5M0617
H5M0673A
54
DIAGNOSTICS [K100] 5-1
1. Sunroof
1. Sunroof
Entry of water into compartment (1) Check roof panel and sunroof panel for improper or poor sealing.
(2) Check drain tube for clogging.
(3) Check sunroof frame seal and body for improper fit.
Booming noise (1) Check roof panel and roof panel for improper clearance.
(2) Check sunroof trim and roof trim for improper clearance.
Abnormal motor noise (1) Check motor for looseness.
(2) Check gears and bearings for wear.
(3) Check cable for wear.
(4) Check cable pipe for deformities.
Failure of sunroof to operate (Motor operates properly.) (1) Check guide rail for foreign particles.
(2) Check guide rail for improper installation.
(3) Check parts for mutual interference.
(4) Check cable slider for improper clinching.
(5) Check cable for improper installation.
(6) Check clutch adjustment nut for improper tightness.
Motor does not rotate or rotates improperly. (Use sun- (1) Check fuse for blowout.
roof wrench to check operation.) (2) Check switch for improper function.
(3) Check motor for incorrect terminal voltage.
(4) Check relay for improper operation.
(5) Check poor grounding system.
(6) Check cords for discontinuity and terminals for poor connections.
(7) Check limit switch for improper operation.
55
5-1 DIAGNOSTICS
MEMO:
56
DOORS AND WINDOWS 5-2
Page
S SPECIFICATIONS AND SERVICE DATA..........................................................2
1. Door Alignment............................................................................................2
C COMPONENT PARTS .......................................................................................4
1. Front Door ...................................................................................................4
2. Rear Door....................................................................................................5
3. Fixed Glass .................................................................................................6
4. Front Door Glass.........................................................................................7
5. Rear Door Glass .........................................................................................8
6. Rear Gate and Glass ..................................................................................9
7. Door Lock Assembly .................................................................................10
8. Door Trim...................................................................................................12
9. Weatherstrip ..............................................................................................13
W SERVICE PROCEDURE .................................................................................14
1. Procedure Chart for Removing and Installing Door and Related Parts ...14
2. Door...........................................................................................................15
3. Rear Gate..................................................................................................27
4. Procedure Chart for Removal and Installing Window Glass ....................31
5. Windshield .................................................................................................32
6. Rear Window Glass ..................................................................................35
7. Rear Quarter Glass ...................................................................................38
K DIAGNOSTICS.................................................................................................41
1. Door Glass ................................................................................................41
2. Door Lock System.....................................................................................44
3. Power Window ..........................................................................................44
5-2 [S1A0] SPECIFICATIONS AND SERVICE DATA
1. Door Alignment
1. Door Alignment
A: SEDAN AND WAGON MODEL
G5M0485
2
SPECIFICATIONS AND SERVICE DATA [S1B0] 5-2
1. Door Alignment
B: COUPE MODEL
G5M0637
3
5-2 [C100] COMPONENT PARTS
1. Front Door
1. Front Door
H5M0903A
4
COMPONENT PARTS [C200] 5-2
2. Rear Door
2. Rear Door
H5M0904A
(1) Weatherstrip (7) Seating cover Tightening torque: N·m (kg-m, ft-lb)
(2) Stabilizer (Outer) (8) Door panel
T1: 7.4±2.0 (0.75±0.2, 5.4±1.4)
(3) Stabilizer (Inner) (9) Lower hinge
T2: 25±3 (2.5±0.3, 18.1±2.2)
(4) Stopper (10) Upper hinge
T3: 29±5 (3.0±0.5, 21.7±3.6)
(5) Knock pin
(6) Checker
5
5-2 [C300] COMPONENT PARTS
3. Fixed Glass
3. Fixed Glass
H5M0698C
(1) Windshield glass (4) Molding (7) Rear quarter glass (Coupe)
(2) Dam rubber (5) Rear window glass (8) Fastener
(3) Locate pin (6) Rear quarter glass (Wagon)
6
COMPONENT PARTS [C400] 5-2
4. Front Door Glass
H5M0905A
(1) Door sash (Front) (6) Regulator handle Tightening torque: N·m (kg-m, ft-lb)
(2) Glass (Except power window)
T1: 7.4±2.0 (0.75±0.2, 5.4±1.4)
(3) Door sash (Rear) (7) Retainer spring
T2: 14±4 (1.4±0.4, 10.1±2.9)
(4) Weatherstrip (Inner) (8) Regulator ASSY
(5) Regulator and motor ASSY
7
5-2 [C500] COMPONENT PARTS
5. Rear Door Glass
H5M0906A
(1) Door sash (Front) (6) Regulator handle Tightening torque: N·m (kg-m, ft-lb)
(2) Glass (Except power window)
T1: 7.4±2.0 (0.75±0.2, 5.4±1.4)
(3) Weatherstrip (Inner) (7) Retainer spring
T2: 14±4 (1.4±0.4, 10.1±2.9)
(4) Door sash (Rear) (8) Regulator ASSY
(5) Regulator and motor ASSY
8
COMPONENT PARTS [C600] 5-2
6. Rear Gate and Glass
H5M0907A
9
5-2 [C7A0] COMPONENT PARTS
7. Door Lock Assembly
H5M0908A
(1) Cover (6) Switch ASSY Tightening torque: N·m (kg-m, ft-lb)
(2) Inner remote ASSY (7) Auto-door lock actuator
T1: 6.4±2.0 (0.65±0.2, 4.7±1.4)
(3) Door outer handle
T2: 7.4±2.0 (0.75±0.2, 5.4±1.4)
(4) Striker
T3: 14±4 (1.4±0.4, 10.1±2.9)
(5) Door latch
10
COMPONENT PARTS [C7B0] 5-2
7. Door Lock Assembly
B: REAR DOOR
H5M0909A
(1) Door outer handle (6) Cover Tightening torque: N·m (kg-m, ft-lb)
(2) Door latch (7) Inner remote ASSY
T1: 6.4±2.0 (0.65±0.2, 4.7±1.4)
(3) Auto-door lock actuator
T2: 7.4±2.0 (0.75±0.2, 5.4±1.4)
(4) Striker
T3: 14±4 (1.4±0.4, 10.1±2.9)
(5) Rod holder
11
5-2 [C800] COMPONENT PARTS
8. Door Trim
8. Door Trim
H5M0928A
12
COMPONENT PARTS [C900] 5-2
9. Weatherstrip
9. Weatherstrip
H5M0700B
(1) Rear gate weatherstrip (3) Upper and side weatherstrip (6) Weatherstrip (Front door)
(Wagon only) (4) Retainer (Center)
(2) Retainer and molding (5) Weatherstrip (Rear door)
13
5-2 [W100] SERVICE PROCEDURE
1. Procedure Chart for Removing and Installing Door and Related Parts
H5M0910A
14
SERVICE PROCEDURE [W2A2] 5-2
2. Door
B5M0329C
G5M0486
Tightening torque:
29±5 N·m (3.0±0.5 kg-m, 21.7±3.6 ft-lb)
CAUTION:
Work carefully to avoid damaging door.
G5M0385
15
5-2 [W2A3] SERVICE PROCEDURE
2. Door
3) Remove gusset cover (C) and screws. I When repairing or replacing sealing cover, use
4) Remove trim panel and then disconnect con- “CEMEDINE 5430L” as sealer. It may be overlaid
nector. (models with power window) on existing sealer.
CAUTION: Sealer:
Be careful not to break clip by applying undue CEMEDINE 5430L
force. CAUTION:
I Any breaks in sealer can cause water leak-
age or entry of air and dust. Be sure sealer is
applied in a continuous line.
I Make sure sealing cover bonded areas are
free from wrinkles or openings.
4. CHECKER
1) Remove trim panel.
2) Remove sealing cover.
3) Apply a cloth to door and body to prevent dam-
aging them, and remove checker pin by driving it
upward.
CAUTION:
Be careful not to damage door and body.
H5M0929A
G5M0391
16
SERVICE PROCEDURE [W2A8] 5-2
2. Door
G5M0395
G5M0396
6) Installation is in the reverse order of removal.
7) Installation is in the reverse order of removal.
NOTE:
If rear door is equipped with child safety lock, Tightening torque (screw):
check that child lock lever moves without dragging. 6.4±2.0 N·m (0.65±0.2 kg-m, 4.7±1.4 ft-lb)
6. DOOR LATCH NOTE:
I Check operation of each part.
1) Remove trim panel. I Check each sliding part for proper lubrication.
2) Remove inner remote assembly.
3) Remove sealing cover around latch service CAUTION:
After installation, be sure lock mechanism
hole.
operates normally.
4) Completely close door glass.
5) Remove latch and actuator assembly: 7. OUTER HANDLE
(1) Turn rod holder to disconnect joint between 1) Remove trim panel.
key lock and rod. 2) Remove sealing cover.
(2) Turn rod holder to disconnect joint between 3) Detach door latch rod from outer handle and
outer handle and rod. key lock.
(3) Turn rod holder to disconnect joint between 4) Loosen nut securing outer handle and then
crank and rod. remove outer handle from outside.
CAUTION:
Be careful not to damage door.
G5M0397
G5M0398
17
5-2 [W2A9] SERVICE PROCEDURE
2. Door
6) Remove key lock from outer handle. 2) Loosen screw one complete rotation, and
7) Installation is in the reverse order of removal. adjust opening/closing direction of door using a
NOTE: hammer covered with a cloth.
Install so that key slot in key lock comes to center CAUTION:
of hole in outer handle. Be careful not to damage striker.
9. GUSSET Hinge tightening torque (body side):
1) Be sure window is all the way down. 29±5 N·m (3.0±0.5 kg-m, 21.7±3.6 ft-lb)
2) Remove gusset cover. Striker tightening torque:
3) Remove trim panel. 14±4 N·m (1.4±0.4 kg-m, 10.1±2.9 ft-lb)
4) Remove door rearview mirror.
5) Remove outer weatherstrip. 2. INNER REMOTE
6) Remove sealing cover. 1) Lock the door.
NOTE: 2) Loosen bolt (A).
Be careful not to drop nuts on the “IN” side. 3) Lower bell crank (B) and then tighten bolt (A).
7) Remove bolts and nuts which secure gusset.
Tightening torque: Bolt
3±3 N·m (1.3±0.3 kg-m, 9.4±2.2 ft-lb)
Tightening torque: Nut
7.4±2.0 N·m (0.75±0.2 kg-m, 5.4±1.4 ft-lb)
H5M0911A
G5M0399
B: ADJUSTMENT
1. DOOR ASSEMBLY
1) Using ST, loosen bolts securing upper and
lower hinges to body, and adjust fore-and-aft and
vertical alignment of door.
ST 925610000 DOOR HINGE WRENCH
G5M0487
18
SERVICE PROCEDURE [W2B3] 5-2
2. Door
H5M0912A
19
5-2 [W2B4] SERVICE PROCEDURE
2. Door
H5M0697B
20
SERVICE PROCEDURE [W2B4] 5-2
2. Door
H5M0728B
21
5-2 [W2B4] SERVICE PROCEDURE
2. Door
3) Lower door glass 10 to 15 mm (0.39 to 0.59 in) 3) If glass tilts to far rearward, loosen adjusting nut
from fully closed position. While applying outward (0C) and adjust glass to be parallel with center
pressure (load) to upper edge of glass above mid- pillar, then after adjustment, tighten adjusting nut
point of two outer stabilizers, press inner stabilizer (0C).
until it just touches the glass, then secure it. Tightening torque:
Load: F 7.4±2.0 N·m (0.75±0.2 kg-m, 5.4±1.4 ft-lb)
Front door glass 44.1±4.9 N (4.5±0.5 kg,
9.9±1.1 lb)
Rear door glass 44.1±4.9 N (4.5±0.5 kg,
9.9±1.1 lb)
H5M0687A
G5M0421
G5M0639
22
SERVICE PROCEDURE [W2B4] 5-2
2. Door
2) Make sure of improper clearance. 2) Increase the upward travel of window glass up
to the position where upper edge just touches
weatherstrip surface with door closed.
H5M0688A
G5M0511
H5M0692B H5M0693A
I Fit adjustment
Door glass fit is adjusted by displacing the glass
front edge with a stabilizer.
NOTE:
Before adjusting glass fit, visually check to deter-
mine relative adjusting positions of retainer and
molding (on roof side) and glass surface.
H5M0691A
23
5-2 [W2B4] SERVICE PROCEDURE
2. Door
1) Alternately adjust two rear sash adjusting bolts 2) Adjust front sash fit using rear sash adjustment
(0A) until dimensions are obtained. procedure outlined in the former procedure as a
CAUTION: guide. Two adjusting bolts must be adjusted by the
Do not loosen two adjusting nuts (A) at the same amount.
same time, as this moves sash fore and aft, NOTE:
creating unequal glass- to-sash clearance. Dur- I Front and rear sash adjustment procedures are
ing adjustment, loosen only one nut and keep basically the same; however, the amount of adjust-
the other tightened. ment is not always the same due to alignment dis-
persion of individual doors.
I Adjust front and rear sash fit, as equally as pos-
sible. Otherwise, effort required to operate regula-
tor may increase.
3) After adjusting front sash-to-glass fit, secure
front sash.
H5M0693A
NOTE:
Always adjust two rear sash adjusting bolts (0A) by
the same amount. Do not adjust the adjusting bolts
with sash bracket inclined toward inner panel, as
this increases effort required to operate regulator.
G5M0510
24
SERVICE PROCEDURE [W2B5] 5-2
2. Door
H5M0913A
25
5-2 [W2C1] SERVICE PROCEDURE
2. Door
H5M0693A
G5M0472
H5M0695A
H5M0696A
2) If any clearance is not correct, adjust affected I After clearance adjustment, make sure that
parts. Re-check that all clearances are correct. all adjusting bolts and nuts are tightened.
CAUTION:
I Repeatedly adjust parts until all clearances
are correct.
26
SERVICE PROCEDURE [W3A1] 5-2
3. Rear Gate
G5M0474
G5M0400
27
5-2 [W3A1] SERVICE PROCEDURE
3. Rear Gate
5) If disconnected harness is re-used, tie connec- 9) Remove the bolts which hold rear gate to hinge
tor with a string and place on the upper side of rear and then detach rear gate.
gate for ready use.
CAUTION:
o not forcefully pull cords, lead wires, etc.
since damage may result; carefully extract
them in a wavy motion while holding connec-
tors.
G5M0403
G5M0490
G5M0402
G5M0491
28
SERVICE PROCEDURE [W3A6] 5-2
3. Rear Gate
G5M0406
G5M0405
29
5-2 [W3A6] SERVICE PROCEDURE
3. Rear Gate
G5M0493
30
SERVICE PROCEDURE [W4A0] 5-2
4. Procedure Chart for Removal and Installing Window Glass
H5M0914A
31
5-2 [W4A1] SERVICE PROCEDURE
5. Windshield
G5M0418
32
SERVICE PROCEDURE [W5B0] 5-2
5. Windshield
G5M0412
G5M0494
33
5-2 [W5B0] SERVICE PROCEDURE
5. Windshield
G5M0495
7) Application of adhesive:
(1) Cut nozzle tip of cartridge as shown in fig-
ure.
G5M0496
G5M0417
34
SERVICE PROCEDURE [W6A2] 5-2
6. Rear Window Glass
G5M0410
NOTE:
A matching pin is cemented to the corners of glass
on compartment side. Use a piano wire when cut-
ting each pin.
G5M0412
2. WAGON MODEL
NOTE:
It is impossible to remove the molding from the
glass. If molding is broken, replace rear glass.
1) Remove rear wiper and rear gate trim.
2) Disconnect connector from rear defogger termi-
nal.
3) Remove high mount stop light.
4) Remove glass in same manner as for wind-
shield.
CAUTION:
Be careful not to damage molding re-installing
the old rear window glass using a piano wire.
35
5-2 [W6B1] SERVICE PROCEDURE
6. Rear Window Glass
G5M0412
B: INSTALLATION
1. SEDAN AND COUPE MODEL
1) Install glass in same manner as in windshield.
2) Firstly, press-fit molding upper, then lower and
lastly, roof molding.
G5M0411
36
SERVICE PROCEDURE [W6B2] 5-2
6. Rear Window Glass
2. WAGON MODEL
1) Install rear gate trim.
2) Install glass in same manner as windshield.
G5M0413
3) About one hour after installation, test for water 5) Install high mount stop light and rear wiper.
leakage. Leave vehicle for 24 hours before using
it.
4) Connect rear defogger connections.
37
5-2 [W7A1] SERVICE PROCEDURE
7. Rear Quarter Glass
G5M0416
2. COUPE MODEL
1) Remove rear quarter molding.
G5M0627
2) Remove glass in same manner as in windshield.
G5M0628
38
SERVICE PROCEDURE [W7B1] 5-2
7. Rear Quarter Glass
G5M0414
G5M0495
39
5-2 [W7B2] SERVICE PROCEDURE
7. Rear Quarter Glass
G5M0629
40
DIAGNOSTICS [K100] 5-2
1. Door Glass
1. Door Glass
Condition Apparent cause/Correction
Glass in fully 1) Glass runs out of weatherstrip lip when considerable hand I Insufficient upward travel of glass
closed position pressure is applied to it from inside. Increase upward travel of glass.
G5M0502
(This condition may cause wind/booming noise during
high- speed operation.)
2) Clearance exists between glass and weatherstrip when light I Insufficient glass-to-door weatherstrip
hand pressure is applied to it at center and rear pillar locations. contact
Check stabilizer and glass for proper
contact.
Increase contact using upper sash
adjustment bolt.
I Insufficient glass-to-door weatherstrip
contact
Check stabilizer and glass for proper
contact.
Increase contact using upper sash
G5M0503 adjustment bolt.
(This condition may cause wind noise and/or water
leakage.)
3) Adjust door glass so that it is aligned with door rearview I Window is not properly adjusted in
mirror gusset up-down/fore-aft direction. Adjust win-
dow. If necessary, move “B” channel for
regulator to eliminate window “tilt”.
I Gusset is not properly adjusted in
fore-aft direction. Adjust gusset after
loosing all bolts and nuts witch tighten-
ing it.
H5M0672A
41
5-2 [K100] DIAGNOSTICS
1. Door Glass
G5M0505
(This condition increases wind/booming noise,
leakage and/or effort required to close door.)
2) Edge of glass contacts retainer when door is fully closed. I Improper glass-to-center pillar weath-
erstrip or excessive glass contact to
weatherstrip
Excessive adjusting in contact to weath-
erstrip causes rear edge of glass to tilt
inboard closer to center pillar. Adjust
rear sash adjustment bolt to reduce
glass contact to weatherstrip.
G5M0506
Raise or lower 1) Considerable effort or time is required to operate regulator. I Sliding resistance increased due to
window glass Standard operating effort: high stabilizer-to-glass contact pressure
I Entire up-down travel except for point 5 mm (0.20 in) below Reduce contact by mounting inner sta-
fully closed position: 29.4 N (3.0 kg, 6.6 lb) bilizer to inside of the car.
I Point 5 mm (0.20 in) below fully closed position: 45.0 N (4.5 I High glass-to-windshield contact
kg, 10.12 lb) pressure
Reduce contact using upper sash
adjustment bolt.
I Unequal contact adjustment stroke
between front and rear sashes
Set to equal stroke.
I Tilt of rear sash adjustment bolt
mounting bracket
Correct tilt of bracket so it is parallel to
inner panel.
G5M0507
42
DIAGNOSTICS [K100] 5-2
1. Door Glass
G5M0508
3) Glass tilts forward by more than 2 mm (0.08 in). I Excessive glass contact pressure or
improper in-out alignment
1) Lower regulator “B” channel to tilt
glass rearward.
2) Reduce contact pressure using
upper sash adjustment bolt.
G5M0509
(Excessive tilt of glass forward is due to excessive
glass “contact” which causes reaction of center pillar weather-
strip.) Glass can be tilted forward due to increase in reaction of
shoulder weatherstrip or free play between sash and roller. Tak-
ing these symptoms into account, glass should be aligned.
43
5-2 [K200] DIAGNOSTICS
2. Door Lock System
3. Power Window
Symptom
All windows do not The window of driver The window of The window of
move. side does not move. driver side does each passenger
not move “AUTO” sides does not
down. move.
Battery (1)
Fuse in fuse box (2)
Circuit breaker and relay (3)
Main switch (4) (1) (1) (1)
Sub switch of each passenger sides (2)
Motor of driver side (2) (2)
Motor of each passenger sides (3)
Regulator assembly of each windows (4)
Power supply line of main switch (5) (3) (3)
Ground line (6)
Haness and connector (7) (4) (4) (5)
(): Figures in a parenthesis refer to diagnostics procedures.
44
SEAT, SEAT BELTS AND
INTERIOR 5-3
Page
C COMPONENT PARTS .......................................................................................2
1. Front Seat....................................................................................................2
2. Rear Seat ....................................................................................................3
3. Front Seat Belt ............................................................................................5
4. Rear Seat Belt.............................................................................................6
5. Inner Accessories ........................................................................................7
6. Inner Trim ....................................................................................................8
W SERVICE PROCEDURE ...................................................................................9
1. Front Seat....................................................................................................9
2. Rear Seat ..................................................................................................10
3. Front Seat Belt ..........................................................................................12
4. Rear Seat Belt...........................................................................................13
5. Inner Trim Panel........................................................................................15
5-3 [C100] COMPONENT PARTS
1. Front Seat
1. Front Seat
H5M0701B
(1) Front seat ASSY (5) Outer slide rail ASSY Tightening torque: N·m (kg-m, ft-lb)
(2) Inner belt ASSY
T1: 23±5 (2.3±0.5, 16.6±3.6)
(3) Inner slide rail ASSY
T2: 29±7 (3.0±0.7, 21.7±5.1)
(4) Connect wire
T3: 52±10 (5.3±1.0, 38±7)
2
COMPONENT PARTS [C2A0] 5-3
2. Rear Seat
2. Rear Seat
A: SEDAN AND COUPE MODEL
H5M0915A
(1) Rear seat reinforcement (4) Rear cushion Tightening torque: N·m (kg-m, ft-lb)
(2) Hook
T1: 10±3 (1.0±0.3, 7.2±2.2)
(3) Backrest
T2: 25±7 (2.5±0.7, 18.1±5.1)
3
5-3 [C2B0] COMPONENT PARTS
2. Rear Seat
B: WAGON MODEL
H5M0916A
(1) Hinge bracket (RH) (8) Hinge Tightening torque: N·m (kg-m, ft-lb)
(2) Hinge bracket (RH) (9) Hinge cover
T1: 2±1 (0.2±0.1, 1.4±0.7)
(3) Backrest (LH) (10) Backrest center hinge
T2: 5.9±1.5 (0.6±0.15, 4.3±1.1)
(4) Striker (11) Belt pocket
T3: 10±3 (1.0±0.3, 7.2±2.2)
(5) Hinge bracket (LH) (12) Pad ASSY pocket
(6) Lock hinge (13) Hook T4: 25±7 (2.5±0.7, 18.1±5.1)
(7) Rear cushion
4
COMPONENT PARTS [C300] 5-3
3. Front Seat Belt
H5M0917A
(1) Adjuster anchor ASSY (5) Outer belt ASSY Tightening torque: N·m (kg-m, ft-lb)
(2) Through cover
T1: 13±3 (1.3±0.3, 9.4±2.2)
(3) Webbing guide
T2: 35±13 (3.6±1.3, 26±9)
(4) Inner belt ASSY
5
5-3 [C400] COMPONENT PARTS
4. Rear Seat Belt
H5M0702B
(1) Webbing cover (RH) (6) Through cap (RH) Tightening torque: N·m (kg-m, ft-lb)
(2) Webbing cover (LH) (7) Through cap (LH)
T1: 13±3 (1.3±0.3, 9.4±2.2)
(3) Outer seat belt (LH) (8) Lap anchor cover (LH)
T2: 35±13 (3.6±1.3, 26±9)
(4) Center seat belt (9) Lap anchor cover (RH)
(5) Outer seat belt (RH)
6
COMPONENT PARTS [C500] 5-3
5. Inner Accessories
5. Inner Accessories
H5M0918A
7
5-3 [C600] COMPONENT PARTS
6. Inner Trim
6. Inner Trim
H5M0703B
(1) Front pillar upper trim (9) Front pillar upper trim (17) Trim bracket
(2) Rear pillar upper trim (10) Rear quarter upper front trim (18) Rear quarter lower trim
(3) Rear pillar lower trim (11) Rear rail trim (19) Side sill rear upper cover
(4) Side sill rear upper cover (12) Rear quarter upper rear trim (20) Side sill rear lower cover
(5) Side sill rear lower cover (13) Rear gate trim (21) Center pillar lower trim
(6) Center pillar lower trim (14) Rear skirt trim (22) Side sill front lower cover
(7) Side sill front lower cover (15) Lamp cover (23) Front pillar lower trim
(8) Front pillar lower trim (16) Cover
8
SERVICE PROCEDURE [W1B0] 5-3
1. Front Seat
H5M0704
H5M0704
2) Pull reclining lever back to fold backrest all the
way forward. Pull slide adjuster lever and move
2) Pull reclining lever back to fold backrest all the lower slide rail all the way backward.
way forward. While pulling slide adjuster lever, 3) Position seat in compartment and align the
move seat all the way forward. holes on the seat with the holes on the car body
3) Disconnect connector under driver’s seat. side.
4) Remove bolt cover at rear end of slide rail. 4) Secure the front of seat using inward and out-
5) Remove bolts securing seat rear. ward bolts (A) and (B) in that order.
5) While pulling slide adjuster lever, move seat all
the way forward.
6) Secure the rear of seat using inward and out-
ward bolts (C) and (D).
H5M0705
9
5-3 [W2A1] SERVICE PROCEDURE
2. Rear Seat
2. Rear Seat 4) Remove the bolt and then remove backrest (LH
side).
A: REMOVAL 5) Remove the bolt and then remove backrest (RH
side) from hinge bracket.
1. SEDAN AND COUPE MODEL
1) Remove bolts securing hinges (located at front
of cushion) to body.
2) Slightly raise front of cushion while pushing
down on cushion in the direction of “C”. With cush-
ion held in that position, move it forward until it is
unhooked.
B5M0333C
B: INSTALLATION
G5M0345 1. SEDAN AND COUPE MODEL
3) Remove bolts securing lower portion of back- 1) Before installing backrest, ensure that trim
rest to body. panel, insulator and seat belt are properly installed.
4) Lift rear seat backrest in direction “A” until it is 2) Transfer outer seat belt webbing to front of
released from upper hooks. backrest and fold backrest forward. Attach seat
belt webbing to upper hooks (2 places), and move
2. WAGON MODEL pillow in the direction of “B” until backrest is aligned
1) Remove bolts securing hinges (located at front with lower mounting holes in body.
of seat) to body.
G5M0348
10
SERVICE PROCEDURE [W2B2] 5-3
2. Rear Seat
4) Slightly raise front section of cushion while 7) Install hinges to front of cushion and tighten
pushing down on cushion in the direction of “C”. with bolts. Check that lock properly engages.
With cushion held in that position, attach rear sec-
tion of cushion to hooks at lower frame location.
5) Secure front of cushion to body with bolts.
CAUTION:
I Before installing seat, ensure that seat belt is
placed on cushion.
I Confirm that winding of three-point type seat
belt can operate regularly.
G5M0353
G5M0352
11
5-3 [W3A1] SERVICE PROCEDURE
3. Front Seat Belt
G5M0640
G5M0354
G5M0355
G5M0642
12
SERVICE PROCEDURE [W4A1] 5-3
4. Rear Seat Belt
G5M0356
G5M0359
G5M0357
8) Remove belt from outlet in rear quarter along
slit.
5) Installation is in the reverse order of removal. 9) Remove inner bolts which secure outer seat.
10) Remove washer from bolt, then remove bolt,
belt assembly, and anchor plate bracket.
11) Remove inner bolts (2 places) from center
seat.
G5M0360
13
5-3 [W4A2] SERVICE PROCEDURE
4. Rear Seat Belt
13) Installation is in the reverse order of removal. I Ensure that seat belts are free from twisting
Ensure that seat belt is properly reeled on and off after installation.
after installation of ELR. I Ensure that tongues, buckles and belts are
properly placed on seat.
CAUTION:
I Be extremely careful not to confuse center
seat anchor plate with outer seat anchor plate
during installation.
I Ensure that seat belts are free from twisting
after installation.
I Ensure that tongues, buckles and belts are
properly placed on seat.
2. WAGON MODEL
1) Raise rear cushion.
2) Remove rear backrest from body.
3) Remove shoulder anchor cover and anchor
bolt.
4) Remove lower portion of rear quarter trim.
5) Remove lap anchor cover and bolt.
G5M0361
G5M0362
14
SERVICE PROCEDURE [W5A5] 5-3
5. Inner Trim Panel
G5M0365
H5M0707
15
5-3 [W5A5] SERVICE PROCEDURE
5. Inner Trim Panel
G5M0368
16
INSTRUMENT PANEL 5-4
Page
C COMPONENT PARTS .......................................................................................2
1. Instrument Panel .........................................................................................2
W SERVICE PROCEDURE ...................................................................................3
1. Instrument Panel ......................................................................3
5-4 [C100] COMPONENT PARTS
1. Instrument Panel
1. Instrument Panel
H5M0931A
2
SERVICE PROCEDURE [W1A0] 5-4
1. Instrument Panel
S5M0046
S5M0047A
S5M0048A
S5M0044A
3
5-4 [W1A0] SERVICE PROCEDURE
1. Instrument Panel
11) Remove two bolts and lower steering column. 13) Disconnect temperature control cable and
mode control cable from heater unit then discon-
nect recirc control cable from intake unit.
NOTE:
Do not move switch and link when installing.
G5M0278
S5M0049A
4
SERVICE PROCEDURE [W1A0] 5-4
1. Instrument Panel
14) Disconnect harness connectors and then remove the installing bolts and nuts.
CAUTION:
Be sure to hold socket section and not harness when disconnecting.
NOTE:
Put matching mark, if necessary, for easy reassembly.
S5M0050A
5
5-4 [W1B0] SERVICE PROCEDURE
1. Instrument Panel
S5M0052A
G5M0602
6
SUPPLEMENTAL RESTRAINT
SYSTEM 5-5
Page
C COMPONENT PARTS .......................................................................................2
1. SRS Airbag..................................................................................................2
W SERVICE PROCEDURE ...................................................................................3
1. General........................................................................................................3
2. Inspection and Replacement Standards .....................................................5
3. Airbag Module .............................................................................................7
4. Main Harness ............................................................................................10
5. Airbag Control Module...............................................................................11
6. Combination Switch...................................................................................12
7. Front Sub Sensor ......................................................................................13
5-5 [C100] COMPONENT PARTS
1. SRS Airbag
1. SRS Airbag
H5M0932A
(1) Combination switch ASSY with (6) Airbag control module Tightening torque: N·m (kgf-m, ft-lb)
roll connector (7) Airbag main harness
T1: 4.4±1.5 (0.45±0.15, 3.3±1.1)
(2) TORXTbolt T30 (8) Front sub sensor harness (RH)
T2: 7.4±2.0 (0.75±0.2, 5.4±1.4)
(3) Airbag module ASSY (Driver) (9) Front sub sensor harness (LH)
T3: 10±2 (1.0±0.2, 7.2±1.4)
(4) Airbag module ASSY (Passen- (10) Front sub sensor (RH)
ger) (11) Front sub sensor (LH) T4: 20±4 (2.0±0.4, 14.5±2.9)
(5) TORXT bolt T40 T5: 25±2 (2.5±0.2, 18.1±1.4)
2
SERVICE PROCEDURE [W1A0] 5-5
1. General
G5M0293
G5M0291
G5M0292
G5M0294
3
5-5 [W1A0] SERVICE PROCEDURE
1. General
I Do not drop the airbag modulator parts, subject I Install the wire harness securely with the speci-
it to high temperatures over 90°C (194°F), or apply fied clips so as to avoid interference or jamming
oil, grease, or water to it; otherwise, the internal with other parts.
parts may be damaged and its reliability greatly
lowered.
G5M0297
G5M0295
G5M0296
4
SERVICE PROCEDURE [W2F2] 5-5
2. Inspection and Replacement Standards
5
5-5 [W2G1] SERVICE PROCEDURE
2. Inspection and Replacement Standards
S5M0213A
G5M0311
6
SERVICE PROCEDURE [W3A0] 5-5
3. Airbag Module
G5M0302
G5M0300
G5M0301
7
5-5 [W3A1] SERVICE PROCEDURE
3. Airbag Module
G5M0604
1. DRIVER SIDE
1) Set front wheels in straight ahead position.
2) Turn ignition switch off.
3) Disconnect ground cable from battery and wait
for at least 20 seconds before starting work.
8
SERVICE PROCEDURE [W3A2] 5-5
3. Airbag Module
4) Using TORXT BIT T30, remove two TORXT 5) Remove seven bolts and then carefully remove
bolts. airbag module.
H5M0662A S5M0215
5) Disconnect airbag connector on back of airbag 6) Refer to “CAUTION:” for handling of a removed
module. <Ref. to 5-5 [M2F2].> airbag module. <Ref. to 5-5 [W3A0].>
7) Installation is in the reverse order of removal.
CAUTION:
Do not allow harness and connectors to inter-
fere or get caught with other parts.
H5M0664
S5M0214
9
5-5 [W4A0] SERVICE PROCEDURE
4. Main Harness
G5M0312
S5M0216
S5M0217A
10
SERVICE PROCEDURE [W5A0] 5-5
5. Airbag Control Module
G5M0322
G5M0312
I If the airbag control module is deformed, or
5) Remove instrument panel console. <Ref. to 5-4
if water damage is suspected, replace the air-
[W1A0].>
bag control module with a new genuine part.
6) Disconnect connector from airbag control mod-
ule.
7) Using T40 TORXT bit (Tamper resistant type),
remove four TORXT bolts in numerical sequence
shown in figure. Discard the old TORXT bolts.
CAUTION:
Use new TORXT bolts during re-assembly.
G5M0323
S5M0219A
G5M0324
11
5-5 [W6A0] SERVICE PROCEDURE
6. Combination Switch
G5M0312
B: ADJUSTMENT
1. CENTERING ROLL CONNECTOR
Before installing steering wheel, make sure to cen-
ter roll connector built into combination switch.
1) Make sure that front wheels are positioned
straight ahead.
2) Install steering gearbox, steering shaft and
H5M0662A combination switch properly. Turn roll connector
pin (A) clockwise until it stops.
6) Disconnect airbag connector on back of airbag
3) Then, back off roll connector pin (A) approxi-
module. Remove airbag module, and place it with
mately 2.65 turns until “G” marks aligned.
pad side facing upward. <Ref. to 5-5 [W3A0].>
H5M0663B
H5M0664
12
SERVICE PROCEDURE [W7A1] 5-5
7. Front Sub Sensor
G5M0291
G5M0310
13
5-5 [W7A2] SERVICE PROCEDURE
7. Front Sub Sensor
4) Disconnect airbag connector (AB3) and (AB8) 8) Remove wiring harness clips.
below steering column.
CAUTION:
Do not reconnect airbag connector at steering
column until front sub sensors are securely re-
installed.
G5M0315
G5M0312
G5M0316
B5M0518
B5M0518
14
SERVICE PROCEDURE [W7A2] 5-5
7. Front Sub Sensor
B5M0519
15
5-5 SERVICE PROCEDURE
MEMO:
16
SUPPLEMENTAL RESTRAINT
SYSTEM 5-5
Page
T DIAGNOSTICS ...................................................................................................2
1. Electrical Components Location..................................................................2
2. Schematic....................................................................................................3
3. Tools for Diagnostics ...................................................................................4
4. Diagnostics Chart for On-board Diagnostic System ...................................9
5. Diagnostics Chart with Trouble Code .......................................................13
5-5 [T100] SUPPLEMENTAL RESTRAINT SYSTEM
1. Electrical Components Location
H5M0934A
2
SUPPLEMENTAL RESTRAINT SYSTEM [T200] 5-5
2. Schematic
2. Schematic
H5M0942A
3
5-5 [T300] SUPPLEMENTAL RESTRAINT SYSTEM
3. Tools for Diagnostics
B5M0112A
4
SUPPLEMENTAL RESTRAINT SYSTEM [T3B0] 5-5
3. Tools for Diagnostics
B: TEST HARNESS I
S5M0340A
5
5-5 [T3C0] SUPPLEMENTAL RESTRAINT SYSTEM
3. Tools for Diagnostics
C: TEST HARNESS F
S5M0247A
6
SUPPLEMENTAL RESTRAINT SYSTEM [T3D0] 5-5
3. Tools for Diagnostics
D: TEST HARNESS H
B5M0553A
7
5-5 [T3E0] SUPPLEMENTAL RESTRAINT SYSTEM
3. Tools for Diagnostics
E: AIRBAG RESISTOR
The airbag resistor is used during diagnostics. The airbag resistor has the same resistance as the airbag
module and thus provides safety when used instead of the airbag module. It also makes it possible to finish,
diagnostics in less time.
B5M0114A
8
SUPPLEMENTAL RESTRAINT SYSTEM [T4B0] 5-5
4. Diagnostics Chart for On-board Diagnostic System
Perform ON-BOARD DIAGNOSTICS. <Ref. to 5-5 1) Turn ignition switch ON (with engine OFF).
2) Connect DIAG. terminal to No. 1 terminal of
[T4B0].>
diagnosis connector located inside lower cover.
: Does trouble code indicate? <Ref. to
5-5 [T5A0].>
: Repair and replace. <Ref. to 5-5
[T5O0].> Go to step 4A3.
: Repair and replace. <Ref. to 5-5
[T5P0].> Go to step 4A3.
9
5-5 [T4C0] SUPPLEMENTAL RESTRAINT SYSTEM
4. Diagnostics Chart for On-board Diagnostic System
S5M0249A
10
SUPPLEMENTAL RESTRAINT SYSTEM [T4D4] 5-5
4. Diagnostics Chart for On-board Diagnostic System
5) Remove lower cover panel <Ref. to 5-4 4D4 : CHECK AIRBAG WARNING LIGHT
[W1A0].> and connect test harness F connector ILLUMINATES.
(1F) to (AB8) with airbag resistor attached to test
harness F connector (3F).
1) Turn ignition switch to “OFF”. Disconnect bat-
tery ground cable, and wait 20 seconds.
2) Connect connector (AB8) to (AB3).
3) Remove driver’s airbag module and connect
test harness F connector (1F) to (AB7). <Ref. to
5-5 [W3A1].>
4) Connect airbag resistor to test harness F con-
nector (3F).
S5M0250A
11
5-5 [T4D5] SUPPLEMENTAL RESTRAINT SYSTEM
4. Diagnostics Chart for On-board Diagnostic System
4D5 : CHECK AIRBAG WARNING LIGHT 4D6 : CHECK AIRBAG WARNING LIGHT
ILLUMINATES. ILLUMINATES.
1) Turn ignition switch to OFF. Disconnect battery 1) Connect battery ground cable and turn ignition
ground cable, and wait 20 seconds. switch to ON.
2) Remove lower cover panel and connect test 2) Check airbag warning light illuminates.
harness F connector (1F) to (AB8) <Ref. to 5-4 NOTE:
[W1A0].> with airbag resistor attached to test har- In some cases the airbag warning light will go OFF
ness F connector (3F). after about 7 seconds but will turn ON again within
30 seconds. In this case continue diagnostics with
the basic diagnostics procedures or trouble code
procedures.
: Does airbag warning light go off after
about 7 seconds and remain off for
more than 30 seconds?
: Perform clear memory. <Ref. to 5-5
[T4C0].>
: Go to step 4D1.
S5M0250A
12
SUPPLEMENTAL RESTRAINT SYSTEM [T5A1] 5-5
5. Diagnostics Chart with Trouble Code
13
5-5 [T5A2] SUPPLEMENTAL RESTRAINT SYSTEM
5. Diagnostics Chart with Trouble Code
B5M0117A
14
SUPPLEMENTAL RESTRAINT SYSTEM [T5B1] 5-5
5. Diagnostics Chart with Trouble Code
S5M0259B
15
5-5 [T5B2] SUPPLEMENTAL RESTRAINT SYSTEM
5. Diagnostics Chart with Trouble Code
5B2 : AIRBAG MAIN HARNESS INSPEC- 5B4 : AIRBAG MAIN HARNESS INSPEC-
TION TION
Measure resistance between test harness I con- 1) Disconnect connector (AB6) from airbag control
nector (2I) and test harness F connector (3F) ter- module <Ref. to 5-5 [W5A0].>, and connect it to
minals. test harness I connector (1I).
2) Measure resistance between test harness I
Connector & terminal connector (2I) terminals and chassis ground.
(2I) No. 4 — (3F) No. 4:
Connector & terminal
(2I) No. 4 (+) — Chassis ground (−):
S5M0260B
S5M0277B
16
SUPPLEMENTAL RESTRAINT SYSTEM [T5C3] 5-5
5. Diagnostics Chart with Trouble Code
S5M0262B
17
5-5 [T5C4] SUPPLEMENTAL RESTRAINT SYSTEM
5. Diagnostics Chart with Trouble Code
S5M0278B
1) Disconnect connector (AB6) from airbag control
: Is resistance more than 200 Ω? module <Ref. to 5-5 [W5A0].>, and connect it to
test harness I connector (1I).
: Go to step 5C5. 2) Connect battery ground cable and turn ignition
: Replace airbag main harness. <Ref. to switch “ON” (engine off).
5-5 [W4A0].> 3) Measure voltage across each test harness I
connector (2I) terminal and chassis ground.
5C5 : AIRBAG MAIN HARNESS INSPEC- Connector & terminal
TION (2I) No. 4 (+) — Chassis ground (−):
S5M0280B
18
SUPPLEMENTAL RESTRAINT SYSTEM [T5E1] 5-5
5. Diagnostics Chart with Trouble Code
S5M0274B
19
5-5 [T5E2] SUPPLEMENTAL RESTRAINT SYSTEM
5. Diagnostics Chart with Trouble Code
20
SUPPLEMENTAL RESTRAINT SYSTEM [T5H1] 5-5
5. Diagnostics Chart with Trouble Code
21
5-5 [T5I0] SUPPLEMENTAL RESTRAINT SYSTEM
5. Diagnostics Chart with Trouble Code
S5M0265B
S5M0264B
22
SUPPLEMENTAL RESTRAINT SYSTEM [T5I5] 5-5
5. Diagnostics Chart with Trouble Code
5I3 : AIRBAG MAIN HARNESS INSPEC- 5I5 : FUSE NO. 11 (IN JOINT BOX) INSPEC-
TION TION
Measure resistance between each terminal of con- Make sure ignition switch is turned “OFF”, then
nectors (5A) and chassis ground. remove and visually check fuse No. 11 (in joint
box).
Connector & terminal
(5A) No. 9 (+) — Chassis ground (−):
S5M0257B
S5M0266A
: Is fuse No. 11 blown?
: Replace fuse No. 11. If fuse No. 11
: Is resistance more than 10 kΩ?
blows again, repair body harness.
: Go to step 5I4. : Repair body harness.
: Replace airbag main harness. <Ref. to
5-5 [W4A0].>
S5M0267B
23
5-5 [T5J0] SUPPLEMENTAL RESTRAINT SYSTEM
5. Diagnostics Chart with Trouble Code
S5M0253B
24
SUPPLEMENTAL RESTRAINT SYSTEM [T5J5] 5-5
5. Diagnostics Chart with Trouble Code
5J3 : AIRBAG MAIN HARNESS INSPEC- 5J5 : FUSE NO. 6 (IN JOINT BOX) INSPEC-
TION TION
Measure resistance between (5A) connector termi- 1) Turn ignition switch “OFF”.
nal and chassis ground. 2) Remove and visually check fuse No. 6 (in joint
box).
Connector & terminal
(5A) No. 1 (+) — Chassis ground (−):
S5M0257A
S5M0255A
: Is fuse No. 6 blown?
: Replace fuse No. 6 if fuse No. 6 blows
: Is resistance more than 10 kΩ?
again, repair body harness.
: Go to step 5J4. : Repair body harness.
: Replace airbag main harness. <Ref. to
5-5 [W4A0].>
S5M0256B
25
5-5 [T5K0] SUPPLEMENTAL RESTRAINT SYSTEM
5. Diagnostics Chart with Trouble Code
B5M0556B
26
SUPPLEMENTAL RESTRAINT SYSTEM [T5K7] 5-5
5. Diagnostics Chart with Trouble Code
5K4 : AIRBAG MAIN HARNESS INSPEC- 5K6 : AIRBAG MAIN HARNESS INSPEC-
TION TION
1) Disconnect connector (AB14) and (AB15), then Measure resistance across test harness I connec-
connect test harness F connector (2F) and con- tor (3I) terminal and chassis ground.
nector (AB14). Connector & terminal
2) Measure resistance between test harness I (3I) No. 2 (+) — Chassis ground (−):
connector (3I) terminal and test harness F connec-
tor (3F) terminal.
Connector & terminal
(3I) No. 2 — (3F) No. 6:
B5M0555B
B5M0556B
27
5-5 [T5K8] SUPPLEMENTAL RESTRAINT SYSTEM
5. Diagnostics Chart with Trouble Code
5K8 : FRONT SUB SENSOR HARNESS 5K9 : FRONT SUB SENSOR HARNESS
(RH) INSPECTION (RH) INSPECTION
1) Connect test harness F connector (1F) and Measure resistance between test harness F con-
connector (AB15). nector (3F) terminal and test harness H connector
2) Disconnect connector (AB16) from front sub (3H) terminal.
sensor (RH) <Ref. to 5-5 [W7A0].> and then test Connector & terminal
harness H connector (1H) and connector (AB16). (3F) No. 4 — (3H) No. 6:
3) Measure resistance between test harness F
connector (3F) terminal and test harness H con-
nector (3H) terminal.
Connector & terminal
(3F) No. 3 — (3H) No. 5:
B5M0563A
B5M0564A
28
SUPPLEMENTAL RESTRAINT SYSTEM [T5K14] 5-5
5. Diagnostics Chart with Trouble Code
5K11 : FRONT SUB SENSOR HARNESS 5K13 : FRONT SUB SENSOR (RH) INSPEC-
(RH) INSPECTION TION
Measure resistance across test harness F connec- Measure resistance across test harness H connec-
tor (3F) terminal and chassis ground. tor (3H) terminal and chassis ground.
Connector & terminal Connector & terminal
(3F) No. 4 (+) — Chassis ground (−): (3H) No. 3 (+) — Chassis ground (−):
B5M0565A B5M0567A
: Is the resistance more than 10 kΩ? : Is the resistance less than 10 kΩ?
: Go to step 5K12. : Go to step 5K14.
: Replace front sub sensor harness (RH). : Replace front sub sensor (RH). <Ref. to
5-5 [W7A0].>
<Ref. to 5-5 [W7A0].>
B5M0568A
29
5-5 [T5L0] SUPPLEMENTAL RESTRAINT SYSTEM
5. Diagnostics Chart with Trouble Code
B5M0559B
30
SUPPLEMENTAL RESTRAINT SYSTEM [T5L7] 5-5
5. Diagnostics Chart with Trouble Code
5L4 : AIRBAG MAIN HARNESS INSPEC- 5L6 : AIRBAG MAIN HARNESS INSPEC-
TION TION
1) Disconnect connector (AB11) and (AB12), then Measure resistance across test harness I connec-
connect test harness F connector (2F) and con- tor (3I) terminal and chassis ground.
nector (AB11). Connector & terminal
2) Measure resistance between test harness I (3I) No. 3 (+) — Chassis ground (−):
connector (3I) terminal and test harness F connec-
tor (3F) terminal.
Connector & terminal
(3I) No. 3 — (3F) No. 6:
B5M0559B
B5M0558B
31
5-5 [T5L8] SUPPLEMENTAL RESTRAINT SYSTEM
5. Diagnostics Chart with Trouble Code
5L8 : FRONT SUB SENSOR HARNESS (LH) 5L9 : FRONT SUB SENSOR HARNESS (LH)
INSPECTION INSPECTION
1) Connect test harness F connector (1F) and Measure resistance between test harness F con-
connector (AB12). nector (3F) terminal and test harness H connector
2) Disconnect connector (AB13) from front sub (3H) terminal.
sensor (LH) <Ref. to 5-5 [W7A0].> and then test Connector & terminal
harness H connector (1H) and connector (AB13). (3F) No. 4 — (3H) No. 6:
3) Measure resistance between test harness F
connector (3F) terminal and test harness H con-
nector (3H) terminal.
Connector & terminal
(3F) No. 3 — (3H) No. 5:
B5M0563A
B5M0564A
32
SUPPLEMENTAL RESTRAINT SYSTEM [T5L14] 5-5
5. Diagnostics Chart with Trouble Code
5L11 : FRONT SUB SENSOR HARNESS 5L13 : FRONT SUB SENSOR (LH) INSPEC-
(LH) INSPECTION TION
Measure resistance across test harness F connec- Measure resistance across test harness H connec-
tor (3F) terminal and chassis ground. tor (3H) terminal and chassis ground.
Connector & terminal Connector & terminal
(3F) No. 4 (+) — Chassis ground (−): (3H) No. 3 (+) — Chassis ground (−):
B5M0565A B5M0567A
: Is the resistance more than 10 kΩ? : Is the resistance less than 10 kΩ?
: Go to step 5L12. : Go to step 5L14.
: Replace front sub sensor harness (LH). : Replace front sub sensor (LH). <Ref. to
5-5 [W7A0].>
<Ref. to 5-5 [W7A0].>
B5M0568A
33
5-5 [T5M0] SUPPLEMENTAL RESTRAINT SYSTEM
5. Diagnostics Chart with Trouble Code
5M1 : CHECK POOR CONTACT IN CON- 2) Connect battery ground cable and turn ignition
NECTORS (AB1) AND (B31). switch “ON”, (engine off) and connect connectors
(3A) and (4A).
1) Remove front pillar lower trim (Driver side).
2) Check poor contact in connectors (AB1) and
(B31).
G5M0455
34
SUPPLEMENTAL RESTRAINT SYSTEM [T5M5] 5-5
5. Diagnostics Chart with Trouble Code
Check connector (AB6) connected to airbag con- : Does the airbag warning light come
trol module. <Ref. to 5-5 [W5A0].> on?
: Is there poor contact in connector : Go to step 5M6.
(AB6)? : Replace airbag main harness. <Ref. to
: Repair poor contact in connector (AB6). 5-5 [W4A0].>
: Go to step 5M5.
35
5-5 [T5M6] SUPPLEMENTAL RESTRAINT SYSTEM
5. Diagnostics Chart with Trouble Code
S5M0271B
S5M0269A
S5M0270A
S5M0272B
: Is resistance less than 10 Ω?
: Go to step 5M8. : Is resistance less than 10 Ω?
: Repair body grounding circuit. : Replace airbag control module. <Ref. to
5-5 [W5A0].>
: Replace airbag main harness. <Ref. to
5-5 [W4A0].>
36
SUPPLEMENTAL RESTRAINT SYSTEM [T5N3] 5-5
5. Diagnostics Chart with Trouble Code
S5M0257C
37
5-5 [T5N4] SUPPLEMENTAL RESTRAINT SYSTEM
5. Diagnostics Chart with Trouble Code
G5M0312
38
SUPPLEMENTAL RESTRAINT SYSTEM [T5O1] 5-5
5. Diagnostics Chart with Trouble Code
39
5-5 [T5O2] SUPPLEMENTAL RESTRAINT SYSTEM
5. Diagnostics Chart with Trouble Code
40
SUPPLEMENTAL RESTRAINT SYSTEM [T5P6] 5-5
5. Diagnostics Chart with Trouble Code
5P3 : SHOWERING INSPECTION TO BODY 5P5 : FUSE NO. 11 (IN JOINT BOX), AIR-
BAG MAIN HARNESS, BODY HAR-
NESS VIBRATION INSPECTION
Spray water on vehicle body.
CAUTION:
Conduct vibration inspection on fuse No. 11, airbag
Do not directly spray water on airbag compo-
main harness and body harness.
nents.
CAUTION:
NOTE:
Do not shake or vibrate airbag control module.
If leaks are noted, also check wiring harnesses as
water may leak along them and wet airbag connec- NOTE:
tors. Gently shake each part.
: Do fuse No. 11, airbag main harness
or body harness malfunction again
when shaking?
: Replace faulty airbag component parts.
: Go to step 5P6.
41
5-5 [T5P7] SUPPLEMENTAL RESTRAINT SYSTEM
5. Diagnostics Chart with Trouble Code
42
ENGINE ELECTRICAL SYSTEM 6-1
Page
S SPECIFICATIONS AND SERVICE DATA..........................................................2
1. Specifications ..............................................................................................2
C COMPONENT PARTS .......................................................................................3
1. Starter..........................................................................................................3
2. Generator ....................................................................................................4
3. Ignition System............................................................................................5
W SERVICE PROCEDURE ...................................................................................6
1. Starter..........................................................................................................6
2. Generator ..................................................................................................12
3. Spark Plug.................................................................................................17
4. Ignition Coil and Ignitor Assembly.............................................................23
5. Spark Plug Cord........................................................................................24
K DIAGNOSTICS.................................................................................................25
1. Starter........................................................................................................25
2. Generator ..................................................................................................26
6-1 [S100] SPECIFICATIONS AND SERVICE DATA
1. Specifications
1. Specifications
Item Designation
Type Reduction type
MT AT
Model
M000T81681 M001T84481
Manufacturer MITSUBISHI
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 characteris- Current 90 A or less
tics Rotating
Starter 3,000 rpm or more
speed
Voltage 8V 7.7 V
Current 280 A or less 300 A or less
Load characteristics Torque 8.5 N·m (0.87 kg-m, 6.27 ft-lb) 9.8 N·m (1.00 kg-m, 7.24 ft-lb)
Rotating
980 rpm or more 1,000 rpm or more
speed
Voltage 4V
Current 780 A or less 980 A or less
Lock characteristics
17.6 N·m (1.80 kg-m, 13.0 ft-lb) or
Torque 23 N·m (2.3 kg-m, 17 ft-lb) or more
more
Type Rotating-field three-phase type, Voltage regulator built-in type
Model A2TB2991
Manufacturer MITSUBISHI
Voltage and output 12 V — 75 A
Polarity on ground side Negative
Generator Rotating direction Clockwise (when observed from pulley side)
Armature connection 3-phase Y-type
1,500 rpm — 30 A or more
Output current 2,500 rpm — 64 A or more
5,000 rpm — 76 A or more
Regulated voltage 14.5+0.3/−0.4 V [20°C (68°F)]
Model FH0137-01R
Manufacturer DEMCO
Ignition coil
Primary coil resistance 0.73 Ω±10%
and ignitor
assembly Secondary coil resistance 12.8 kΩ±15%
Insulation resistance between
More than 10 MΩ
primary terminal and case
Type and manufac- Standard RC10YC4 .......... CHAMPION
turer Alternate BKR5E-11 .......... NGK
Spark plug
Thread size mm 14, P = 1.25
Spark gap mm (in) 1.0 — 1.1 (0.039 — 0.043)
2
COMPONENT PARTS [C100] 6-1
1. Starter
1. Starter
H6M0492B
3
6-1 [C200] COMPONENT PARTS
2. Generator
2. Generator
H6M0493B
4
COMPONENT PARTS [C300] 6-1
3. Ignition System
3. Ignition System
S6M0329A
(1) Spark plug (4) Spark plug cord (#2, #4) Tightening torque: N·m (kg-m, ft-lb)
(2) Spark plug cord (#1, #3)
T: 22±2 (2.2±0.2, 15.9±1.4)
(3) Ignition coil and ignitor ASSY
5
6-1 [W1A1] SERVICE PROCEDURE
1. Starter
G2M0309
G2M0309
2. 2500 cc MODEL
B2M1679 1) Disconnect battery ground cable.
3) Disconnect connector and terminal from starter.
G6M0095
S6M0002A
(A) Terminal
(B) Connector
6
SERVICE PROCEDURE [W1B1] 6-1
1. Starter
2) Remove air intake chamber. <Ref. to 2-7 6) Installation is in the reverse order of removal.
[W18A0].> Tightening torque:
50±4 N·m (5.1±0.4 kg-m, 36.9±2.9 ft-lb)
S6M0007
only)
B: TEST
1. SWITCH ASSEMBLY OPERATION
1) Connect terminal S of switch assembly to posi-
tive terminal of battery with a lead wire, and starter
body to ground terminal of battery. Pinion should
be forced endwise on shaft.
CAUTION:
With pinion forced endwise on shaft, starter
S6M0023
motor can sometimes rotate because current
flows, through pull-in coil, to motor. This is not
4) Disconnect connector and terminal from starter. a problem.
2) Disconnect connector from terminal M, and
connect positive terminal of battery and terminal M
using a lead wire and ground terminal to starter
body.
In this test set up, pinion should return to its origi-
nal position even when it is pulled out with a screw-
driver.
S6M0002A
(A) Terminal
(B) Connector
G6M0029
G2M0309
7
6-1 [W1B2] SERVICE PROCEDURE
1. Starter
G6M0031
8
SERVICE PROCEDURE [W1C1] 6-1
1. Starter
G6M0032
G6M0036
H6M0494A
H6M0495A
9
6-1 [W1C2] SERVICE PROCEDURE
1. Starter
G6M0039
G6M0038
G6M0041
2. YOKE
Make sure pole is set in position.
10
SERVICE PROCEDURE [W1E0] 6-1
1. Starter
G6M0044
E: ASSEMBLY
Assembly is in the reverse order of disassembly
procedures. Observe the following:
1) Carefully assemble all parts in the order of
assembly and occasionally inspect nothing has
H6M0496A been overlooked.
2) Apply grease to the following parts during
2) Brush movement assembly.
Be sure brush moves smoothly inside brush I Front bracket sleeve bearing
holder. I Armature shaft gear
3) Brush spring force I Outer periphery of plunger
Measure brush spring force with a spring scale. If I Mating surface of plunger and lever
it is less than the service limit, replace brush I Gear shaft splines
spring. I Mating surface of lever and clutch
Brush spring force: I Ball at the armature shaft end
Standard I Internal and planetary gears
21.6 N (2.2 kg, 4.9 lb) (when new) 3) After assembling parts correctly, check to be
sure starter operates properly.
Service limit
5.9 N (0.6 kg, 1.3 lb)
11
6-1 [W2A0] SERVICE PROCEDURE
2. Generator
H2M1499
H6M0402 H2M1499
B2M0017
G6M0065
G2M0286
12
SERVICE PROCEDURE [W2B0] 6-1
2. Generator
2) Hold rotor with a vise and remove pulley nut. 4) Remove screws which secure IC regulator to
rear cover, and unsolder connection between IC
regulator and rectifier to remove IC regulator.
G6M0066
CAUTION: G6M0069
When holding rotor with vise, insert aluminum 5) Remove the brushes by unsoldering at the pig-
plates or wood pieces on the contact surfaces tails.
of the vise to prevent rotor from damage.
G6M0070
H6M0498A
6) Remove the nut and insulating bushing at ter-
3) Unsolder connection between rectifier and sta- minal B. Remove rectifier.
tor coil to remove stator coil.
CAUTION:
Finish the work rapidly (less than three sec-
onds) because the rectifier cannot withstand
heat very well.
G6M0071
G6M0068
13
6-1 [W2C1] SERVICE PROCEDURE
2. Generator
G6M0075
4) Insulation test
Check continuity between slip ring and rotor core
or shaft. If continuity exists, the rotor coil is short-
circuited, and so replace rotor assembly.
G6M0072
G6M0076
G6M0073
2. ROTOR
1) Slip ring surface
Inspect slip rings for contamination or any rough-
ness of the sliding surface. Repair slip ring surface
using a lathe or sand paper.
2) Slip ring outer diameter
Measure slip ring outer diameter. If slip ring is worn G6M0077
replace rotor assembly.
Slip ring outer diameter:
Standard
22.7 mm (0.894 in)
Limit
22.1 mm (0.870 in)
14
SERVICE PROCEDURE [W2C4] 6-1
2. Generator
G6M0078
G6M0079
4. BRUSH
1) Measure the length of each brush. If wear
exceeds the service limit, replace the brush. Each
brush has the service limit mark on it.
Brush length:
Standard
18.5 mm (0.728 in)
Service limit
5.0 mm (0.197 in)
H6M0499A
15
6-1 [W2C5] SERVICE PROCEDURE
2. Generator
G6M0144 G6M0146
(3) Set a new bearing and closely install a fit 2) Heat the rear bracket [50 to 60°C (122 to
tool on the bearing outer race. Press the bear- 140°F)] and press the rear bearing into the rear
ing down into place with a hand press or vise. bracket. Then lubricate the rear bracket.
A socket wrench can serve as the tool. CAUTION:
(4) Install front bearing retainer. Grease should not be applied for the rear bear-
ing.
Remove oil completely if it is found on the
bearing box.
3) After reassembly, turn the pulley by hand to
check that the rotor turns smoothly.
G6M0145
16
SERVICE PROCEDURE [W3A1] 6-1
3. Spark Plug
G6M0095 B2M2306
2) Remove air intake duct and resonator chamber. 3) Remove air cleaner upper case and air cleaner
(2200 cc California SPEC. vehicle) element. (Except 2200 cc California SPEC.
vehicle)
(1) Remove bolt which installs air intake duct
(1) Disconnect mass air flow sensor connector.
on the front side of body.
B2M2018
S6M0708
(2) Remove two clips securing air cleaner
(2) Remove bolt which installs air intake duct upper cover.
on body. (3) Loosen the clamp screw and separate air
cleaner upper cover from air intake duct.
B2M2284
B2M2290
17
6-1 [W3A2] SERVICE PROCEDURE
3. Spark Plug
G6M0095
B6M0922A
5) Remove spark plug with the spark plug socket. 2) Remove #2 spark plug cord by pulling boot, not
cord itself.
B6M0923
B6M0927A
6) Installation is in the reverse order of removal.
Tightening torque (Spark plug): 3) Remove spark plug with the spark plug socket.
20.6±2.9 N·m (2.10±0.30 kg-m, 15.19±2.14
ft-lb)
B6M0924
18
SERVICE PROCEDURE [W3A3] 6-1
3. Spark Plug
B2M2306
B2M2018
B2M2284
B2M2290
(3) Remove air intake duct as a unit.
(4) Remove air cleaner element.
B2M2012
19
6-1 [W3A4] SERVICE PROCEDURE
3. Spark Plug
4) Remove #3 spark plug cord by pulling boot, not 2) Disconnect washer motor connector.
cord itself.
S2M0546
B6M0928A
3) Disconnect rear window glass washer hose
5) Remove spark plug with the spark plug socket. from washer motor, then plug connection with a
suitable cap.
4) Remove the two bolts which hold the washer
tank, then take the tank away from the working
area.
B6M0925
B6M0929A
G6M0095
6) Remove spark plug with the spark plug socket.
B6M0926
20
SERVICE PROCEDURE [W3B0] 6-1
3. Spark Plug
G6M0086
1) Normal
Brown to grayish-tan deposits and slight electrode
wear indicate correct spark plug heat range.
G6M0087
2) Carbon fouled
Dry fluffy carbon deposits on insulator and elec-
trode are mostly caused by slow speed driving in
city, weak ignition, too rich fuel mixture, dirty air
cleaner, etc.
It is advisable to replace with plugs having hotter
heat range.
G6M0088
21
6-1 [W3C0] SERVICE PROCEDURE
3. Spark Plug
G6M0089
4) Overheating
White or light gray insulator with black or gray
brown spots and bluish burnt electrodes indicate
engine overheating. Moreover, the appearance
results from incorrect ignition timing, loose spark
G6M0091
plugs, wrong selection of fuel, hotter range plug,
etc. It is advisable to replace with plugs having
colder heat range.
G6M0090
22
SERVICE PROCEDURE [W4B0] 6-1
4. Ignition Coil and Ignitor Assembly
B6M0931A
[Secondary side]
Between (A) and (B)
12.8 kΩ±15%
Between (C) and (D)
B6M0932 12.8 kΩ±15%
4) Remove ignition coil and ignitor assembly.
B6M0773C
23
6-1 [W5A0] SERVICE PROCEDURE
5. Spark Plug Cord
S6M0337
24
DIAGNOSTICS [K100] 6-1
1. Starter
1. Starter
Trouble Probable cause
Magnet switch poor contact or disconti-
Magnet switch does not operate. nuity of pull-in coil circuit
(no clicks are heard.) Improper sliding of magnet switch
plunger
Poor contact of magnet switch’s main
contact point
Starter does not start. Layer short of armature
Magnet switch operates. Contaminants on armature commutator
(clicks are issued.) High armature mica
Improper grounding of yoke field coil
Insufficient carbon brush length
Insufficient brush spring pressure
Worn pinion teeth
Failure of pinion gear to engage ring
Improper sliding of overrunning clutch
Starter starts but does not crank engine. gear
Improper adjustment of stud bolt
Clutch slippage Faulty clutch roller spring
Poor contact of magnet switch’s main
contact point
Layer short of armature
Discontinuity, burning or wear of arma-
Starter starts but engine cranks too slowly. ture commutator
Poor grounding of yoke field coil
Insufficient brush length
Insufficient brush spring pressure
Abnormal brush wear
Starter overruns. Magnet switch coil is a layer short.
25
6-1 [K200] DIAGNOSTICS
2. Generator
2. Generator
B6M0771
26
BODY ELECTRICAL SYSTEM 6-2
Page
S SPECIFICATIONS AND SERVICE DATA..........................................................2
1. Body Electrical.............................................................................................2
W SERVICE PROCEDURE ...................................................................................3
1. Precautions..................................................................................................3
2. Battery .........................................................................................................3
3. Ignition Switch .............................................................................................5
4. Lighting ........................................................................................................5
5. Front Wiper and Washer .............................................................................9
6. Rear Wiper and Washer ...........................................................................12
7. Rear Window Defogger.............................................................................15
8. Combination Meter ....................................................................................17
9. Radio, Speaker and Antenna ....................................................................18
10. Front Fog Light..........................................................................................18
11. Cruise Control ...........................................................................................19
K DIAGNOSTICS.................................................................................................23
1. AT Shift Lock System ................................................................................23
2. Combination Meter ....................................................................................29
6-2 [S100] SPECIFICATIONS AND SERVICE DATA
1. Body Electrical
1. Body Electrical
Type MT model: 55D23L (MF) AT model: 75D23L (MF)
Battery Reverse capacity MT model: 100 minutes AT model: 120 minutes
Capacity
Cold cranking ampere MT model: 430 amperes AT model: 520 amperes
Speedometer Electric pulse type
Temperature gauge Thermistor cross coil type
Fuel gauge Resistance cross coil type
Tachometer Electric impulse type
Turn signal indicator light 12 V — 1.4 W
Charge indicator light 12 V — 1.4 W
Oil pressure indicator light 12 V — 1.4 W
ABS warning light 12 V — 1.4 W
Combination CHECK ENGINE warning light (Malfunc-
12 V — 1.4 W
meter tion indicator light)
HI-beam indicator light 12 V — 3.4 W
Door open warning light 12 V — 1.4 W
Seat belt warning light 12 V — 1.4 W
Brake fluid and parking brake warning light 12 V — 3.4 W
FWD indicator light 12 V — 1.4 W
AIRBAG warning light 12 V — 1.4 W
Meter illumination light 12 V — 3.4 W
AT OIL TEMP. warning light 12 V — 1.4 W
Headlight 12 V — 60/55 W (Halogen)
Front fog light 12 V — 55 W
Front turn signal light 12 V — 27 W
Side turn signal light 12 V — 3.8 W
Side marker/Parking light 12 V — 3.8 W
Tail/Stop light 12 V — 8/27 W
Rear combination light Turn signal light 12 V — 27 W
Back-up light 12 V — 27 W
License plate light 12 V — 3.8 W
High-mount stop light Sedan: 12 V — 18 W Wagon: 12 V — 13 W
Room light 12 V — 8 W
Spot light 12 V — 8 W
Trunk room light 12 V — 5 W
Luggage room light 12 V — 5 W
Front wiper
Input 12 V — 54 W or less
motor
Rear wiper motor Input 12 V — 42 W or less
Front washer Pump type Centrifugal
motor Input 12 V — 36 W or less
Rear washer Pump type Centrifugal
motor Input 12 V — 36 W or less
Horn 12 V — 350 Hz
Accessory socket Input 12 V — 120 W
Rear window Input 12 V — 160 W
defogger Indicator light 12 V — 50 mA
Cargo socket Input 12 V — 120 W
2
SERVICE PROCEDURE [W2B0] 6-2
2. Battery
1. Precautions 2. Battery
I Before disassembling or reassembling parts, A: REMOVAL AND INSTALLATION
always disconnect battery ground cable. When
repairing radio, control units, etc. which are 1) Disconnect the positive (+) terminal after dis-
provided with memory functions, record connecting the negative (− ) terminal of battery.
memory contents before disconnecting battery 2) Remove flange nuts from battery rods and take
ground cable. Otherwise, these contents are off battery holder.
cancelled upon disconnection.
I Reassemble parts in reverse order of disas-
sembly procedure unless otherwise indicated.
I Adjust parts to specifications contained in
this manual if so designated.
I Connect connectors and hoses securely dur-
ing reassembly.
I After reassembly, ensure functional parts
operate smoothly.
CAUTION:
I Airbag system wiring harness is routed near G6M0102
the electrical parts and switch.
I All Airbag system wiring harness and con- 3) Remove battery.
nectors are colored yellow. Do not use electri- 4) Installation is in the reverse order of removal.
cal test equipment on these circuits. Tightening torque:
I Be careful not to damage Airbag system wir- 3.4±1.0 N·m (0.35±0.1 kg-m, 2.5±0.7 ft-lb)
ing harness when servicing the ignition key
cylinder. NOTE:
I Clean battery cable terminals and apply grease
to retard the formation of corrosion.
I Connect the positive (+) terminal of battery and
then the negative (− ) terminal of the battery.
B: INSPECTION
WARNING:
I Electrolyte has toxicity; be careful handling
the fluid.
I Avoid contact with skin, eyes or clothing.
Especially at contact with eyes, blush with
water for 15 minutes and get prompt medical
attention.
I Batteries produce explosive gasses. Keep
sparks, flame, cigarettes away.
I Ventilate when charging or using in enclosed
space.
I For safety, in case an explosion does occur,
wear eye protection or shield your eyes when
working near any battery. Never lean over a
battery.
I Do not let battery fluid contact eyes, skin,
fabrics, or paint-work because battery fluid is
corrosive acid.
I To lessen the risk of sparks, remove rings,
metal watch-bands, and other metal jewelry.
Never allow metal tools to contact the positive
battery terminal and anything connected to it
while you are at the same time in contact with
any other metallic portion of the vehicle
because a short circuit will be caused.
3
6-2 [W2B1] SERVICE PROCEDURE
2. Battery
4
SERVICE PROCEDURE [W4A1] 6-2
4. Lighting
G6M0020
G6M0105
H6M0709A
5
6-2 [W4B1] SERVICE PROCEDURE
4. Lighting
H6M0400
H6M0399
M6A0139
6
SERVICE PROCEDURE [W4B4] 6-2
4. Lighting
S6M0046
S6M0042
7
6-2 [W4C1] SERVICE PROCEDURE
4. Lighting
S6M0048A
S6M0048A
S6M0136A
8
SERVICE PROCEDURE [W5B3] 6-2
5. Front Wiper and Washer
B6M0107A
G6M0118
9
6-2 [W5B3] SERVICE PROCEDURE
5. Front Wiper and Washer
2) Disconnect electric connector, and remove 5) Remove wiper link from service hole in front
motor attaching bolts. panel.
Tightening torque:
5.9±1.5 N·m (0.6±0.15 kg-m, 4.3±1.1 ft-lb)
G6M0121
G6M0120
G6M0021
10
SERVICE PROCEDURE [W5C2] 6-2
5. Front Wiper and Washer
G6M0122
H6M0501B
G6M0123
G6M0124
S6M0137
11
6-2 [W6A0] SERVICE PROCEDURE
6. Rear Wiper and Washer
4) Reconnect battery and ensure that wiper motor 6. Rear Wiper and Washer
stops at “AUTO STOP” after operating at low
speed. A: ADJUSTMENT
1) Adjust wiper blade in original position as shown
in figure by changing wiper arm installation.
Original position:
A: 30±5 mm (1.18±0.20 in)
G6M0125
G6M0126
G6M0127
B6M0107A
12
SERVICE PROCEDURE [W6B4] 6-2
6. Rear Wiper and Washer
G6M0128
Tightening torque:
5.9±1.5 N·m (0.6±0.15 kg-m, 4.3±1.1 ft-lb) 6) Installation is in the reverse order of removal.
3. WIPER MOTOR Tightening torque:
5.9±1.5 N·m (0.6±0.15 kg-m, 4.3±1.1 ft-lb)
1) Remove cap and special nut.
4. WASHER TANK
CAUTION:
Be careful not to strike service tool against 1) Remove rear quarter trim.
nozzle during removal. 2) Disconnect washer hose and connector.
3) Remove attaching bolts.
Tightening torque:
7.4±1.5 N·m (0.75±0.15 kg-m, 5.4±1.1 ft-lb)
G6M0022
13
6-2 [W6C1] SERVICE PROCEDURE
6. Rear Wiper and Washer
G6M0132
G6M0133
S6M0137
2. WIPER MOTOR
1) Operational check:
Connect battery to wiper motor and check opera-
tion of wiper motor.
G6M0131
14
SERVICE PROCEDURE [W7A1] 6-2
7. Rear Window Defogger
G6M0135
S6M0075A
G6M0136
15
6-2 [W7B0] SERVICE PROCEDURE
7. Rear Window Defogger
G6M0138
G6M0137
16
SERVICE PROCEDURE [W8B0] 6-2
8. Combination Meter
H6M0524A
17
6-2 [W9A1] SERVICE PROCEDURE
9. Radio, Speaker and Antenna
H6M0525
S5M0048A
18
SERVICE PROCEDURE [W11A0] 6-2
11. Cruise Control
S6M0138A
19
6-2 [W11B1] SERVICE PROCEDURE
11. Cruise Control
S6M0089
S6M0090
S6M0087
8) Installation is in the reverse order of removal.
4) Remove cruise control cable end from throttle Tightening torque:
cam. 7.4±2.0 N·m (0.75±0.2 kg-m, 5.4±1.4 ft-lb)
CAUTION:
When inserting vacuum hose to intake
manifold, apply sealant to the fitting hose.
Fluid packing:
THREE BOND 1105 or equivalent
CAUTION:
I Be careful not to apply excessive load to the
wire cable when adjusting and/or installing;
otherwise, the actuator may be deformed or
S6M0088
damaged.
I Do not bend cable sharply with a radius less
than 100 mm (3.94 in); otherwise, cable may
bend permanently, resulting in poor perfor-
mance.
I When installing cable, be careful not to
sharply bend or pinch the inner cable;
otherwise, the cable may break.
20
SERVICE PROCEDURE [W11B3] 6-2
11. Cruise Control
2. CRUISE CONTROL MAIN SWITCH 4) Using TORXT BIT T30 (Tamper resistant type),
remove two TORXT bolts which secure driver’s air-
1) Remove screws and clip from instrument panel
bag module.
lower cover.
2) Remove panel lower cover.
S6M0094A
S6M0092A
S6M0095
S6M0093
21
6-2 [W11B4] SERVICE PROCEDURE
11. Cruise Control
S6M0097
S6M0098
22
BODY ELECTRICAL SYSTEM
(CRUISE CONTROL) 6-2
Page
T DIAGNOSTICS ...................................................................................................2
1. Precaution ...................................................................................................2
2. Pre-inspection..............................................................................................2
3. Electrical Components Location..................................................................7
4. Schematic....................................................................................................8
5. Control Module I/O Signal.........................................................................10
6. Diagnostics Chart for On-board Diagnosis System ..................................12
7. Diagnostics Chart for Power Line .............................................................14
8. Diagnostics Chart with Diagnostic Code...................................................19
9. Diagnostics Chart with Select Monitor ......................................................42
6-2 [T1A0] BODY ELECTRICAL SYSTEM (CRUISE CONTROL)
1. Precaution
1. Precaution 2. Pre-inspection
A: SUPPLEMENTAL RESTRAINT A: FUNCTION TESTS
SYSTEM “AIRBAG” Conduct road tests by selecting a smooth, flat road
Airbag system wiring harness is routed near the or use free rollers for road test simulation.
cruise control module and cruise control command
switch. 1. CRUISE CONTROL MAIN SWITCH
CAUTION: 1) Turn ignition switch to ON.
I All Airbag system wiring harness and con- 2) Check that cruise control main switch indicator
nectors are colored yellow. Do not use electri- light comes on when main switch is pressed (ON).
cal test equipment on these circuits. 3) Check that main switch indicator light goes out
I Be careful not to damage Airbag system wir- when main switch is pressed again (OFF).
ing harness when servicing the cruise control 4) Turn ignition switch to OFF with main switch ON
module and cruise control command switch. (indicated by illumination). Turn ignition switch ON
again to ensure that main switch indicator light
remains OFF.
2. CRUISE CONTROL COMMAND SWITCH
1) Check that cruise control command switch is
properly set in “SET/COAST”, “RESUME/ACCEL”,
or “CANCEL” mode.
2) Also check that command switch returns to the
original position when released.
3. CONSTANT SPEED TEST
1) Turn cruise control main switch to ON.
2) Drive the vehicle at a speed greater than 40
km/h (25 MPH).
3) Press command switch to set in “SET/COAST”
mode.
4) Ensure that vehicle is maintained at the speed
set when command switch was pressed.
4. ACCELERATION TEST
1) Set vehicle speed at a speed greater that 40
km/h (25 MPH).
2) Ensure that vehicle continues to accelerate
while holding command switch in “RESUME/
ACCEL” mode, and that vehicle maintains that
optional speed when command switch is released.
5. DECELERATION TEST
1) Set vehicle speed at an optional speed greater
than 40 km/h (25 MPH).
2) Ensure that vehicle continues to decelerate
while holding command switch in “SET/COAST”
mode, and that it maintains that optional speed
when command switch is released.
NOTE:
When vehicle speed reaches the lower speed limit
of 30 km/h (19 MPH) during deceleration, cruise
control will be released.
2
BODY ELECTRICAL SYSTEM (CRUISE CONTROL) [T2C1] 6-2
2. Pre-inspection
B6M0241A
S6M0099A
S6M0099A
3
6-2 [T2D1] BODY ELECTRICAL SYSTEM (CRUISE CONTROL)
2. Pre-inspection
S6M0102A
4
BODY ELECTRICAL SYSTEM (CRUISE CONTROL) [T2D7] 6-2
2. Pre-inspection
2D4 : MEASURE RESISTANCE OF VALVE. 2D6 : CHECK FOR LEAKAGE AND STICK-
ING OF VALVES.
Measure resistance between terminals of actuator.
When the battery cable is disconnected from
Terminals
former condition <Ref. to 6-2 [T2D5].> Step 2),
No. 2 — No. 4:
make sure the cable returns to its original position
smoothly.
: Does cruise control cable get back to
its original position within 1.5 sec-
onds?
: Go to step 2D7.
: Replace actuator. <Ref. to 6-2
[W11B1].> Go to step 2D7.
S6M0105
5
6-2 [T2D8] BODY ELECTRICAL SYSTEM (CRUISE CONTROL)
2. Pre-inspection
S6M0105
Check the condition of the main and other fuses,
: Does cruise control perform hold and harnesses and connectors. Also check for
operation? proper grounding.
: Go to step 2D9. : Is there anything unusual about the
: Replace actuator. <Ref. to 6-2 appearance of main fuse, fuse,
[W11B1].> Go to step 2D9. harness, connector and grounding?
: Repair or replace faulty parts. End of
2D9 : CHECK CABLE MOVEMENT. pre-inspection.
: End of pre-inspection.
Connect + (positive) battery cable to terminal No.
2 and − (negative) battery cable to terminal No. 4
of actuator connector.
S6M0105
6
BODY ELECTRICAL SYSTEM (CRUISE CONTROL) [T300] 6-2
3. Electrical Components Location
S6M0106A
(1) Actuator (with valves) (4) Cruise control command switch (7) Clutch switch (MT)
(2) Inhibitor switch (AT) (5) Cruise control module
(3) Cruise control main switch (6) Stop and brake switch
7
6-2 [T400] BODY ELECTRICAL SYSTEM (CRUISE CONTROL)
4. Schematic
4. Schematic
S6M0325
8
BODY ELECTRICAL SYSTEM (CRUISE CONTROL) [T400] 6-2
4. Schematic
MEMO:
9
6-2 [T500] BODY ELECTRICAL SYSTEM (CRUISE CONTROL)
5. Control Module I/O Signal
G6M0015
Content Terminal No. Measuring conditions and I/O signals (ignition switch ON and engine idling)
Vent valve 1 I Power supply is ON when vehicle is stopped.
I ON-and-OFF (“0”-and-battery voltage) operation is alternately repeated while
cruise control is operating.
Safety valve 2 I Power supply is ON when vehicle is stopped.
I ON-and-OFF (“0”-and-battery voltage) operation is alternately repeated while
cruise control is operating.
Ignition switch 3 I Battery voltage is present when ignition switch is turned ON.
I “0” volt is present when ignition switch is turned OFF.
Cruise control main switch 4 I Battery voltage is present when main power is turned ON.
I “0” volt is present when main power is turned OFF.
Power supply to vacuum valve, 5 I Battery voltage is present when main power is turned ON.
vent valve, safety valve and I “0” volt is present when main power is turned OFF.
indicator light
SET/COAST switch 6 I Battery voltage is present when command switch is turned to SET/COAST
position.
I “0” volt is present when command switch is released.
RESUME/ACCEL switch 7 I Battery voltage is present when command switch is turned to RESUME/
ACCEL position.
I “0” volt is present when command switch is released.
Brake switch 8 Set selector lever to any position other than “P” or “N” position (AT) / leave
clutch pedal released (MT), while cruise control main switch is turned ON.
Then check that;
I Battery voltage is present when brake pedal is released.
I “0” volt is present when brake pedal is depressed, or
I Battery voltage is present when clutch pedal is released (MT).
I “0” volt is present when clutch pedal is depressed (MT).
I Battery voltage is present when selector lever is in any position other than
“P” or “N” position (AT).
I “0” volt is present when selector lever is set to “P” or “N” position (AT).
Clutch switch (MT)/ 9 I Battery voltage is present when clutch pedal is released (MT).
Inhibitor switch (AT) I “0” volt is present when clutch pedal is depressed (MT).
I Battery voltage is present when selector lever is in any position other than
“P” or “N” position (AT).
I “0” volt is present when selector lever is set to “P” or “N” position (AT).
Vacuum valve 11 I Power supply is ON when vehicle is stopped.
I ON-and-OFF (“0”-and-battery voltage) operation is alternately repeated while
cruise control is operating.
Set signal to transmission con- 12 I TCM emits a ground-level signal while driving vehicle at least 40 km/h (25
trol module (AT) MPH) with SET switch ON.
Ground 13 —
Check connector/ 14 —
OBD-II service connector
Check connector/ 15 —
OBD-II service connector
10
BODY ELECTRICAL SYSTEM (CRUISE CONTROL) [T500] 6-2
5. Control Module I/O Signal
Content Terminal No. Measuring conditions and I/O signals (ignition switch ON and engine idling)
Vehicle speed sensor 2 (MT) 18 Lift-up the vehicle until all four wheels are raised off ground, and then rotate
Automatic transmission control any wheel manually. Approx. 5 and 0 volt pulse signals are alternately input to
module (AT) cruise control module.
Stop light switch 19 Turn ignition switch to OFF. Then check that;
I Battery voltage is present when brake pedal is depressed.
I “0” volt is present when brake pedal is released.
Ground 20 —
NOTE:
Voltage at terminals 1, 2, 11 and 12 cannot be checked unless vehicle is driving by cruise control operation.
11
6-2 [T6A1] BODY ELECTRICAL SYSTEM (CRUISE CONTROL)
6. Diagnostics Chart for On-board Diagnosis System
6A4 : CHECK CRUISE SPEED IS HELD : Does cruise speed release when
WITHIN SET SPEED. clutch pedal is depressed?
: Cruise control system is in correct order.
: Does cruise speed hold within set : Go to “Diagnostics Chart with Trouble
speed ±3 km/h (2 MPH)? Code”. <Ref. to 6-2 [T800].>
: Go to step 6A5.
: Go to pre-inspection of actuator. <Ref.
to 6-2 [T2D0].>
12
BODY ELECTRICAL SYSTEM (CRUISE CONTROL) [T6B3] 6-2
6. Diagnostics Chart for On-board Diagnosis System
B: ON-BOARD DIAGNOSIS WITH 4) Drive vehicle at least 40 km/h (25 MPH) with
cruise speed set.
SELECT MONITOR 5) If cruise speed is canceled itself (without doing
1. GENERAL any cancel operations), a diagnostic code will
appear on select monitor display.
The on-board diagnosis function of the cruise con-
trol system uses an external select monitor. CAUTION:
The on-board diagnosis function operates in two I A diagnostic code will also appear when
categories, which are used depending on the type cruise cancel is effected by driver. Do not con-
of problems; fuse.
I Have a co-worker ride in vehicle to assist in
NOTE: diagnosis during driving.
Select monitor cartridge:
No. 24082AA090 NOTE:
Diagnostic code will be cleared by turning ignition
1) Cruise cancel conditions diagnosis switch or cruise control main switch to OFF.
(1) This category of diagnosis requires actual
vehicle driving in order to determine the cause,
3. REAL-TIME DIAGNOSIS
(as when cruise speed is cancelled during driv- 1) Connect select monitor.
ing although cruise cancel condition is not 2) Turn ignition switch and cruise control main
entered). switch to ON.
(2) Cruise control module memory stores the 3) Select the “Current Data Display & Save” mode
cancel condition (Code No.) which occurred on the select monitor “Cruise Control Diagnosis”
during driving. When there are plural cancel screen.
conditions (Code No.), they are shown on the 4) Ensure that normal indication is displayed when
select monitor. controls are operated as indicated below:
I Depress/release the brake pedal. (Stop light
CAUTION: switch and brake switch turn ON.)
I The cruise control memory stores not only I Turn ON the “SET/COAST” switch.
the cruise “cancel” which occurred (although I Turn ON the “RESUME/ACCEL” switch.
“cancel” operation is not entered by the I Depress/release the clutch pedal. (MT)
driver), but also the “cancel” condition input by I Set the selector lever to P or N. (AT)
the driver.
I The content of memory is cleared when igni-
tion switch or cruise main switch is turned OFF.
2) Real-time diagnosis
The real-time diagnosis function is used to deter-
mine whether or not the input signal system is in
good order, according to signal emitted from
switches, sensors, etc.
(1) Vehicle cannot be driven at cruise speed
because problems occurs in the cruise control
system or its associated circuits.
(2) Monitor the signal conditions from switches
and sensors.
2. CRUISE CANCEL CONDITIONS
DIAGNOSIS
1) Connect select monitor.
2) Start the engine and turn cruise control main
switch to ON.
3) Set select monitor in “All System Diagnosis”
mode.
NOTE:
The diagnostic code is also shown in the “Each
System Check” mode. This mode is called up on
the “Cruise Control Diagnosis” screen by selecting
the item “Cancel Code(s) Display”.
13
6-2 [T7A1] BODY ELECTRICAL SYSTEM (CRUISE CONTROL)
7. Diagnostics Chart for Power Line
S6M0108
14
BODY ELECTRICAL SYSTEM (CRUISE CONTROL) [T7B3] 6-2
7. Diagnostics Chart for Power Line
7B1 : CHECK CRUISE CONTROL MAIN 7B3 : CHECK CIRCUIT BETWEEN CRUISE
SWITCH. CONTROL MODULE AND CRUISE
CONTROL MAIN SWITCH INDICATOR
LIGHT.
1) Remove cruise control main switch.
2) Measure resistance between cruise control
main switch terminals. 1) Turn the ignition switch and cruise control main
switch to OFF.
Terminals 2) Remove the connector from the cruise control
No. 1 — No. 6: main switch.
3) Measure resistance of ground circuit between
the cruise control main switch connector and chas-
sis ground.
Connector & terminal
(B161) No. 6 (+) — Chassis ground (−):
S6M0109A
B6M0528B
15
6-2 [T7C0] BODY ELECTRICAL SYSTEM (CRUISE CONTROL)
7. Diagnostics Chart for Power Line
S6M0108
16
BODY ELECTRICAL SYSTEM (CRUISE CONTROL) [T7C4] 6-2
7. Diagnostics Chart for Power Line
S6M0110A
G6M0244
17
6-2 [T7C5] BODY ELECTRICAL SYSTEM (CRUISE CONTROL)
7. Diagnostics Chart for Power Line
G6M0244
switch is OFF.)
: Is voltage more than 10 V?
: Go to step 7C6.
: Go to step 7C8.
: Replace cruise control main switch.
: Repair or replace wiring harness.
<Ref. to 6-2 [W11B2].>
S6M0111A
18
BODY ELECTRICAL SYSTEM (CRUISE CONTROL) [T8A0] 6-2
8. Diagnostics Chart with Diagnostic Code
19
6-2 [T8B0] BODY ELECTRICAL SYSTEM (CRUISE CONTROL)
8. Diagnostics Chart with Diagnostic Code
S6M0112
20
BODY ELECTRICAL SYSTEM (CRUISE CONTROL) [T8B3] 6-2
8. Diagnostics Chart with Diagnostic Code
1) Turn ignition switch to ON. Check circuit between brake switch terminal.
2) Turn cruise control main switch to ON. Terminals
3) Apply parking brake securely. No. 1 — No. 4: (Brake switch)
4) Set select monitor in “Current Data Display &
Save” mode.
5) Depress the brake pedal and check signals for
proper operation.
(1) The Stop Lamp Switch shown on the dis-
play turns from “OFF” to “ON”.
(2) The Brake Switch shown on the display
turns from “OFF” to “ON”.
6) Release the brake pedal.
7) Remove connector of stop and brake switch.
8) Check circuit between brake switch terminal.
G6M0183
Terminals
No. 1 — No. 4: (Brake switch) : Is resistance more than 1 MΩ? (When
brake pedal is depressed.)
: Go to step 8B3.
: Replace brake and stop light switch.
<Ref. to 4-5 [C100].>
G6M0183
21
6-2 [T8B4] BODY ELECTRICAL SYSTEM (CRUISE CONTROL)
8. Diagnostics Chart with Diagnostic Code
G6M0183
22
BODY ELECTRICAL SYSTEM (CRUISE CONTROL) [T8B4] 6-2
8. Diagnostics Chart with Diagnostic Code
MEMO:
23
6-2 [T8C0] BODY ELECTRICAL SYSTEM (CRUISE CONTROL)
8. Diagnostics Chart with Diagnostic Code
S6M0113
24
BODY ELECTRICAL SYSTEM (CRUISE CONTROL) [T8C2] 6-2
8. Diagnostics Chart with Diagnostic Code
8C1 : CHECK CLUTCH SWITCH. (MT) 8C2 : CHECK CLUTCH SWITCH. (MT)
G6M0184
25
6-2 [T8C3] BODY ELECTRICAL SYSTEM (CRUISE CONTROL)
8. Diagnostics Chart with Diagnostic Code
8C3 : CHECK INHIBITOR SWITCH. (AT) 8C4 : CHECK INHIBITOR SWITCH. (AT)
B6M0242
26
BODY ELECTRICAL SYSTEM (CRUISE CONTROL) [T8C4] 6-2
8. Diagnostics Chart with Diagnostic Code
MEMO:
27
6-2 [T8D0] BODY ELECTRICAL SYSTEM (CRUISE CONTROL)
8. Diagnostics Chart with Diagnostic Code
S6M0326
28
BODY ELECTRICAL SYSTEM (CRUISE CONTROL) [T8D4] 6-2
8. Diagnostics Chart with Diagnostic Code
B6M0946A
29
6-2 [T8D5] BODY ELECTRICAL SYSTEM (CRUISE CONTROL)
8. Diagnostics Chart with Diagnostic Code
8D5 : CHECK VEHICLE SPEED SENSOR 2. 8D6 : CHECK VEHICLE SPEED SENSOR 2.
B6M0947A
B3M0289
30
BODY ELECTRICAL SYSTEM (CRUISE CONTROL) [T8D8] 6-2
8. Diagnostics Chart with Diagnostic Code
S6M0328A
31
6-2 [T8E0] BODY ELECTRICAL SYSTEM (CRUISE CONTROL)
8. Diagnostics Chart with Diagnostic Code
S6M0123
32
BODY ELECTRICAL SYSTEM (CRUISE CONTROL) [T8E3] 6-2
8. Diagnostics Chart with Diagnostic Code
S6M0124
33
6-2 [T8E4] BODY ELECTRICAL SYSTEM (CRUISE CONTROL)
8. Diagnostics Chart with Diagnostic Code
8E4 : CHECK CRUISE CONTROL COM- 8E6 : CHECK CRUISE CONTROL COM-
MAND SWITCH. MAND SWITCH.
Measure voltage between cruise control command 1) Turn ignition switch to OFF.
switch connector and chassis ground. 2) Disconnect connector from cruise control com-
Terminals mand switch.
No. 2 (+) — Chassis ground (−): 3) Measure resistance between terminals of
cruise control command switch connector (switch
side) to check the switch operation.
Terminals
No. 1 — No. 2:
S6M0124
S6M0124
34
BODY ELECTRICAL SYSTEM (CRUISE CONTROL) [T8E10] 6-2
8. Diagnostics Chart with Diagnostic Code
8E7 : CHECK CRUISE CONTROL COM- 8E9 : CHECK CRUISE CONTROL COM-
MAND SWITCH. MAND SWITCH.
Measure resistance between terminals of cruise Measure resistance between terminals of cruise
control command switch connector (switch side) to control command switch connector (switch side) to
check the switch operation. check the switch operation.
Terminals Terminals
No. 1 — No. 2: No. 1 — No. 3:
S6M0125 S6M0125
: Is resistance more than 1 MΩ? (When : Is resistance more than 1 MΩ? (When
SET/COAST switch is OFF.) RESUME/ACCEL switch is OFF.)
: Go to step 8E8. : Go to step 8E10.
: Replace cruise control command : Replace cruise control command
switch. <Ref. to 6-2 [W11B3].> switch. <Ref. to 6-2 [W11B3].>
S6M0125
35
6-2 [T8E11] BODY ELECTRICAL SYSTEM (CRUISE CONTROL)
8. Diagnostics Chart with Diagnostic Code
S6M0127A
36
BODY ELECTRICAL SYSTEM (CRUISE CONTROL) [T8E11] 6-2
8. Diagnostics Chart with Diagnostic Code
MEMO:
37
6-2 [T8F0] BODY ELECTRICAL SYSTEM (CRUISE CONTROL)
8. Diagnostics Chart with Diagnostic Code
S6M0128
38
BODY ELECTRICAL SYSTEM (CRUISE CONTROL) [T8F3] 6-2
8. Diagnostics Chart with Diagnostic Code
1) Disconnect connector from actuator. Measure resistance of vacuum valve, vent 2 valve
2) Measure resistance of vacuum valve, vent 2 and vent 1 valve.
valve and vent 1 valve. Terminals
Terminals No. 2 — No. 4:
No. 2 — No. 3:
S6M0104
S6M0104
: Is resistance less than 55 Ω?
: Is resistance less than 22 Ω? : Go to step 8F4.
: Go to step 8F2. : Replace actuator. <Ref. to 6-2
: Replace actuator. <Ref. to 6-2 [W11B1].>
[W11B1].>
S6M0104
39
6-2 [T8F4] BODY ELECTRICAL SYSTEM (CRUISE CONTROL)
8. Diagnostics Chart with Diagnostic Code
8F4 : PERFORM A CIRCUIT TEST IN HAR- 8F5 : PERFORM A CIRCUIT TEST IN HAR-
NESS BETWEEN ACTUATOR NESS BETWEEN ACTUATOR
(VACUUM VALVE, VENT 2 VALVE (VACUUM VALVE, VENT 2 VALVE
AND VENT 1 VALVE) AND CRUISE AND VENT 1 VALVE) AND CRUISE
CONTROL MODULE. CONTROL MODULE.
1) Disconnect connector from cruise control mod- Measure resistance of harness connector between
ule. cruise control module, vacuum valve, vent 2 valve
2) Measure resistance of harness connector and vent 1 valve.
between cruise control module, vacuum valve, Connector & terminal
vent 2 valve and vent 1 valve. (B7) No. 2 — (B94) No. 8:
Connector & terminal
(B7) No. 1 — (B94) No. 1:
S6M0131A
40
BODY ELECTRICAL SYSTEM (CRUISE CONTROL) [T8F7] 6-2
8. Diagnostics Chart with Diagnostic Code
8F6 : PERFORM A CIRCUIT TEST IN HAR- 8F7 : PERFORM A CIRCUIT TEST IN HAR-
NESS BETWEEN ACTUATOR NESS BETWEEN ACTUATOR
(VACUUM VALVE, VENT 2 VALVE (VACUUM VALVE, VENT 2 VALVE
AND VENT 1 VALVE) AND CRUISE AND VENT 1 VALVE) AND CRUISE
CONTROL MODULE. CONTROL MODULE.
Measure resistance of harness connector between Measure resistance of harness connector between
cruise control module, vacuum valve, vent 2 valve cruise control module, vacuum valve, vent 2 valve
and vent 1 valve. and vent 1 valve.
Connector & terminal Connector & terminal
(B7) No. 3 — (B94) No. 11: (B7) No. 4 — (B94) No. 2:
S6M0133A
S6M0132A
41
6-2 [T8G0] BODY ELECTRICAL SYSTEM (CRUISE CONTROL)
9. Diagnostics Chart with Select Monitor
42
DIAGNOSTICS [K1A0] 6-2
1. AT Shift Lock System
H6M0503
23
6-2 [K1B0] DIAGNOSTICS
1. AT Shift Lock System
H6M0504
24
DIAGNOSTICS [K1C0] 6-2
1. AT Shift Lock System
H6M0505
25
6-2 [K1D0] DIAGNOSTICS
1. AT Shift Lock System
H6M0506
26
DIAGNOSTICS [K1E0] 6-2
1. AT Shift Lock System
H6M0507
27
6-2 [K1F0] DIAGNOSTICS
1. AT Shift Lock System
H6M0508
28
DIAGNOSTICS [K2A3] 6-2
2. Combination Meter
29
6-2 [K2A4] DIAGNOSTICS
2. Combination Meter
1) Disconnect connector from vehicle speed sen- 1) Turn ignition switch to OFF.
sor 2. 2) Measure resistance between vehicle speed
2) Measure resistance of harness connector sensor 2 connector (B17) and engine ground.
between vehicle speed sensor 2 and combination Connector & terminal
meter. (B17) No. 2 (+) — Engine ground (−):
Connector & terminal
(B17) No. 1 — (i12) No. 10:
B6M0946A
H6M0595A
: Is the resistance less than 10 Ω?
: Go to step 2A7.
: Is the resistance less than 10 Ω? : Repair harness connector between
: Go to step 2A5. vehicle speed sensor 2 and engine
ground.
: Repair wiring harness.
B6M0945A
30
DIAGNOSTICS [K2A8] 6-2
2. Combination Meter
2A7 : CHECK VEHICLE SPEED SENSOR 2. 2A8 : CHECK VEHICLE SPEED SENSOR 2.
B6M0947A
B3M0289
31
6-2 [K2A9] DIAGNOSTICS
2. Combination Meter
H6M0596A
32
WIRING DIAGRAM 6-3
Page
D WIRING DIAGRAM ............................................................................................2
1. General Description.....................................................................................2
2. Basic Diagnostics Procedure ......................................................................6
3. Working Precautions ...................................................................................8
4. How to Use Wiring Diagram .....................................................................10
5. Wiring Diagram..........................................................................................12
6. Electrical Wiring Harness and Ground Point ............................................67
6-3 [D1A0] WIRING DIAGRAM
1. General Description
1. General Description
A: WIRING DIAGRAM
The wiring diagram of each system is illustrated so
that you can understand the path through which
the electric current flows from the battery.
Sketches and codes are used in the diagrams.
They should read as follows:
I Each connector and its terminal position are
indicated by a sketch of the connector in a discon-
nected state which is viewed from the front.
G6M0193
I The number of poles or pins, presence of a lock, and pin number of each terminal are indicated in the
sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the
connector has. For example, the sketch of the connector shown in figure indicates the connector has 9
poles.
Connector shown in wiring diagram
Connector used in vehicle
Sketch Symbol Number of poles
G6M0194 G6M0196
G6M0198
G6M0195 G6M0197
2
WIRING DIAGRAM [D1A0] 6-3
1. General Description
I When one set of connectors is viewed from the I The following color codes are used to indicate
front side, the pole numbers of one connector are the colors of the wires used.
symmetrical to those of the other. When these two
connectors are connected as a unit, the poles Color code Color
which have the same number are joined. L Blue
B Black
Y Yellow
G Green
R Red
W White
Br Brown
Lg Light green
Gr Gray
P Pink
Or Orange
G6M0199 Lb Light Blue
V Violet
I Electrical wiring harness:
SA Sealed (Inner)
The connectors are numbered along with the num-
SB Sealed (Outer)
ber of poles, external colors, and mating connec-
tions in the accompanying list.
I The sketch of each connector in the wiring dia-
gram usually shows the (A) side of the connector.
The relationship between the wire color, terminal
number and connector is described in figure.
NOTE:
A wire which runs in one direction from a connec-
tor terminal sometimes may have a different color
from that which runs in the other direction from that
terminal.
H6M0509A
G6M0201
I In wiring diagram, connectors which have no ter-
minal number refer to one-pole types. Sketches of
these connectors are omitted intentionally.
G6M0216
3
6-3 [D1A0] WIRING DIAGRAM
1. General Description
I The wire color code, which consists of two let- I Each unit is directly grounded to the body or
ters (or three letters including Br or Lg), indicates indirectly grounds through a harness ground termi-
the standard color (base color of the wire covering) nal. Different symbols are used in the wiring dia-
by its first letter and the stripe marking by its sec- gram to identify the two grounding systems.
ond letter.
G6M0203
G6M0202
I The ground points shown in the wiring diagram
I The table lists the nominal sectional areas and refer to the following:
allowable currents of the wires.
NOTE:
CAUTION: All wiring harnesses are provided with a ground
I When replacing or repairing a wire, be sure
point which should be securely connected.
to use the same size and type of the wire which
was originally used.
NOTE:
I The allowable current in the table indicates the
tolerable amperage of each wire at an ambient
temperature of 40°C (104°F).
I The allowable current changes with ambient
temperature. Also, it changes if a bundle of more
than two wires is used.
Outside
No. of B6M0747B
Nominal sec- diameter of Allowable
strands/
tional area finished wir- current
strand diam-
mm2 ing Amps/40°C
eter
mm
0.3 7/0.26 1.8 7
0.5 7/0.32 2.2 (or 2.0) 12
0.75 30/0.18 2.6 (or 2.4) 16
0.85 11/0.32 2.4 (or 2.2) 16
1.25 16/0.32 2.7 (or 2.5) 21
2 26/0.32 3.1 (or 2.9) 28
3 41/0.32 3.8 (or 3.6) 38
5 65/0.32 4.6 (or 4.4) 51
8 50/0.45 5.5 67
4
WIRING DIAGRAM [D1A0] 6-3
1. General Description
I Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more
contacts.
The wiring diagram shows the relay mode when the energizing circuit is OFF.
B6M0748
5
6-3 [D2A1] WIRING DIAGRAM
2. Basic Diagnostics Procedure
I Each connector number shown in the wiring dia- 2. Basic Diagnostics Procedure
gram corresponds to that in the wiring harness.
The location of each connector in the actual A: BASIC PROCEDURE
vehicle is determined by reading the first character
of the connector (for example, a “F” for F8, “i” for 1. GENERAL
i16, etc.) and the type of wiring harness. The most important purpose of diagnostics is to
The first character of each connector number determine which part is malfunctioning quickly, to
refers to the area or system of the vehicle. save time and labor.
Symbol Wiring harness and cord 2. IDENTIFICATION OF TROUBLE
F Front wiring harness SYMPTOM
B Bulkhead wiring harness
Determine what the problem is based on the symp-
E Engine wiring harness
tom.
Transmission cord,
T
Rear oxygen sensor cord 3. PROBABLE CAUSE OF TROUBLE
Door cord LH & RH,
Rear door cord LH & RH, Look at the wiring diagram and check the system’s
D circuit. Then check the switch, relay, fuse, ground,
Rear gate cord,
Rear gate lock adapter cord etc.
Instrument panel center harness
i
Instrument panel meter harness
4. LOCATION AND REPAIR OF TROUBLE
Rear wiring harness, 1) Using the diagnostics narrow down the causes.
R
Rear defogger cord (Ground), 2) If necessary, use a voltmeter, ohmmeter, etc.
Fuel tank cord, 3) Before replacing certain component parts
Roof cord (switch, relay, etc.), check the power supply,
ground, for open wiring harness, poor connectors,
etc. If no problems are encountered, check the
component parts.
5. CONFIRMATION OF SYSTEM
OPERATION
After repairing, ensure that the system operates
properly.
B: INSPECTION
1. VOLTAGE MEASUREMENT
1) Using a voltmeter, connect the negative lead to
a good ground point or negative battery terminal
and the positive lead to the connector or compo-
nent terminal.
2) Contact the positive probe of the voltmeter on
connector (A).
The voltmeter will indicate a voltage.
3) Shift the positive probe to connector (B). The
voltmeter will indicate no voltage.
G6M0205
H6M0510A
6
WIRING DIAGRAM [D2B3] 6-3
2. Basic Diagnostics Procedure
4) With test set-up held as it is, turn switch ON. 3. HOW TO DETERMINE AN OPEN
The voltmeter will indicate a voltage and, at the CIRCUIT
same time, the light will come on.
5) The circuit is in good order. If a problem such 1) Voltmeter Method:
as a lamp failing to light occurs, use the proce- An open circuit is determined by measuring the
dures outlined above to track down the malfunc- voltage between respective connectors and
tion. ground using a voltmeter, starting with the connec-
tor closest to the power supply. The power supply
2. CIRCUIT CONTINUITY CHECKS must be turned ON so that current flows in the cir-
cuit. If voltage is not present between a particular
1) Disconnect the battery terminal or connector so connector and ground, the circuit between that
there is no voltage between the check points. connector and the previous connector is open.
Contact the two leads of an ohmmeter to each of
the check points.
If the circuit has diodes, reverse the two leads and
check again.
2) Use an ohmmeter to check for diode continuity.
When contacting the negative lead to the diode
positive side and the positive lead to the negative
side, there should be continuity.
When contacting the two leads in reverse, there
should be no continuity.
G6M0208
2) Ohmmeter method:
Disconnect all connectors affected, and check con-
tinuity in the wiring between adjacent connectors.
When the ohmmeter indicates “infinite”, the wiring
is open.
G6M0207
B6M0749
7
6-3 [D2B4] WIRING DIAGRAM
3. Working Precautions
B: PRECAUTIONS IN TROUBLE
DIAGNOSIS AND REPAIR OF
ELECTRIC PARTS
G6M0210
1) The battery cable must be disconnected from
2) Ohmmeter method: the battery’s (−) terminal, and the ignition switch
Disconnect all affected connectors, and check con- must be set to the OFF position, unless otherwise
tinuity between each connector and ground. When required by the diagnostics.
ohmmeter indicates continuity between a particular 2) Securely fasten the wiring harness with clamps
connector and ground, that connector is shorted. and slips so that the harness does not interfere
with the body end parts or edges and bolts or
screws.
3) When installing parts, be careful not to catch
them on the wiring harness.
4) When disconnecting a connector, do not pull
the wires, but pull while holding the connector
body.
G6M0211
G6M0212
8
WIRING DIAGRAM [D3B0] 6-3
3. Working Precautions
5) Some connectors are provided with a lock. One 6) When checking continuity between connector
type of such a connector is disconnected by push- terminals, or measuring voltage across the termi-
ing the lock, and the other, by moving the lock up. nal and ground, always contact tester probe(s) on
In either type the lock shape must be identified terminals from the wiring connection side. If the
before attempting to disconnect the connector. probe is too thick to gain access to the terminal,
To connect, insert the connector until it snaps and use “mini” test leads.
confirm that it is tightly connected. To check water-proof connectors (which are not
accessible from the wiring side), contact test
probes on the terminal side being careful not to
bend or damage the terminals.
G6M0214
G6M0213
9
6-3 [D400] WIRING DIAGRAM
4. How to Use Wiring Diagram
B6M0213B
10
WIRING DIAGRAM [D4M0] 6-3
4. How to Use Wiring Diagram
11
6-3 [D5A0] WIRING DIAGRAM
5. Wiring Diagram
5. Wiring Diagram
A: POWER SUPPLY ROUTING
12
WIRING DIAGRAM [D5A0] 6-3
5. Wiring Diagram
13
6-3 [D5A0] WIRING DIAGRAM
5. Wiring Diagram
14
WIRING DIAGRAM [D5B0] 6-3
5. Wiring Diagram
B: GROUND DISTRIBUTION
15
6-3 [D5B0] WIRING DIAGRAM
5. Wiring Diagram
16
WIRING DIAGRAM [D5B0] 6-3
5. Wiring Diagram
17
6-3 [D5C0] WIRING DIAGRAM
5. Wiring Diagram
C: AIRBAG SYSTEM
18
WIRING DIAGRAM [D5D0] 6-3
5. Wiring Diagram
19
6-3 [D5D0] WIRING DIAGRAM
5. Wiring Diagram
20
WIRING DIAGRAM [D5E0] 6-3
5. Wiring Diagram
21
6-3 [D5E0] WIRING DIAGRAM
5. Wiring Diagram
22
WIRING DIAGRAM [D5F0] 6-3
5. Wiring Diagram
23
6-3 [D5F0] WIRING DIAGRAM
5. Wiring Diagram
24
WIRING DIAGRAM [D5G0] 6-3
5. Wiring Diagram
25
6-3 [D5H0] WIRING DIAGRAM
5. Wiring Diagram
H: AUDIO SYSTEM
26
WIRING DIAGRAM [D5I0] 6-3
5. Wiring Diagram
I: CHARGING SYSTEM
27
6-3 [D5J0] WIRING DIAGRAM
5. Wiring Diagram
J: COMBINATION METER
28
WIRING DIAGRAM [D5K0] 6-3
5. Wiring Diagram
29
6-3 [D5L1] WIRING DIAGRAM
5. Wiring Diagram
30
WIRING DIAGRAM [D5L1] 6-3
5. Wiring Diagram
31
6-3 [D5L1] WIRING DIAGRAM
5. Wiring Diagram
32
WIRING DIAGRAM [D5L1] 6-3
5. Wiring Diagram
33
6-3 [D5L2] WIRING DIAGRAM
5. Wiring Diagram
34
WIRING DIAGRAM [D5L2] 6-3
5. Wiring Diagram
35
6-3 [D5L2] WIRING DIAGRAM
5. Wiring Diagram
36
WIRING DIAGRAM [D5L2] 6-3
5. Wiring Diagram
37
6-3 [D5M0] WIRING DIAGRAM
5. Wiring Diagram
38
WIRING DIAGRAM [D5N0] 6-3
5. Wiring Diagram
39
6-3 [D5O0] WIRING DIAGRAM
5. Wiring Diagram
40
WIRING DIAGRAM [D5P0] 6-3
5. Wiring Diagram
41
6-3 [D5P0] WIRING DIAGRAM
5. Wiring Diagram
42
WIRING DIAGRAM [D5Q1] 6-3
5. Wiring Diagram
43
6-3 [D5Q2] WIRING DIAGRAM
5. Wiring Diagram
44
WIRING DIAGRAM [D5R1] 6-3
5. Wiring Diagram
45
6-3 [D5R2] WIRING DIAGRAM
5. Wiring Diagram
46
WIRING DIAGRAM [D5S0] 6-3
5. Wiring Diagram
47
6-3 [D5T0] WIRING DIAGRAM
5. Wiring Diagram
48
WIRING DIAGRAM [D5U0] 6-3
5. Wiring Diagram
49
6-3 [D5V0] WIRING DIAGRAM
5. Wiring Diagram
50
WIRING DIAGRAM [D5W0] 6-3
5. Wiring Diagram
51
6-3 [D5X1] WIRING DIAGRAM
5. Wiring Diagram
52
WIRING DIAGRAM [D5X2] 6-3
5. Wiring Diagram
53
6-3 [D5X2] WIRING DIAGRAM
5. Wiring Diagram
54
WIRING DIAGRAM [D5Y0] 6-3
5. Wiring Diagram
55
6-3 [D5Z0] WIRING DIAGRAM
5. Wiring Diagram
56
WIRING DIAGRAM [D5AA0] 6-3
5. Wiring Diagram
57
6-3 [D5AB0] WIRING DIAGRAM
5. Wiring Diagram
58
WIRING DIAGRAM [D5AC0] 6-3
5. Wiring Diagram
59
6-3 [D5AD0] WIRING DIAGRAM
5. Wiring Diagram
60
WIRING DIAGRAM [D5AE0] 6-3
5. Wiring Diagram
61
6-3 [D5AF0] WIRING DIAGRAM
5. Wiring Diagram
62
WIRING DIAGRAM [D5AG0] 6-3
5. Wiring Diagram
63
6-3 [D5AH0] WIRING DIAGRAM
5. Wiring Diagram
64
WIRING DIAGRAM [D5AI0] 6-3
5. Wiring Diagram
65
6-3 [D5AI0] WIRING DIAGRAM
5. Wiring Diagram
MEMO:
66
WIRING DIAGRAM [D6A0] 6-3
6. Electrical Wiring Harness and Ground Point
H6M0531A
(1) Front wiring harness (8) Rear wiring harness (15) Transmission cord
(2) Engine wiring harness (9) Rear defogger cord (Ground) (16) Rear gate cord
(3) Bulkhead wiring harness (10) Fuel tank cord (17) Rear gate lock adapter cord
(4) Instrument panel meter harness (11) Rear door cord LH (18) Rear oxygen sensor cord
(5) Front door cord RH (12) Rear door adapter cord LH (19) Instrument panel center harness
(6) Rear door adapter cord RH (13) Front door cord LH (20) Combination switch cord
(7) Rear door cord RH (14) Roof cord (21) Trunk lid cord
67
6-3 [D6B1] WIRING DIAGRAM
6. Electrical Wiring Harness and Ground Point
68
WIRING DIAGRAM [D6B2] 6-3
6. Electrical Wiring Harness and Ground Point
2. LOCATION
69
6-3 [D6C1] WIRING DIAGRAM
6. Electrical Wiring Harness and Ground Point
70
WIRING DIAGRAM [D6C2] 6-3
6. Electrical Wiring Harness and Ground Point
2. LOCATION
71
6-3 [D6D1] WIRING DIAGRAM
6. Electrical Wiring Harness and Ground Point
72
WIRING DIAGRAM [D6D2] 6-3
6. Electrical Wiring Harness and Ground Point
2. LOCATION
73
6-3 [D6E1] WIRING DIAGRAM
6. Electrical Wiring Harness and Ground Point
Connector Connecting to
No. Pole Color Area No. Name
T1 2 Gray C-1 B24
Bulkhead wiring harness (MT)
T2 2 Brown C-1 B25
T3 12 ★ C-3 B12
Bulkhead wiring harness (AT)
T4 16 ★ C-3 B11
T7 12 ★ C-4 Inhibitor switch (AT)
T8 2 ★ C-1 B17 Bulkhead wiring harness (MT)
★: Non-colored
74
WIRING DIAGRAM [D6E2] 6-3
6. Electrical Wiring Harness and Ground Point
2. LOCATION
75
6-3 [D6F1] WIRING DIAGRAM
6. Electrical Wiring Harness and Ground Point
76
WIRING DIAGRAM [D6F2] 6-3
6. Electrical Wiring Harness and Ground Point
2. LOCATION
77
6-3 [D6G1] WIRING DIAGRAM
6. Electrical Wiring Harness and Ground Point
78
WIRING DIAGRAM [D6G2] 6-3
6. Electrical Wiring Harness and Ground Point
2. LOCATION
79
6-3 [D6H1] WIRING DIAGRAM
6. Electrical Wiring Harness and Ground Point
H: DOOR CORD
1. LIST OF ITEMS
Connector Connecting to
No. Pole Color Area No. Name
D1 13 ★ C-3 B30 Bulkhead wiring harness
D2 2 ★ C-3 Front speaker LH
D3 2 Green C-3 Front power window motor LH
D5 6 ★ C-3 Remote control rearview mirror LH
16 ★ C-3 Power window main switch (Sedan and Wagon model)
D7
12 ★ C-3 Power window main switch (Coupe model)
D8 4 ★ C-3 Front door lock actuator LH
D11 13 ★ B-2 B101 Bulkhead wiring harness
D12 2 ★ B-2 Front speaker RH
D13 2 Green B-2 Front power window motor RH
D15 6 ★ B-2 Remote control rearview mirror RH
D17 5 ★ B-2 Front power window sub switch RH
D18 4 ★ B-2 Front door lock actuator RH
D21 8 ★ C-3 R11 Rear wiring harness
D23 2 ★ C-4 Rear door speaker LH
D24 2 Green C-4 Rear power window motor LH
D25 5 ★ B-4 Rear power window sub switch LH
D26 4 ★ B-4 Rear door lock actuator LH
D27 8 ★ B-2 R14 Rear wiring harness
D29 2 ★ B-3 Rear door speaker RH
D30 2 Green B-3 Rear power window motor RH
D31 5 ★ B-2 Rear power window sub switch RH
D32 4 ★ B-3 Rear door lock actuator RH
D50 9 ★ B-2 B113 Bulkhead wiring harness
D53 3 ★ B-2 B124 Bulkhead wiring harness
D54 8 ★ C-3 D55 Rear door cord LH
D55 8 ★ C-3 D54 Rear door adapter cord LH
D56 8 ★ B-2 D57 Rear door cord RH
D57 8 ★ B-2 D56 Rear door adapter cord RH
D62 8 ★ B-2 Door lock switch RH
★: Non-colored
80
WIRING DIAGRAM [D6H2] 6-3
6. Electrical Wiring Harness and Ground Point
2. LOCATION
81
6-3 [D6I1] WIRING DIAGRAM
6. Electrical Wiring Harness and Ground Point
82
WIRING DIAGRAM [D6I2] 6-3
6. Electrical Wiring Harness and Ground Point
2. LOCATION
83
6-3 [D6J1] WIRING DIAGRAM
6. Electrical Wiring Harness and Ground Point
Connector Connecting to
No. Pole Color Area No. Name
D33 2 ★ C-3 R37
D34 4 ★ C-3 R38 Rear wiring harness
D35 4 ★ C-3 R39
D39 2 ★ B-2 High-mount stop light
D40 1 ★ B-3 Rear defogger (Power)
D43 4 ★ A-3 Rear wiper motor
D46 2 Black A-3 Rear gate latch switch
D47 4 ★ A-3 Rear gate lock actuator
D48 1 ★ A-3 Rear defogger (Ground)
D58 2 ★ A-3 D59 Rear gate lock adapter cord
D59 2 ★ A-3 D58 Rear gate cord
★: Non-colored
84
WIRING DIAGRAM [D6J2] 6-3
6. Electrical Wiring Harness and Ground Point
2. LOCATION
85
6-3 WIRING DIAGRAM
MEMO:
86
Subaru Impreza Part Numbers
1993-2001 Coupe, Sedan, Wagon, Outback
A/C / Heater/Ventilation 652
A/C Refrigerant Capacities 652
ABS/Brakes 654
Air Bag System 654
Air Cleaner 660
Back Window 673
Center Console 665
Clear Coat Identification 650
Cooling 651
Cowl & Dash 663
Cruise Control System 655
Electrical 662
Emission System 662
Engine/Trans 658
Engine/Trans Mounts 659
Exhaust 661
Front Bumper 650
Front Door 668
Front Drive Axle 656
Front Fender 653
Front Inner Structure 654
Front Lamps 650
Front Seat 667
Front Steering Linkage/Gear 657
Front Suspension 656
Fuel Tank 679
Grille 650
Hood 651
Information Labels 650
Instrument Panel 663
Liftgate 677
Luggage Lid 676
Paint Code Location 650
Quarter Glass 676
Quarter Panel 674
Rear Body 680
Rear Bumper 681
Rear Door 671
Rear Drive Axle 679
Rear Lamps 680
Rear Seat 667
Rear Suspension 677
Rocker/Pillars/Floor 665
Roof 672
Seat Belts 668
Special Cautions 650
Steering Pump 657
Steering Wheel/Column 657
Sunroof 673
Underhood Dimensions 654
Wheel 655
Windshield 663